How important is a temperature resilient environment in food production?  

Amid rising global temperatures, food production facilities need to change. We’re looking at what can be done to make cold storage environments resilient to extreme weather conditions.

Global temperatures are rising. We’ve seen a summer that produced the UK’s hottest day on record, with temperatures often exceeding 30°C. These temperatures can pose problems for the UK’s temperature-controlled environments.

Here at Ambrey Baker, the demand for temperature-resilient storage facilities has never been higher. Working with both food and drink producers, as well as pharmaceutical companies, we’ve received growing requests to help keep products sensitive to temperature changes safe.

For medicine, chocolate and other perishable goods, even slight temperature changes can generate a huge impact. We’ve seen an increase in the demand for temperature-resilient environments, whether that’s upgrading existing property or building anew. Heatwaves we have recently experienced will be increasingly commonplace, so infrastructure must be in place to protect temperature-sensitive goods.

Medicine has to be stored at very precise temperatures and products like meat and fish can spoil in warmer conditions. Therefore, there are health and financial implications to storage facilities susceptible to changes in temperature.

Risk management

When it’s plus 30°C outside, how do cold storage units continue to work at -60°C? Especially without a huge strain on energy consumption?

Executive Director Paul Waldeck says “It’s about being able to anticipate all eventualities, through a disciplined approach, we can eradicate risks before they can arise.

“With a new nationwide focus of lowering carbon emissions, it further refines the strategies we implement to protect cold-storage units for our clients.”

For previous clients, simple maintenance works have yielded positive results. These works can reverse the effects even minor degradation can have on a cold storage unit’s efficiency and effectiveness.

Temperature resilient but low effort

Panels, equipment and the likes of gaskets and doors all degrade over time. If these aren’t able to perform at their optimum levels, refrigeration equipment needs to work a lot harder and use a lot more energy, which goes against net zero ambitions. In some cases, no matter how much energy is expelled, if units are compromised they won’t be able to get to the required temperature, so these minor improvement works can be very effective.

The corrosion of doors and gaskets over time, which can be particularly costly within cold storage, is an issue we see commonly. If a door fails to seal properly, refrigeration equipment may have to work a lot harder than usual to perform, yet these gaskets are often overlooked.

Prioritising regular maintenance, including tasks such as clearing ice and dust, can be of great benefit to a unit’s efficiency. The only expenditure here is a short amount of time dedicated to these tasks. Replacing fluorescent tube lighting with LEDs can provide a quick win for energy savings.

Refurb or new facility?

There is a certain appeal of a brand new facility, but the effectiveness of refurbishments is too often overlooked. Strategic re-designs of operations and workflows and renovating properties – from top to bottom if needed –  can make your factory and its storage facilities feel like new at a fraction of the cost and with a much smaller carbon footprint.

Our “to do” list on refurb projects includes tasks such as; replacing faulty doors, installing sweeper gaskets to make seals airtight, checking and changing the HVAC system, overlaying new flooring, and installing hygienic planking to internal walls.

Optimised factories produce much lower emissions and minimise the risk of products becoming spoiled. With companies often stockpiling raw materials and finished goods to create supply chain resilience and meet customer demands, these facilities’ reliability is paramount.

Refurbishment works also present the perfect opportunity to integrate automation and adopt renewable energy sources too,” he expands. “Factory roofs are the perfect canvas for solar PV systems, allowing many factories to become self-sufficient with their energy.

Future proof

Automation, meanwhile, eradicates the need for sealed doors to constantly open and close for forklift trucks throughout the day. When temperatures outside are soaring, you don’t want your cold storage units to work any harder than they have to. That degree of isolation can go a long way.

Half the battle regarding net zero targets is acknowledging that more needs to be done. It’s also a responsibility everyone needs to shoulder.

Energy bills have skyrocketed in recent months; investing in optimising your factory’s efficiency in line with carbon-neutral targets is vital. Futureproofing your facilities will help stem the negative effects of the UK’s current environmental and financial climates.

Whatever the budget, improvements can be made to keep cold storage units cold. Whether you take small steps or giant leaps, the benefits are there for your pocket and the planet.

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