In this blog, we will discuss some of the tips we recommend you take to install a walk-in cooler or freezer. Walk-in coolers and freezers are an essential part of a business, and it is important for them to be installed properly to ensure long-term efficiency.
Applying Butyl
Butyl is a type of caulk that provides a highly flexible and waterproof sealing solution. When installing your walk-in, this is a critical step to protect your walk-in for years to come. Both the application and the amount of butyl you apply is crucial.
When applying butyl, cut the tip of the tube flat, not at an angle like you would a regular caulking tube. If cut at an angle, the butyl will drag along the panel instead of staying at our recommended consistent 3/8-inch bead. Apply straight down the side of the groove on the warm side of the panel down to the end where you can then seal the bottom side of the panel as well.
Make sure you are using a battery or air-powered caulk gun when applying the butyl as it allows a continuous flow outside of the tube, giving you an easy finish on the panels.
Ensure Panels Are Level
When your panels are set up, always ensure they are level with each other. Look at the top of the panels and run your hand across to make sure they are aligned and flat.
Misaligned panels can leave gaps, which could cause air leaks and intrusion of moisture that can damage your panel’s efficiency. Locking misaligned panels can also put stress on the cam-lock inside the panel’s edges that could lead to damage and warping over time.
Once you have made sure the top of your panels are level, start locking the cam-locks from the top down to the bottom.
Resetting the Cam-lock
KPS Global uses cam-lock hardware that secures our panels together to allow fast and easy installation, as well as help provide airtight seals for your walk-in cooler or freezer.
If you are experiencing any problems when trying to lock the panels together, first ensure the panels are properly aligned and that there is no debris in the locking mechanism that could block engagement with the other panel.
Once that is checked, we recommend you try resetting the cam-lock properly. Using the provided locking wrench, turn the tool all the way counterclockwise, allowing the cam-lock to be in a fully open position and then turn the wrench clockwise again to re-lock the panel.
Apply Silicone Evenly
Now that your panels are locked together, apply a bead of silicone if there are any significant gaps between the panels. Start by applying the silicone in the panel joint, moving from the top-down. Next, using the back of an old silicone tube, move from the bottom-up to scoop the excess silicone out of the joint.
Applying in this manner provides an airtight seal to prevent any moisture or ice buildup, ensuring thermal efficiency for your walk-in.
Checking for Thermal Breaks
If you are installing a freezer and your blueprints call for a thermal break, KPS Global recommends that you ensure it is cut in the correct position and no metal is touching to effectively minimize heat transfer and maintain energy efficiency. Ensure the insulation material on the thermal break is intact, free of any damage. Additionally, check for no gaps or leaks that could lead to energy loss or moisture buildup.
Make Sure Door is Plumb
When installing, you want to make sure your door section is square and plumb. You can do this by checking the measurements with a tape measure or laser level.
Start by measuring across the bottom to the top to ensure they are the same, as well as diagonally from top to bottom on each side to confirm that the door is vertically aligned before you install the door stabilizer.
Properly Adjust Door Sweep
If you run into any problems while installing the door sweep for your walk-in cooler or freezer, you can adjust the sweep to make sure it is aligned properly with the door. Using a Phillips head screwdriver, loosen the screws on the sweep and adjust the top lip of the sweep up or down to your desired level.
You want to make sure the sweep just comes in contact with the threshold to ensure proper installation.
Installing Top Trim
One of the most important steps to ensure your walk-in cooler or freezer is aesthetically pleasing is installing top trim. When installing top trim on your walk-in, you want to make sure it is not crooked or installed incorrectly as this will make the walk-in look poorly assembled.
The most common challenges we see installers face when installing top trim is either butting the two pieces of trim together creating a long vertical gap or when overlaying two pieces of trim which causes a bump near the bottom of the trim that is visible.
To address these situations, KPS Global recommends putting a small dog ear cut at the bottom edge of the trim. This allows you to overlay the other panel over the dog ear cut and push the bottoms together, creating a seamless flow that looks clean.
Adjust Dial Thermometer
Finally, after your walk-in is built, if your unit has a dial thermometer, KPS Global recommends you adjust your thermometer when the walk-in cooler or freezer has reached the desired temperature and the refrigeration is on and running.
The quickest way to do this is to take a cup of ice water, insert the bulb of the thermometer into the cup of ice water and wait around two minutes for the thermometer to come down to the desired temperature, which is what you should set your thermometer to.
Using a small flat-head screwdriver, pop the glass off the center of the thermometer and loosen the small groove in the middle of the needle counterclockwise adjusting the thermometer to your desired degree. Tighten it clockwise, pop the dial’s glass back on and your thermometer is now set.
Best Practices
Whether your walk-in is used for a ghost kitchen, grocery store or refrigerated warehouse, the process of building the unit involves a series of detailed steps. Dedicating time to carefully follow each phase of the process can make for a better performing unit.
A thorough and precise installation not only supports the functionality of your walk-in but also optimizes its performance in the long run. For additional tips & tricks about the process of installing a unit from KPS Global, check out our YouTube channel or contact us to speak to one of our knowledgeable experts.
