Walk-in coolers and freezers are designed for specific uses with the necessary refrigeration to handle products using an optimized layout. However, if adjustments, either increasing the size or changing the use arise, KPS Global® works to understand these needs to determine the best solution. Before any modifications are made, there are a few important considerations.
R-Value
First, the function of the box and initial construction must be considered because walk-in coolers and freezers have different R-Value requirements. Coolers require a minimum R-Value of R-28 and freezers require a minimum R-Value of R-32. The minimum R-Values of KPS Global wall panels is R-8 per inch. KPS Global panels are as follows:
- 3 ½” panels, R-28
- 4” panels, R-32
- 5” panels, R-40
While it is possible to convert a cooler to a freezer, we advise against doing so. Freezers use thicker panels and an insulated slab floor or insulated floor panels to meet requirements. Other circumstances apply where wood panel frames could present issues when attempting a walk-in modification from a cooler to a freezer.
When a walk-in freezer is being considered for modification, the floor must be taken into account. If the freezer was installed on an insulated slab, the footprint of the walk-in cannot change because freezer floors require an R-Value of R-28. This means that a walk-in freezer built with an insulated slab floor can be modified, but the insulated floor will also need to be modified or insulated floor panels will have to be added.
Panel Condition
Panel age may be a good top-of-mind question when considering a walk-in modification. However, panel age is relative, as every store situation and level of care is different. There are old walk-ins that still appear and function extremely well, while newer walk-ins may be in very poor condition due to abuse and neglect within the store environment.
The condition of the panel is the most crucial element. Primary issues to address are if there is damage to the panels or water penetration in the panels. Should those issues be present across the walk-in, a modification reusing existing panels is not recommended.
Further, there is a possibility of condensation accumulating within wood frame panel joints. This condensation can lead to the growth of mildew, mold and other bacteria. This also risks rusting the cam-locks that hold the panels together and can cause the panel joints to buckle. Wood frames provide superior structural support, but lower thermal performance quality compared to other KPS Global frame options like FUSIONFRAME® or INSULFRAME®. If cam-locks are rusted and cannot be disengaged without destroying the locking mechanism or the pin, both panels will need to be discarded.
Alternatively, a tool known within KPS Global as a “plant-on” or a “cam adapter” may be used. This is a modification tool that lags into one panel and “resets” the tongue and groove portion of the panel with fresh camlocks.
Types of Walk-In Modifications
Footprint
There are many ways a walk-in can be modified. The footprint can be adjusted to add an additional area or to join two existing walk-ins. If this type of modification is requested, our experienced design team at KPS Global can pull the original drawings and compare them to the requested new design. This allows us to identify the best way to achieve the revised design using the maximum number of existing panels. Designers will then determine what additional panels will be needed.
For these types of modifications, KPSG needs to know how much variance in the design is allowable. We can design to meet exact dimensions when it is necessary. If there is some possibility of variability, we may be able to modify the design slightly to be able to re-use more existing panels, which reduces costs. Involving the experts at KPS Global in the initial design phases of a modification project will allow customers to balance cost with design.
Height Increase
Sometimes, modifications are needed to house more product in a walk-in cooler or freezer, but the footprint cannot change for the existing box. In these situations, customers may choose to stack material vertically to increase the height of the walk-in, rather than increasing the footprint. This requires replacing most of the existing walk-in because the vertical panels that make up the height need to be engineered and designed to support. It may also be possible to re-use the ceiling panels of the walk-in.
Exterior Walk-Ins
When changing the height or footprint of a current walk-in is not feasible, KPS Global offers walk-ins for exterior use. While the design of outdoor walk-ins is not drastically different from indoor walk-ins, there are a few critical elements to consider including roofing, outdoor elements, panel thickness and more.
Innovative Solutions
KPS Global is committed to driving innovation in the cold storage industry. In fact, innovations from KPS Global align directly with walk-in needs discussed above.
FUSIONFRAME® helps solve issues with condensation causing damage to panels, cam-locks and other thermal performance issues.
DEFENDOOR™, the newest KPS Global product innovation, provides an additional layer of protection to walk-in doors. Its reinforced material reduces the risk of damage caused by wear and tear, ultimately extending the life of the door and nearby panels.
Conclusion
KPS Global is committed to providing high-quality cold storage solutions for both new construction and modifications to existing walk-ins. It is not necessary to have a solution in mind before reaching out about modifying walk-ins. We have internal engineering and design teams that will evaluate a request from all sides to work with customers to find the best solution for each specific need. Contact the trusted experts in cold storage today for more information!
