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As recently as a couple of years ago, the need to maintain precise temperature and humidity control in an IT space was a top priority for data center managers and a primary motivator behind the purchase of a precision air conditioning system. Over the last several years, however, the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) has relaxed its recommendations and widened the temperature and humidity ranges deemed acceptable within environments that house sensitive IT equipment, including data centers, server rooms, network closets, technology rooms, or other spaces like medical equipment suites, laboratories, and telecommunications centers. Consequently, precision cooling in its most literal sense is no longer seen as the absolute necessity that it once was.
However, proper IT thermal management most certainly remains a critical priority. Precision air conditioning — or data center-grade cooling systems — are still very much needed, even if precise (within 1 or 2 degrees) temperature and humidity set points are no longer mandatory. In part, this is because even while the spectrum of allowable temperatures in IT space has expanded, so too has the amount of heat generated by the increasingly sophisticated servers needed to support today’s power- and data-intensive applications, including Internet of Things (IoT), artificial intelligence (AI), and others. And properly managing that heat is the key to ensuring IT equipment performs at optimal levels.
Furthermore, the consequences for exceeding recommended heat thresholds are just as serious as they ever were. Excessive heat can take a toll on equipment, leading to component failures or sometimes complete system shutdown, and it can all happen in a matter of minutes. IT equipment failures often snowball into unplanned downtime for a business, which comes at a staggeringly high cost that exceeds the cost of equipment damage and includes lost revenue opportunity, customer service disruption, and reputational damage that can persist long after the equipment is repaired, and the business is back up and running.
To help prevent potentially disastrous threats to business-critical continuity, precision air conditioning — or what Vertiv more commonly refers to as thermal management — is still very much a necessity in data center and IT spaces.
In some IT spaces, such as server or technology rooms located in an administrative building, facilities managers will often rely on the building’s comfort cooling system to maintain the environment in the IT space. It is true that a commercial AC solution can play some role in controlling temperature, humidity, and air quality in these rooms. But the systems are lacking in many ways, starting with the fact that comfort cooling for people spaces and precision cooling for IT spaces are specifically engineered for very different purposes.
Think of it like this: cars and trucks share all the same basic components (engines, steering wheels, brakes, etc.), but you wouldn’t choose a sedan for an off-roading excursion. In other words, the vehicles are intended for very different applications. The same is true for precision air conditioning or thermal management systems.
Specifically, these specialty cooling solutions are built to do the following:
While there are several different types of precision air conditioning or thermal management systems designed to meet the unique needs of a variety of applications, all systems generally work in the same manner. The equipment provides optimum air temperature to the inlet fans of the IT equipment using a unit or units installed in the IT space, either at the perimeter of the room, in the row, or in the racks or ceiling if floor space is at a premium. These interior units use refrigeration or rely on cold water or glycol-based coolant to chill the air. They use fans and airflow to guide the cool air to the right places.
As the same time, the hot air generated by the equipment is collected up and rejected from the IT space. The thermal management system’s heat rejection unit removes the heat in one of several ways:
In addition to the indoor units and the heat rejection components, thermal management solutions often include other critical components or can work in conjunction with other pieces of hardware and software to optimize the cooling strategy. These components include:
While cooling systems need to work reliably, they are also expected to work as efficiently as possible. IT thermal management systems account for about 38% of total energy consumption in a typical data center. It’s imperative to choose a precision cooling or thermal management system that is built for both reliability and efficiency.
Some features to look for include:
As this article illustrates, there are many factors to consider when selecting a precision cooling or IT thermal management solution. However, in most applications, the choice boils down to three key factors:
The following chart can help you compare the different types of solutions available and provides examples of each for your consideration:
Chilled Water
Indoor air handler(s) connected to a building chilled water plant
Chilled water
Liebert® CW
Liebert® PCW
Liebert® Mini-Mate
Air-Cooled Direct Expansion
One-to-one indoor CRAC unit with outdoor heat rejection
Outdoor ambient air
None
Small to mid-size rooms
Liebert® DS
Liebert® DSE
Liebert® PDX
Liebert® Mini-Mate
Water-Cooled Direct Expansion
Indoor CRAC unit connected to a warm building water loop
Process water
Operational costs and environmental considerations due to water consumption and treatment
Liebert ® DS
Liebert® PDX
Liebert® Mini-Mate
Glycol-Cooled Direct Expansion
Indoor CRAC unit(s) connected to an outdoor fluid cooler
Warm water/ glycol antifreeze solution
Valuable roof space is needed to accommodate multiple heat rejection units
Small to mid-size rooms
Liebert® DS
Liebert® Mini-Mate
Liquid Cooling
Cool liquid is circulated to cold-plate heat exchangers embedded in IT equipment
Specialty liquid
Specialized IT equipment with built-in liquid/fluid heat exchanger
Highly efficient
Space and cost associated with deploying dedicated liquid cooling infrastructure
Liebert® XDU
Ultimately, a true and comprehensive thermal management system provides more than a way to collect and reject heat in an IT space. While precise temperature control — maintaining the temperature within one to two degrees — is not the issue it once was, thermal management continues to play a critical role in the operation of any data center or IT space. The right thermal management system, comprised of intelligent controls and advanced sensors, efficiency-enhancing features, and a monitoring solution, gives data center staff the ability to efficiently manage the environment and optimize equipment performance around the clock, safeguarding against system failure and costly downtime for the business.
Walk-in coolers and freezers provide exceptional storage capacity to keep your products fresher longer. The first consideration is deciding whether you need a cooler, which keeps products at +35°F or above, or a freezer, which keeps products around -10°F for proper preservation and prolonged use. Depending on the size, type, and layout of your operation, it’s likely you may require a combination of both.
Deciding on a cooler or freezer ultimately depends on the products you want to store. For traditional foodservice applications, food safety is always the priority. Often, coolers are used to store quickly perishable items like fresh produce and dairy, and items you’re looking to offload quickly. Freezers are ideal for preserving product for longer periods, and often used for meat, seafood, and desserts.
Given that both coolers and freezers need to sustain their respective temperatures, the right insulation and construction plays a critical role and has a direct impact on energy savings. To maintain lower temperatures, freezers usually require more insulation and thicker panels. More on insulation and construction below.
Location is one of the first considerations when outfitting the best walk-in solution. Is your unit going to be installed inside or outside? Your back-of-house size and layout will be a factor, as well as your storage requirements.
First, assess your available space. Is there enough room for doors to open fully and employees to maneuver safely? Will it be easy to access with minimal disruptions? Consider the frequency of use during rush periods, as well deliveries, especially if large quantities are being stored. The chosen location will need adequate airflow and ventilation, and utility access for electrical wiring, drainage, and refrigeration lines.
Local regulations also play a part. Every municipality has different zoning regulations. You’ll need to verify your local building codes and requirements for the proposed location, and ensure it meets health department guidelines for food storage.
There are pros and cons to both indoor and outdoor coolers. Ultimately, the decision hangs on available space, storage requirements, and the environment.
Indoor coolers take up valuable indoor space; however, they allow employees quick access without exposure to outdoor weather conditions and closer proximity to the kitchen for enhanced efficiency. Indoor environments are more controlled than outdoor, meaning there’s less risk of vandalism and create consistent operating conditions. Consistent conditions reduce the strain on the refrigeration system, resulting in a longer unit life and lower maintenance costs. Typically, there are fewer zoning considerations for indoor units than there are for outdoor, which can simplify the permit process.
However, refrigeration units can be noisy, and improper ventilation can cause heat buildup, which may result in an uncomfortable work environment. Pending the layout and available utilities, installation may be more complex than outdoor units. Retrofitting an indoor space for a walk-in cooler can involve structural modifications and higher labor costs.
