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Cold Room Installation: Detailed Step-by-Step Guide


1. Needs Analysis and Planning

Steps:

  • Determining Needs:

  • The type, quantity and ideal storage conditions (temperature and humidity levels) of the products to be stored must be determined. For example, different temperature and humidity values ​​may be required for food products and different for medicines.

  • Field Analysis:

  • The area where the cold room will be installed should be measured and a layout plan should be made. The suitability of the area, ease of access and energy efficiency should be taken into consideration. It should be checked whether there is sufficient ventilation and electrical installation.

  • Legislation and Standards:

  • Local and international refrigeration standards and legislation must be taken into account. For example, HACCP (Hazard Analysis and Critical Control Points) standards must be followed.


2. Selection of Appropriate Components

Components:

  • Insulation Panels:

  • Material:  Materials such as polyurethane, polystyrene or rock wool can be used. Polyurethane provides energy saving with its high insulation value.

  • Thickness:  Panel thickness should be determined depending on the internal temperature of the cold room and external environmental conditions. It usually varies between 80 mm - 200 mm.

  • Compressor:

  • Capacity:  It should be suitable for the size of the cold room and the cooling capacity required. Capacity is measured in BTU/h or kW.

  • Efficiency:  Compressors with high energy efficiency should be preferred. Attention should be paid to efficiency values ​​such as EER (Energy Efficiency Ratio) or COP (Coefficient of Performance).

  • Noise Level:  Compressors with low noise levels should be preferred, especially if they are to be used in noise-sensitive areas.

  • Ease of Maintenance:  Models that are easy to maintain and have easy spare parts to supply should be selected.

  • Capacitor:

  • Heat Transfer Capacity:  Must be compatible with the capacity of the cooling system. Sufficient capacity directly affects the cooling performance.

  • Air or Water Cooled:  Air cooled condensers consume less water and require less maintenance, while water cooled condensers provide higher efficiency.

  • Material and Durability:  Must be made of corrosion-resistant materials. If used in harsh environments such as sea water or salty air, models with special coatings should be preferred.

  • Evaporator:

  • Capacity:  Must be suitable for the cooling load. Capacity is measured in BTU/h or kW.

  • Air Flow:  It should provide good air circulation. The placement of fans and the direction of air flow are important.

  • Defrost Feature:  It must have an effective defrost system (electric, hot gas or air defrost) to prevent icing problems.

  • Expansion Valve:

  • Type:  Thermostatic expansion valve (TXV) and electronic expansion valve (EXV) are the most commonly used. TXVs are simple and reliable, while EXVs provide more precise control.

  • Capacity:  Must be suitable for the capacity of the cooling system.

  • Adjustability:  It provides the advantage of being adjustable according to different load and temperature conditions.

  • Control Systems:

  • Sensors and Control Panels:  Systems that monitor and control parameters such as temperature, humidity and pressure should be selected. Automatic alarm systems warn of temperature deviations.

  • Data Recording Systems:  Provides historical analysis by recording temperature and humidity data.

  • Lighting and Ventilation:

  • Lighting:  Energy efficient LED lighting should be preferred. The lighting system should provide clear visibility of the products and the work area.

  • Ventilation:  Appropriate ventilation systems maintain indoor air quality and humidity balance. Effective air circulation is important, especially in large-volume cold rooms.


3. Site Preparation and Installation

Steps:

  • Site Preparation:

  • Cleaning:  The floor, wall and ceiling surfaces of the area where the cold room will be installed should be cleaned and leveled.

  • Surface Preparation:  It should be made suitable for the placement of insulation panels. Smooth surfaces facilitate panel installation.

  • Installation of Insulation Panels:

  • Wall Panels:  Wall insulation panels should be installed and the joints should be sealed. The gaps between the panels should be filled with insulation material.

  • Ceiling and Floor Panels:  Ceiling and floor panels must be installed. The joints of the panels must be sealed.

  • Door Installation:

  • Door Placement:  The cold room door should be installed at the planned location. It should be checked whether the door closes properly.

  • Door Insulation:  Door insulation and sealing must be ensured. A gasket must be placed around the door and the sealing must be tested.

  • Cooling System Installation:

  • Component Placement:  Components such as compressor, condenser, evaporator and expansion valve should be placed in the planned locations.

  • Pipe Connections:  Pipe connections between cooling system components must be made. The insulation and sealing of the pipes must be checked.

  • Electrical Installation:  Electrical connections must be made and their compliance with safety standards must be checked.

  • Control and Monitoring Systems:

  • Sensors:  Temperature, humidity and pressure sensors should be installed.

  • Control Panels:  Control panels must be installed and connected to sensors.

  • Lighting and Ventilation:

  • Lighting Installation:  LED lighting should be installed and checked to make sure they are working.

  • Ventilation Systems:  Ventilation systems should be installed and air circulation should be ensured to be effective.

4. Testing and Commissioning

Steps:

  • System Tests:

  • Start:  The cooling system should be started and all components should be checked for proper operation.

  • Parameter Monitoring:  Temperature, humidity and pressure values ​​should be monitored. It should be ensured that the specified values ​​are provided.

  • Leakage Check:

  • Insulation Test:  The sealing of insulation panels and doors should be checked. If any leakage is detected, it should be corrected.

  • Defrost Systems:

  • Defrost Test:  The evaporator's defrost system should be tested. It should be checked for icing and freezing problems.

  • Security systems:

  • Alarm Test:  Alarm and security systems should be tested and ensured to operate properly.


5. Maintenance and Monitoring

Steps:

  • Regular Maintenance Schedule:

  • Maintenance Schedule:  A plan should be established to ensure regular maintenance of the cold room. Compressor, condenser, evaporator and other components should be checked periodically.

  • Maintenance Records:  Keeping records of maintenance performed is important to prevent future problems.

  • Sensor and Control Systems:

  • Calibration:  Sensors and control systems that monitor temperature, humidity and other parameters should be calibrated regularly.

  • Spare Parts and Emergency Plan:

  • Spare Parts Stock:  A spare parts stock should be created for possible malfunctions.

  • Emergency Plan:  A plan for emergencies should be prepared and employees should be informed about this plan.

Conclusion

Cold room installation is a complex process that requires careful planning and correct component selection. Determining the requirements, selecting the appropriate components, site preparation, installation, testing and commissioning must be carried out meticulously. Regular maintenance and monitoring ensure that the cold room operates efficiently and reliably. By following this guide, you can minimize the problems you may encounter during the installation and operation of your cold room and maintain the quality of your products.

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