Situation
In March 2025, KPS Global® delivered a repair and insulation upgrade for critical cold storage in a membership club wholesaler in Aruba that ensured zero operational downtime while significantly improving energy efficiency. Facing challenges like severe panel damage from humidity and forklift impact, along with restrictive zoning laws, our innovative thermal liner panel installation and walk-in cooler restoration approach restored critical refrigeration systems without shutting down operations. This cost-effective solution also improved the longevity and thermal performance of the membership club wholesaler’s commercial refrigeration system.
Compounding the issue, new zoning regulations1 in Aruba, which restrict the expansion of commercial space and effectively halted plans for constructing a new warehouse. With high operating costs, no backup facility, and constant exposure to Aruba’s humid climate, turning off the freezers wasn’t an option. Shutting them down could allow warm, moist air to seep into the damaged floors. When restarted, that trapped moisture would freeze and expand, building up pressure beneath the surface and potentially causing the floors to crack, lift or burst. Thus, the membership club wholesaler could not afford to shut down walk-in coolers and freezers.
Given these logistical, legal, and financial constraints, rebuilding was ruled out. KPS Global, an insulated panel manufacturer, was tasked with delivering a solution to restore the cold storage, preserve refrigeration uptime and improve both structural performance and thermal energy efficiency.
Response
To complete the project, KPS Global team specified over 17,000 square feet of Thermal Liner Panels, along with 200 Batten Strips to reinforce the most vulnerable joints. The Thermal Liner Panels were installed over the existing panels to enhance insulation, while Batten Strips were used to reinforce seams that had been significantly compromised.
The scope of work included:
- Back of House Walk-in Cooler Boxes:
- Meat Prep – 10’ height
- Bakery Prep – 10’ height
- Overstock Cooler (Produce) – 26’ height
- Front of House Walk-in Freezer Boxes (Exposed to Ambient Air):
- Overstock Freezer (Dairy) – 26’ height
- Overstock Freezer (Bakery) – 26’ height
- Overstock Freezer (Meat) – 26’ height
The Thermal Liner Panels were installed over the existing panels to enhance insulation and restore a like-new appearance, while the Batten Strips were used to strengthen seams where significant damage and wear was present. This method allowed refrigeration to remain on during installation and minimized on-site labor requirements.
The entire material load was transported from Georgia to Aruba in just two 40’ containers. Impressively, the on-site installation team consisted of only three crew members, demonstrating the scalability and effectiveness of the solution.
Documented benefits2 included:
- Increased R-value significantly reducing thermal leakage and improving refrigeration system efficiency replacement
- Extended panel lifespan without full tear-down or replacement
- Minimal labor requirements, with only a 3-person crew needed
- No refrigeration downtime, ensuring uninterrupted store operations
Before 24°C
After 8°C
Door Before
Door After
Installation was performed in a controlled 10°C environment, critical to adhesive performance and required the use of high-access lifts for work up to 7.5 meters (26 feet) in height.
Results
KPS Global restoration solution achieved measurable operational and financial outcomes:
- Almost 50% faster completion: 5 weeks vs. 10 weeks
- Reduced labor footprint: 3-person crew vs. 7 for full rebuild
- Zero operational downtime: All systems remained online throughout installation
- Improved food safety and air quality through better humidity control and environmental stability
- Existing panel life can be increased by up to 5 years
- Meets NSF standards
Conclusion
With over 75 years of experience, KPS Global consistently delivers solutions to complex challenges. Our ability to innovate and adapt ensures that we provide cost-effective, efficient and sustainable results for any project. Whether overcoming environmental constraints or meeting stringent operational needs, KPS Global is committed to improving performance, enhancing energy efficiency and extending the longevity of systems. This project is a prime example of how we use our expertise to create tailored solutions that drive success in even the most challenging conditions.
1Regulations of the Spatial Development Plan Aruba (ROPv)
2REFRIGERACION Soluciones Frigirificas 2025
