Developing cold solutions
September 1st 2011

Hörmann and ISD Cold Stores co-operate on better loading bay insulation as economic chill bites harder than environmental pressures

Sustainability and environmental impact are having an effect on warehouse design, but it is the economic climate that is now driving change. Designs and products originally developed for cold stores, such as insulated doors, are being employed on ambient storage as these are becoming increasingly cost effective as energy costs continue to rise. In addition, more efficient, options are being developed for cold storage.

One consequence of this demand is increased co-operation between Hörmann (UK) and ISD Cold Stores. Hörmann's industrial door and loading bay technology combined with the cold store expertise of ISD Cold Stores has led the two firms to work together on more projects.

A step change in warehouse design is being pioneered by ISD with a single envelope cold store design. Two warehouses featuring the clad rack design have already been completed for Unilever in Gloucester and Lamb Weston in Wisbech.

Instead of building a cold store within a warehouse, the entire building is insulated, which offers significant benefits. In the first instance, fewer raw materials are needed for the build compared with the traditional method of creating a building within a building. Additionally the insulated cladding can span a wider gap therefore reducing the amount of secondary steel required for the construction. Reduced material cost, quicker build time and fewer deliveries to site all add to the sustainability, and reduce the carbon footprint of the build. The completed building is also much more energy efficient, reducing its long term impact on the environment.

For the developer this more cost effective build also gives them a more flexible building that will appeal to a wider number of potential tenants. Adding to the popularity of this new design is the concern over food miles and increased transport costs leading to the development of more distribution centres.

New products are also being developed as a result of the partnership. Hörmann has introduced the ThermoFrame, a thermal break for sectional loading bay doors, which can improve insulation values by as much as 40%.Where level access is required the energy efficient high speed spiral door has been improved upon with a new more insulated version - the HS7030.

An example of their combined expertise can also be seen in the SPAR distribution centre, built for James Hall and Co. in Preston.

For the cold storage loading bays, ISD insulated the dock leveller pits before Hörmann installed HTL-2 dock levellers with telescopic lips. Double insulated DPU doors were fitted with a thermal U value for each panel of only 0.3 W/m2K.With this level of insulation, double seals at the lintel and floor reduce energy losses. The key design element is doors that close in front of the dock leveller and sit on the insulated plates that form the base of the dock leveller pit, maximising the insulation.

More articles from Hormann UK Ltd: