Blog

Moving Out The Old Walk-in Cooler and Freezer Panel Press

2008-09-11T23:13:00Z

There comes a time when old equipment just can’t keep up with new production demands. This time we made a big move.

Friday we shut down our panel press area, all three presses, and let a backlog of frames build up while we moved our old vertical panel press out of the area. Then we cleaned the area and moved our new panel press into place. The old panel press handled our largest panels, but it was slower to set up and operate than our horizontal presses.

The new horizontal panel press holds more panels on each platen than the old press, more than either of our other two horizontal presses, and the new press has more platens than the old press. Better yet, it takes up less floor space than the old vertical press so the panel press crew has more room to move and the work flow is smoother.

Here’s pictures of the move:

Our old press

Positioning a dolly under the new press.

A second dolly positioned under the new press.

Pulling the new press out of the way where the old press will be stored.

Leaving just enough room between the wall and the new press for the old press to move.

Moving the old press out of it’s spot and down the wall, and starting on cleanup for placing the new press.

Finishing and inspecting the cleanup before placing the new press.

Moving the new panel press into place.

We spent the weekend making final adjustments on the new panel press and preparing it for joining the work flow on Monday morning. More pictures and stories to come.

Solar Powered Refrigeration The Next Big Thing?

2008-08-21T01:27:00Z

In a series of announcements, GreenCore Air, Inc., has moved solar-powered air conditioning into reality. A McDonald’s franchise in Dallas, TX, “will be supplementing its traditional air conditioning system with the GreenCore solar DC air conditioners in order to reduce energy usage and related monthly operating costs. (CNNmoney.com)"

This is a great step forward in lowering energy costs in foodservice. The next great step will be when the technology is efficient enough to handle the requirements for walk-in coolers and freezers. Definitely, that is a big step up in power requirement, but the change could be on the horizon.

The US Navy is even getting into the act, purchasing and installing units in a remote installation of the Naval Research Laboratories. The Navy requirement is to operate grid-free and uninterrupted 24/7 for all 365 days of the year, a tall order.

Technology like this will eventually help isolate the foodservice business from extreme rises in energy pricing, helping control costs and keeping prices in line with customer expectations.

A Place For Sustainable Culture In Foodservice

2008-08-21T00:56:00Z

Lenny’s article in Foodservice Equipment & Supplies online addresses a number of great ways to control energy costs.

While his ideas are great, we want to add inspecting and possibly replacing the walk-in cooler and freezer doors, they could be silently stealing any planned energy savings, and considering upgrades to system conponenets that can pay back in months. Also, if a project is in the design stage, we can consult on energy saving design and equipment specification decisions, and we can help find incentives and rebates offered by government bodies and utilities--some upgrades can be entirely paid for with rebates and incentives, depending on the installation location. Our suggestions also meet the January 1, 2009 requirements of the Energy Independence Act of 2007.

You can read more about our design ideas on the rest of our web site, or give us a call at 1-800-238-4093.

ThermoSteel Door Hardware Isolates Heat Transfer On Walk-in Coolers And Freezers

2008-08-16T00:40:00Z

Using ThermoSteel door hardware backing reduces another point of thermal loss, and electrolytic corrosion, by thermally separating the steel hardware from the finished skin of the door. ThermoSteel combines the strength of steel with better thermal efficiency than wood, a winning combination.

The traditional manufacturing method for fabricating steel door backing for refrigeration hardware is mounting steel backing behind the exterior finished metal skin on the door frame. The door hardware is then attached directly to the exposed side of the exterior finished metal skin and the interior steel
door backing.

Two Long-Term Drawbacks With Uninsulated Steel Hardware
While steel door-backing is the strongest and most durable method to mount refrigeration door hardware, there are two long-term drawbacks. One drawback to traditional steel door backing systems is the steel backing promotes premature corrosion through electrolysis when used with certain exterior finished metal skins, such as aluminum, a very common skin material.

The second drawback is “telegraphing”, the thermal conduction created between two metals contacting one another in cold storage/ambient air conditions. The conduction between these two metals causes them to sweat, eventually staining and then rusting the finish metal on the door and frame.