If space is a primary concern, an outdoor walk-in cooler or freezer may be the way to go. Outdoor units offer more location flexibility allowing for installation near loading docks, production areas, or other strategic locations. The heat generated by these units remains outside, reducing the strain on indoor HVAC systems, and installation may be simpler because there’s no need to alter existing indoor structures.
Outdoor coolers are more subject to wear and tear from environmental factors, and may require additional weatherproofing, increasing initial costs. In areas with extreme weather, an indoor cooler might offer better protection and overall operational efficiency.
Pro tip: Choosing a location that minimizes heat transfer and is close to power and water sources can save on energy costs.
A note on temperature: When researching the right cooler or freezer unit, you’re likely to notice references to two different types of temperatures: ambient temperature and room temperature.
Ambient temperature: Refers to the temperature of the overall environment of the cooler, not just inside the cooler, and directly impacts the operating conditions.
For more row level chilled water precision air conditionerinformation, please contact us. We will provide professional answers.
Room temperature: Refers specifically to the indoor space where people are working. Whereas ambient temperature is broader and has a greater range, room temperature generally falls within a standard range comfortable for humans. Ambient temperature plays a crucial role when deciding between an indoor and outdoor unit.
The size of the cooler or freezer you need will also help determine the location. The size will depend on the types of items, and how much you’re needing to store. Plan for proper shelving to maximize vertical store, as well as sufficient aisle space for easy access to products.
To assess your storage needs, first consider your inventory volume. Estimate the amount of perishable goods you’ll store at max capacity, factoring in daily or weekly inventory turnover. A good rule of thumb for food storage is to allocate approximately 1-2 cubic feet of storage per meal served daily. Remember to factor in future growth to avoid outgrowing your unit too soon.
Standard box sizes most commonly advertise range from 6’x6’ to 10’x14’. Because every location, application, and need are different, walk-in coolers and freezers are highly customizable. Whatever size or cooler/freezer combo you need, Norlake can design in-house.
Ideal for small businesses or restaurants.
Ideal for mid-sized operations.
Ideal for large facilities or warehouses.
Choosing the right size is about balancing current needs, future growth, and available space. When in doubt, it’s better to err on the slightly larger side for added flexibility and to avoid overcrowding, which can hinder cooling efficiency.
Actual size vs. Nominal size: Norlake is also one of the only walk-in cooler and freezer manufacturers to refer to our units with actual, precise sizes, meaning what you see is what you get. Our dimensions are exact after the unit is built. Most walk-in cooler manufacturers use nominal sizing, which is more approximate and can vary.
Using actual sizing adds additional space for shelving.
Walk-in coolers and freezers can come with or without built-in floors. If you decide to save a little money upfront and go without a floor, you’ll need to ensure the location is on a level, concrete surface. You may also need to invest in additional insulation to ensure proper energy efficiency. Concrete floors without proper insulation can act as a thermal bridge that allows heat to enter and increase energy consumption. Local codes also play a factor – some require specific flooring depending on use case – so make sure you verify prior to deciding.
Walk-ins with floors offer a host of benefits, including:
Better insulation – built-in floors improve thermal efficiency and minimize the risk of heat transfer from uninsulated concrete or other surfaces, reducing energy consumption and maintaining consistent temperatures.
Easier installation – pre-fabricated floors are ready to use, so there’s no need to add more insulation or vapor barriers.
Prevents moisture issues – built-in floors often include a vapor barrier which reduces the risk of condensation and moisture build-up, mold, and water damage over time.
Floor structures can vary depending on use case to support heavier weight capacities. Most are made are smooth aluminum, designed for light to medium-duty traffic.
Ideal for foot traffic and lighter stationary loads.
Ideal for light wheeled traffic and heavy items on shelving.
Ideal for heavy carts and hand pallet jacks. Not recommended for use with electric pallents jacks or forklifts.
