The Ultimate Guide to Walk-In Coolers & Freezers

Here, we outline key considerations to help make this process as smooth as possible. If you need any other support, we encourage you to connect directly with an expert by emailing rsgsales@refsg.com, or calling 800.955.5253.

location sizing & storage flooring panels & insulation refrigeration controls

Important Walk-In Cooler & Freezer Considerations

Walk-in coolers and freezers provide exceptional storage capacity to keep your products fresher longer. The first consideration is deciding whether you need a cooler, which keeps products at +35°F or above, or a freezer, which keeps products around -10°F for proper preservation and prolonged use. Depending on the size, type, and layout of your operation, it’s likely you may require a combination of both.

Deciding on a cooler or freezer ultimately depends on the products you want to store. For traditional foodservice applications, food safety is always the priority. Often, coolers are used to store quickly perishable items like fresh produce and dairy, and items you’re looking to offload quickly. Freezers are ideal for preserving product for longer periods, and often used for meat, seafood, and desserts.

Given that both coolers and freezers need to sustain their respective temperatures, the right insulation and construction plays a critical role and has a direct impact on energy savings. To maintain lower temperatures, freezers usually require more insulation and thicker panels. More on insulation and construction below.

Location: Indoor or Outdoor Walk-In Units

Location is one of the first considerations when outfitting the best walk-in solution. Is your unit going to be installed inside or outside? Your back-of-house size and layout will be a factor, as well as your storage requirements.

First, assess your available space. Is there enough room for doors to open fully and employees to maneuver safely? Will it be easy to access with minimal disruptions? Consider the frequency of use during rush periods, as well deliveries, especially if large quantities are being stored. The chosen location will need adequate airflow and ventilation, and utility access for electrical wiring, drainage, and refrigeration lines.

Local regulations also play a part. Every municipality has different zoning regulations. You’ll need to verify your local building codes and requirements for the proposed location, and ensure it meets health department guidelines for food storage.

There are pros and cons to both indoor and outdoor coolers. Ultimately, the decision hangs on available space, storage requirements, and the environment.

Indoor coolers take up valuable indoor space; however, they allow employees quick access without exposure to outdoor weather conditions and closer proximity to the kitchen for enhanced efficiency. Indoor environments are more controlled than outdoor, meaning there’s less risk of vandalism and create consistent operating conditions. Consistent conditions reduce the strain on the refrigeration system, resulting in a longer unit life and lower maintenance costs. Typically, there are fewer zoning considerations for indoor units than there are for outdoor, which can simplify the permit process.

However, refrigeration units can be noisy, and improper ventilation can cause heat buildup, which may result in an uncomfortable work environment. Pending the layout and available utilities, installation may be more complex than outdoor units. Retrofitting an indoor space for a walk-in cooler can involve structural modifications and higher labor costs.

If space is a primary concern, an outdoor walk-in cooler or freezer may be the way to go. Outdoor units offer more location flexibility allowing for installation near loading docks, production areas, or other strategic locations. The heat generated by these units remains outside, reducing the strain on indoor HVAC systems, and installation may be simpler because there’s no need to alter existing indoor structures.

Outdoor coolers are more subject to wear and tear from environmental factors, and may require additional weatherproofing, increasing initial costs. In areas with extreme weather, an indoor cooler might offer better protection and overall operational efficiency.

Pro tip: Choosing a location that minimizes heat transfer and is close to power and water sources can save on energy costs.

A note on temperature: When researching the right cooler or freezer unit, you’re likely to notice references to two different types of temperatures: ambient temperature and room temperature.

Ambient temperature refers to the temperature of the overall environment of the cooler, not just inside the cooler, and directly impacts the operating conditions.

Room temperature refers specifically to the indoor space where people are working. Whereas ambient temperature is broader and has a greater range, room temperature generally falls within a standard range comfortable for humans. Ambient temperature plays a crucial role when deciding between an indoor and outdoor unit.

Size & Storage Capacity

The size of the cooler or freezer you need will also help determine the location. The size will depend on the types of items, and how much you’re needing to store. Plan for proper shelving to maximize vertical store, as well as sufficient aisle space for easy access to products.

