Pharmaceutical Manufacturer in North Wales

Design, supply & installation of Walk In Pharmaceutical Freezer


North Wales


February 2020

Value Range

£150k - £200k

Product Category


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A manufacturer of diagnostic kits to test for diseases such as cancers through analyzing body fluids, required a new walk-in freezer to store products.

The intended use of the -25°C walk-in freezer was to store pharmaceutical products manufactured onsite, with a maximum storage condition -20°C.

The estimated value of product to be stored in the new freezers was several million pounds.

Scope of work

Our scope of works was to build a new walk-in freezer including all insulated walls, doors, and ceiling, together with the design, supply and installation refrigeration systems to provide a temperature-controlled environment of below -20°C. The temperature was to be maintained 24 hours per day, 365 days per year.

LED lighting was to be provided within the new freezer to a level of above 300 lux.

On completion of the project, the room was to be validated and temperature mapped to ensure that the room temperature doesn’t to fall out of the specified parameters.

How ICE helped

Detailed heatload calculations were undertaken for the new freezer and our equipment was selected based the results.

The freezer was designed to operate at -25°C to provide a buffer in case of issues or excessive door openings.

The new walk-in freezer was built by our coldroom contractors Heritage Hygienic Ltd and was approximately 16.00m long x 14.00m wide, with a height of 2.70m.

To form the floor to the freezer, we supplied and installed a 25mm modular heater mat with transformer controls, 100mm thickness LPC approved PIR core panel, with 12mm marine ply ready for a low temperature resin finish by others, including all necessary flashings, covings, anti-fungicidal silicone, and fixings.

The main access to the new walk-in freezer was via a 1.0m x 2.0m pedestrian door and a 1.5m x 2.0m trolley door. The doors were operated via a Fermod auto door kit, with both horizontal and vertical safety sensors. The doors automatically close after an adjustable pre-set amount of time.

There was also an emergency door installed at the side of the freezer, along with a door switch installed on each door to alarm locally after a pre-set and adjustable time.

To serve the above enclosure, we selected and installed three independent, direct expansion refrigeration systems operating on R449A refrigerant, utilising fully housed packaged condensing units and ceiling mounted evaporator coolers.

Each installed system was capable of 18.18kw of refrigeration duty, providing a total duty of 54.54kw under the conditions specified.

The three systems ran together, with any two capable of maintaining the desired room temperature in the event of a failure to one of the systems or whilst another

 Is defrosting. This provided a fully flexible run and standby operation for the room.

The condensing units were manufactured by Copeland, and each contained a Copeland Stream compressor, integral condenser fans, fan speed control, filter drier, sight glass, oil separator, PRV and automatic safety controls. In the event of a fault the condensing units send a fault signal to the internal control panel.

The condensing units were positioned externally on concrete pads in a designated plant area.

The evaporator coolers were of copper tube/aluminium fin construction and manufactured by Searle. Defrosting of the evaporators and drip trays was via electrical defrost heaters installed within the coolers.

An IP65 control panel housing ID974 Eliwell plus controllers was installed to serve each system along with all breakers, contactors, and run/fault lamps was installed within the Airlock Area. 

Volt free contacts were provided within our controls to interface with the clients BMS alarm system.

Energy efficient LED lighting was installed by our electrical contractors PDR Electrical Ltd and operated via PIR sensors, providing a minimum lighting level of 300 lux. Emergency lighting was also installed.


All installed systems were installed to the highest of standards and passed validation without any issues.

Lighting tests of the freezer passed specified lux levels.

Since commissioning the freezer has performed well and have stayed within the specified temperature limits, producing perfect temperature graphs.

The systems are under a maintenance agreement with ICE Ltd and the client would receive a 4 hours response to emergency breakdowns.

We are ready to help with your air conditioning, refrigeration and ventilation enquiries.

If you have an enquiry, please complete the contact form and our team will be in touch. We look forward to hearing from you and look forward to building a winning partnership

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