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The construction process of your walk-in is a central factor in the structural integrity, energy efficiency, and longevity of your unit. The panel material (the walls of your walk-in) can vary, but Norlake’s standard is acrylic-coated galvanized steel. This offers many benefits, including:
Corrosion resistance. The coating protects the steel from rust and corrosion, which is especially important in high-moisture or colder environments.
Highly durable. Galvanized steel stands up well to daily wear and tear, and provides excellent structural integrity, helping maintain insulation performance and stability over time.
Cost-effective and low maintenance. The protective zinc layer reduces the need for frequent repairs or repainting, and the surfaces are easy to clean and disinfect – ideal for foodservice environments.
The walls of your panels are then filled with insulation to keep interior temperatures contained and consistent. Like panel material, the foam insulation installed on the insides of the panels plays a major factor in the quality and efficiency of your unit. This is measured in R-value, the thermal resistance to heat transfer. The higher the R-value, the better the insulation and the unit’s ability to keep the inside temperature cool, saving you money on energy consumption. The industry’s standard R-Value in 25. Norlake’s R-value is 32.
The insulation, of course, has a direct impact on the R-value. Most panels are 4” thick for optimum insulation, and you may notice the term foamed-in-place. This refers to a process where the foam insulation is applied directly to the inside of the panel walls as a liquid spray that expands on contact, effectively filling all gaps to create a continuous insulating layer. This process provides excellent thermal resistance and can act as a vaper barrier, reducing the risk of moisture while increasing your unit’s R-value. Some manufacturers opt not to use this process, which leaves the unit vulnerable to exterior air and decreased thermal resistance, resulting in a loss of cooling efficiency.
Polyurethane and Polystyrene are the two most common insulation materials. Polyurethane is a rigid, closed-cell foam with a high thermal resistance (R-value) and is ideal for temperature-controlled environments. Polystyrene, available as Expanded Polystyrene (EPS) or Extruded Polystyrene (XPS), is a lightweight, cost-effective foam ideal for budget-friendly operations. Both are widely used and offer unique benefits.
Like foam insulation options, walk-in coolers and freezers have two common panel construction processes: soft-nose and high-density (H.D.) rail.
Soft-nose features full foam panels that offer more flexibility, both in panel construction and the insulation edge, creating an airtight seal for optimal thermal resistance and a high R-value.
Hard-density foam is more difficult to install, especially on large walk-ins, and is much more rigid, offering less flexibility.
Foamed-in-place gaskets and cams, permanently secured panel components with no messy gluing.
Metal cam-locks for remarkable durability and damage resistance.
Double gasket doors for an airtight seal that reduces energy costs and protects perishables.
Seamless gaskets for easy assembly, eliminating the need for additional sealant.
Durable design reduces warranty and repair costs for long-term savings.
Foamed-in-place gaskets and cams, permanently secured panel components with no messy gluing.
Metal cam-locks for remarkable durability and damage resistance.
Double gasket doors for an airtight seal that reduces energy costs and protects perishables.
Seamless gaskets for easy assembly, eliminating the need for additional sealant.
Durable design reduces warranty and repair costs for long-term savings.
The next step is deciding on refrigeration, both your system (self-contained or remote) and the type of refrigerant.
A self-contained refrigeration system houses all the components inside the unit, like the condenser and evaporator, making them easier to install and ideal for smaller commercial kitchens and locations with limited space. A remote refrigeration system houses the condenser and evaporator separately, with the condenser and compressor usually outdoors or in a cool basement. These systems are best designed for larger operations.
Quick, simplified repairs.
Compact, space saving design.
Lower upfront and maintenance costs.
Can be readily moved or relocated easily for flexibility.
Easy installation; plugin and go design requires minimal setup and there’s no need for additional piping or external components.
More customizable, readily tailored to specific requirements to accommodate more complex setups.
Reduced heat and noise; these are expelled outside for a more comfortable indoor working environment.
