A large food processing facility specialising in frozen products faced an unexpected refrigeration crisis that put millions of pounds\u2019 worth of goods at risk. In response, a rapid and innovative deployment of temporary low temperature cooling ensured business continuity and the preservation of inventory.<\/p>\n\n\n\n
Late on a Friday evening, the site\u2019s primary ammonia-based refrigeration equipment suffered a catastrophic condensing coil failure. The resulting loss of cooling threatened to raise the deep freeze storage temperature above safe levels. With no quick alternatives available for storing such a large quantity of frozen products, and restricted space within the facility, immediate action was necessary to prevent spoilage and significant financial loss.<\/p>\n\n\n\n
By Monday, a technical team from ICS Cool Energy were on site for a rapid assessment. Conventional options, such as external cold storage, were not feasible due to capacity and logistical constraints. Instead, two high-capacity low temperature cooling units were deployed, supported by a dedicated dry air cooler and on-site power generation. The installation leveraged air handlers placed within cleared racking inside the storage area, and a total of eight low temperature units were used\u2014each equipped with advanced motorised valves and customised defrost controls to maintain continuous operation.<\/p>\n\n\n\n
Additional measures included enhanced trace heating of coils and drains to prevent ice blockage, and comprehensive lagging of hoses and equipment to avoid excessive ice build-up. Teams worked in alternating shifts to cope with the demanding sub-zero environment, ensuring both rapid installation and ongoing safety.<\/p>\n\n\n\n
The emergency solution became fully operational in less than four days. For the duration of the two-week intervention, storage temperatures remained safely below threshold, protecting all inventory. The successful resolution not only avoided a substantial loss but also demonstrated our ability to deliver effective emergency cooling for complex ammonia-based cold storage failures in the food manufacturing sector.<\/p>\n\n\n\n
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