The ThermoSteel door hardware backing system incorporates the use of 3/4-inch thick Thermo-Lite® insulated boardstock sandwiched between the cold storage door hardware and 10-gauge galvanized backing plates. The remainder of the cavity inside the door and frame sections is foamed in place with urethane foam. The Thermo-Lite board acts as an isolator between ferrous and non-ferrous metals, eliminating any chance for electrolysis to occur.

The insulating value of the Thermo-Lite inhibits conduction from cold transfer between the backing plates and the finished wall metals. This eliminates any rust or corrosion from forming on the exterior finished wall metals. The Thermo-Lite composite material is present throughout the entire door frame section and provides superior strength without the use of conductive materials attached directly to the door hardware.

Call or email Nick Stahl (1-800-238-4093) for more information on how ThermoSteel works for you.

COUNTDOWN TO ENERGY INDEPENDENCE Walk-in Cooler and Freezer Fan Motor Changes

2008-08-15T23:48:01Z

(E) for evaporator fan motors of under 1 horsepower and less than 460 volts, use:
(i) electronically commutated motors (brushless direct current motors); or
(ii) 3-phase motors;
(F) for condenser fan motors of under 1 horsepower, use:
(i) electronically commutated motors;
(ii) permanent split capacitor-type motors; or
(iii) 3-phase motors;

Reducing The Heat Load And Microcontrollers Further Raise Efficiency
Moving directly to EC motors will actually raise energy efficiency more than any other solution and compound the cost savings because they emit less heat than either typical Shaded Pole or Permanent Split-Capacitor (PSC) motors. Reducing the heat load inside of the walk-in effectively reduces the compressor’s run time. Fewer refrigeration cycles not only saves energy it extends the life of the compressor as well.

Current EC motors operate at approximately 85% efficiency. This makes EC motors 50-60% more efficient than the older Shaded Pole motors and 30% or more over PSC motors. These efficiencies quickly add up to real cost savings when applied to the 50-85 watt motors capable of turning the 10-18-inch fans producing the higher airflows required to effectively cool walk-in coolers and freezers. EC motors are also available with microcontrollers for precisely matching environmental requirements which constantly vary.

Adjusting Designs Is Easy, Simply Exchange The Part Number
Designing refrigeration systems with EC motors is relatively easy: a change in nomenclature simply replaces the current choice of Shaded Pole or PSC motors. No changes in design are required past specifying the motor, especially since the electrical requirements will be lower with EC motors. EC motors are designed to be compatible with existing evaporator cabinets without any change in physical dimensions. Rebates are available for retro-fitting EC motors in California.

For more information on securing walk-in coolers and freezers, call or email Nick Stahl (1-800-238-4093).

Imperial announces change to 245fa blowing agent.

2008-07-03T01:20:00Z

Imperial now joins leading walk in cooler / freezer manufacturers in providing the highest R value panels available. Imperial 4” panels exceed federal 2009 freezer standards and Imperial’s unique 3-1/2” panel exceed federal 2009 cooler standards! These standards will go into effect January 1, 2009 as required by the US Energy Independence and Security Act of 2007.

We cover all this information and more in our “Countdown To Implementation: Energy Independence Act 2007” web site.

While Imperial exceeds 2009 federal standards with minimal thicknesses of panel, we strongly believe in maximum energy savings. That means going far beyond federal minimums. California Energy Commission (and Oregon Building Code in 2009) already requires R values considerably higher than federal standards. Cooler panels need to be 4” thick and freezer panels need to be 5” thick to meet these standards. We have met these stringent standards since inception and, in fact, are the first Walk-in manufacturer to be tested and validated by an Energy Star testing agency. Imperial is receiving energy incentive rebates for its industry-leading Walk-in Cooler and Freezer systems.

Bookmark this site for regular updates.

Product Security Helps Foodservice Businesses Handle Cost Control

2008-06-16T21:18:00Z

Lock hasps are a simple method for securing walk-in cooler and freezer contents. While the main advantage is avoiding product loss, the secondary advantage of access control ensures that product is not exposed to undue harm from exposure to heat or other damaging conditions by unauthorized entrances.

Using a cylinder lock in the latch is a substitute for using a hasp. Cylinder locks require more care with key security because the lock cannot be changed immediately. Lost or misplaced keys can require expensive replacement of the cylinder on an irregular basis.