Longer lifespan since components will be housed in a cooler environment, resulting in less stress and wear-and-tear .
Greater cooling capacity and energy efficiency; remote systems don’t counteract heat buildup in the same space and are suitable for large-scale or high-demand refrigeration needs.
The main factors to consider are application size, budget, environment, and how much flexibility is needed. If mobility or quick installation is a priority, self-contained units are the way to go. Remote systems have higher upfront costs usually tied to the complex installation that may involve additional piping, electrical work, and labor; however, over time they may offer more savings in operational costs.
Your refrigeration system uses refrigerant, a chemical compound, to cool. Understanding the main refrigerant types is important for cooling efficiency and adhering to federal and state regulations.
The American Innovation and Manufacturing Act, also known as the AIM Act, was enacted by the Environmental Protection Agency (EPA) in December to phase down the production and consumption of hydrofluorocarbons (HFCs), potent greenhouse gases commonly used in refrigeration. The AIM Act established a schedule to reduce production of HFCs by 85% over 15 years. This has encouraged the development and use of safer, more environmentally friendly alternatives to HFCs.
The American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) classifies refrigerants based on their potential hazards, using a numbering system that begins with R-, followed by the ASHRAE assigned number. The most common refrigerant classifications fall under three buckets:
1. Environmental impact, rated by Global Warming Potential (GWP) and Ozone Depletion Potential (ODP); lower GWP values are better for the environment
2. Flammability, broken down by A1 (non-flammable), A2 (mildly flammable), and A3 (highly flammable)
3. Toxicity, classified as either A (low toxicity) or B (high toxicity, such as HFCs, and rarely used)
The most common types of refrigerants currently used in walk-in coolers and freezers include:
With the phase-down of HFCs underway, refrigeration manufacturers are adapting to meet regulations. R-290 (propane) is a top choice many are considering, given its environmental friendliness and energy efficiency. It’s a hydrocarbon refrigerant with an ultra-low GWP (3) and excellent cooling performance, often outperforming synthetic refrigerants in systems designed for its use. It’s especially great for small, self-contained refrigeration systems commonly used in foodservice operations. R-290 is also a natural refrigerant.
Norlake is leading the charge to help operations adapt quickly to the regulated phase-down of HFCs. We’re one of the only manufacturers with self-contained walk-in coolers and freezers available with R-290 refrigeration, all manufactured in-house in the U.S.A. to future-proof operations from potential supply chain shortages.
See all Norlake refrigeration system options.Norlake is the trusted partner of choice in cold storage solutions. We offer the best warranty on walk-in coolers and freezers in the industry—15 years on panels and 18 months on parts and labor—to ensure you can feel confident with your purchase.
We’re here to see you through from start to finish, from worry-free installation to aftercare support. Our commissioning program takes out all the hassle of installation—we handle all the startup and inspection details, thoroughly testing newly installed equipment, checking temperatures and pressures, ensuring all connections and construction meet manufacturer specifications, and providing a detailed report with photos and select repairs and warranty services at no extra cost, leaving you free to focus on your business.
Our units are completely customizable to meet your needs and the only walk-ins available with environmentally friendly R290 refrigerant manufactured in-house, future-proofing your operation against supply chain shortages. We offer three levels of customization:
1. Kold Locker™: The total package in two days! More than 14,000 configurations available that can ship out in two days – the fastest shipping in the industry!
2. Fast-Trak®: Fast and flexible options – featuring coolers, freezers, and combo units in additional sizes.
3. Fineline™: What you need, we can build. Any size, shape, and finish – Fineline units are completely customizable.t
Quick ship single-compartment coolers or freezers. Over 14,000
configurations available. The total package, Shipped in just two days.
Semi-custom coolers, freezers, and
combo units. More size, more options, and available remote
refrigeration.
If you can dream it we can build
it. Fully custom walk-ins any size
and shap, precision built to
your needs.
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