Physical Mounting
Hasps are secured to the door frame using tamper-proof fasteners and are thermally separated from the inside temperature. The staples are mounted on the door using a through-bolt inside release. This configuration placing a staple on the door and the hasp on the frame is the most secure against forced entry because it places the most force against the heavier built frame instead of the lighter door panel.

Hasps can be defeated, even with tamper proof bolts; a locking bar is an even more secure method for protecting product in walk-in coolers and freezers.

The locking bar uses two staples, one mounted on either side of the door through the frame. The staples are mounted to the door frame using a threaded rod and a twist-off inside release on the interior. Once the bar is in place, there is no access to the mounting hardware because the hardware is covered by the bar. The main drawback to a locking bar is that two locks are required, one for each side of the door, both locks must be removed to open the door. Using two locks adds some minor complexity to maintaining keys for the locks, but locks can be quickly replaced and keys can be synched.

Keys Versus Combinations
Keyed locks are preferred because keys control access physically, a person must have a key in order to access the secure area. Combination locks are not recommended because control of the secure factor, the combination, is easily passed along from one person to the next and replicated each time it is passed along; controlling physical keys is much more secure.

More About Tamperproof Fasteners
Tamperproof fasteners provide an extra level of security by making it very difficult for unauthorized persons to remove hinges and latches. Without the proper tools and access, tamperproof fasteners are extremely difficult to remove, foiling quick attempts to pilfer product by removing hardware. Many styles and designs of tamperproof fasteners are available to handle specific situations, matching various security requirements and tool designs.

For more information on securing walk-in coolers and freezers, call or (1-800-238-4093).

Energy Act Requires Automatic Door Closers

2008-06-14T00:22:00Z

This requirement covers all doors up to 3 feet 9 inches wide and up to 7 feet tall, anything beyond these dimensions is exempt. Most doors beyond the sizes mentioned either already have some door-closing action incorporated or are subject to other special requirements.

R-Plus Doors use a self-closing door package that has a magnetic gasket to ensure a proper seal. Spring hinges swing the door to the closed position and the door closer uses a spring to pull the door completely closed and ensure the door is latched shut. The latch has a more sensitive action that works in combination with the door closer.

Other styles of door closers are available for larger applications. Hydraulic door closers are also available.

Gear Up For The 2nd Annual Commuter Challenge

2008-05-30T18:18:00Z

You know I enjoy this. Anytime I can cut the cost of commuting and get a chance to ride my bike to work. OK, some days I cheat and use the MAX line to get over, or under, the hills, but at least I give it a try. Here’s our press release on our involvement this year

A whole bunch of us won awards from the WTA last year and we had some fun getting the awards. So who’s up for the Commuter Challenge this year?

FE&S Remarks on New National Walk-in Cooler and Freezer Requirements

2008-05-19T21:04:00Z

Dan Greenberg, Associate Director, E Source, writes about the new rulings required nationally and how only five states are currently working with similar requirements: California, Connecticut, Maryland, Oregon or Rhode Island. The bill was signed into law by President Bush in December 2007 and goes into effect on January 1, 2009.

According to Greenberg, ....” an analysis conducted for Pacific Gas & Electric in advance of California’s adoption of these standards, these features will add, on average, slightly less than $1,000 to the cost of a walk-in. The good news is that they’ll cut energy consumption by as much as 55 percent, yielding a simple payback to the user of 1.5 years for freezers and 3.4 years for refrigerators, on average.”

Our own Paul Nastari recently published two articles in FCSI’s The Consultant covering energy-efficiency and the technologies used in walk-in coolers and freezers. You can read both these articles to get a very good understanding of the technology and background behind conforming to these new regulations.

FCSI Quarter 4 2007 - R You Insulated Against the Next Phase (Out)? (PDF)

FCSI Quarter 1 2008 - Capturing Financial Savings through Energy Efficiency in Commercial Refrigeration (PDF)

Comment here or give Paul a call if you want to discuss how to handle these regulations.

Energy-Efficiency and Alternative Energy Ranked Highest by 37% of Americans

2008-05-01T03:38:00Z

We are working pretty hard with our customers in foodservice and other industries to help lower energy use and the accompanying costs through better, and sometimes “green”, technologies. Many subsidies are available from federal, state and local governments and utility companies, that will pay for a large portion or possibly the entire cost of the upgrade. So these energy-efficiency efforts just make good business sense, and now they make customer-interest sense, too.

The interest in saving energy and reducing costs is only going to rise for the foreseeable future, so this is a great time to stay in step with the public and show that our businesses can be publicly responsible and still be profitable. In fact, many of these energy-efficient solutions return higher cash flow and greater profitability within months. Given a choice, this survey indicates customers will find an energy-efficient solution more attractive, whether that is a fuel-efficient delivery vehicle or a energy-efficient walk-in cooler or freezer.

You can read the entire FECDA report on their web site. Additional energy and cost-savings technical information is available from this web site, including information on the hidden costs of using pre-charged line sets, and the efficiencies of using split systems versus self-contained systems. More information on how Imperial Manufacturing approaches energy-efficiency is available from your Imperial representative.

State Policies On Energy Savings--Look For Effects On Walk-in Coolers & Freezers

2008-04-17T04:17:00Z

This contact information came from the State Energy Efficiency Policy Bulletin, your connection to legislative, regulatory, and industry news from accross the country.

Kickplates: Essential Protection for Walk-in Cooler and Freezer Doors

2008-04-16T20:53:00Z

Even simple push carts or hand trucks can degrade a door over time. The act of opening a door with the hand truck blade or the ends of a cart cause wear and eventually break down the door surface unless it is protected. Mounting a kickplate can avoid damage requiring the door to be replaced before it’s standard lifetime.

Kickplates are mounted on each side of an R-Plus door using screws and sealed with color-matching silicone. This mounting process maintains the integrity of the door finish underneath the kickplate, further enhancing the longevity of the door. The kickplates prevent unsightly damage and maintain the integrity of the interior environment by protecting against puncture, but they can also be quickly replaced in less time and at less cost than replacing a full door.

Available finishes are standard in 1/8-inch aluminum, 18-gauge stainless steel, and 16-gauge galvanized steel. But special orders are available through consultation with your R-Plus Doors factory representative. Stainless steel is the best surface for corrosive environments, especially those exposed to salt-laden sea air, and in manufacturing facilities that are constantly in wash-down cycles. Aluminum is the next best choice for these corrosive environments; galvanized steel will eventually develop rust, especially in where exposed to external environments.

Although kickplates do add weight to a door, this is rarely an issue. In some installations, on extremely large doors, the additional weight can require the use of a heavier-duty hinge or an additional hinge. R-Plus sliding door hangers are already designed to manage heavier weight than the standard doors and easily manage the addition of kickplates.

Obviously, using a kickplate has many advantages. Kickplates extend the service life of the door, protect the door from common bumps and scrapes during typical use, and are quickly replaced when necessary while maintaining the integrity of the environment they enclose. For more information on kickplate options or R-Plus Doors, contact your local R-Plus Doors representative.

Smith & Greene Installs Imperial Walk-in Cooler at Tutta Bella in Seattle

2008-04-14T18:43:00Z

Due to the unique site in Westlake the cooler has to take on some interesting challenges with beams, columns and a mezzanine, not to mention the entrance is at an angle with a ramp. Despite all that was going on with this plan, Smith & Greene and Imperial answered the call. A great place, with an elegant pizzeria atmosphere this site has excellent neighborhood views into the heart of Seattle. Check out their web site for more about this fantastic pizzeria and their coveted Verace Pizza Napoletana “VPN” certification.

Whether planning new construction or remodeling an existing space, a proper analysis and specification can win big bottom line rewards on an annual energy usage basis and on the overall construction investment. Contact our nearest rep to see what savings might be available in your project.

Curtis Restaurant Equip Installs Imperial Walk-in Cooler at Albany, OR, Sizzler

2008-04-14T18:01:00Z

On this project the City of Albany required structural calculation of the walk-in, requiring that the walk-in would stand up to the worst imaginable weather conditions as well as a catastrophic event, if one were to arise. Working with Miller Consulting Engineers, Imperial provided a walk-in that both meets the Sizzler’s growing needs but also is extremely safe from a structural standpoint.

In many cases Imperial’s walk-ins do not require any changes to the normal construction approach. In this particular case, Miller Consulting Engineers recommended a moment frame to ensure stability of the walk-in under the most extreme conditions. Imperial Manufacturing constructed and incorporated a steel moment frame at a very minimal cost, giving Sizzler’s of Albany a very useful and safe cold storage walk-in.