To assess your storage needs, first consider your inventory volume. Estimate the amount of perishable goods you’ll store at max capacity, factoring in daily or weekly inventory turnover. A good rule of thumb for food storage is to allocate approximately 1-2 cubic feet of storage per meal served daily. Remember to factor in future growth to avoid outgrowing your unit too soon.

Standard box sizes most commonly advertise range from 6’x6’ to 10’x14’. Because every location, application, and need are different, walk-in coolers and freezers are highly customizable. Whatever size or cooler/freezer combo you need, Norlake can design in-house.

Common sizes include:

With or Without a Floor

Walk-in coolers and freezers can come with or without built-in floors. If you decide to save a little money upfront and go without a floor, you’ll need to ensure the location is on a level, concrete surface. You may also need to invest in additional insulation to ensure proper energy efficiency. Concrete floors without proper insulation can act as a thermal bridge that allows heat to enter and increase energy consumption. Local codes also play a factor – some require specific flooring depending on use case – so make sure you verify prior to deciding.

Walk-ins with floors offer a host of benefits, including:

• Better insulation – built-in floors improve thermal efficiency and minimize the risk of heat transfer from uninsulated concrete or other surfaces, reducing energy consumption and maintaining consistent temperatures.
• Easier installation – pre-fabricated floors are ready to use, so there’s no need to add more insulation or vaper barriers.
• Prevents moisture issues – built-in floors often include a vaper barrier which reduces the risk of condensation and moisture build-up, mold, and water damage over time.

Floor structures can vary depending on use case to support heavier weight capacities. Most are made are smooth aluminum, designed for light to medium-duty traffic.

Norlake offers three tiers of floor structures, depending on your use case:

Panel Construction, Insulation, & R-Value

The construction process of your walk-in cooler is one of the defining differences between manufacturers and is a central factor in the durability, longevity, and energy efficiency of your unit. Panel material (the walls of your walk-in) varies, with most manufacturers opting for either aluminum, stainless steel, or galvanized steel.

The walls of your panels are then filled with insulation to keep interior temperatures contained and consistent. Like panel material, the foam insulation installed on the insides of the panels plays a major factor in the quality and efficiency of your unit. This is measured in R-value, the thermal resistance to heat transfer. The higher the R-value, the better the insulation and the unit’s ability to keep the inside temperature cool, saving you money on energy consumption. The industry’s standard R-Value in 25. Norlake’s R-value is 32.

The insulation, of course, has a direct impact on the R-value. Most panels are 4” thick for optimum insulation, and you may notice the term foamed-in-place. This refers to a process where the foam insulation is applied directly to the inside of the panel walls as a liquid spray that expands on contact, effectively filling all gaps to create a continuous insulating layer. This process provides excellent thermal resistance and can act as a vaper barrier, reducing the risk of moisture while increasing your unit’s R-value. Some manufacturers opt not to use this process, which leaves the unit vulnerable to exterior air and decreased thermal resistance, resulting in a loss of cooling efficiency.

Polyurethane and Polystyrene are the two most common insulation materials. Polyurethane is a rigid, closed-cell foam with a high thermal resistance (R-value) and is ideal for temperature-controlled environments. Polystyrene, available as Expanded Polystyrene (EPS) or Extruded Polystyrene (XPS), is a lightweight, cost-effective foam ideal for budget-friendly operations. Both are widely used and offer unique benefits.

Benefits of Norlake’s Panel Construction & Polyurethane Insulation

Refrigeration Type & Systems

The next step is deciding on refrigeration, both your system (self-contained or remote) and the type of refrigerant.

Self-Contained vs. Remote Refrigeration Systems

A self-contained refrigeration system houses all the components inside the unit, like the condenser and evaporator, making them easier to install and ideal for smaller commercial kitchens and locations with limited space. A remote refrigeration system houses the condenser and evaporator separately, with the condenser and compressor usually outdoors or in a cool basement. These systems are best designed for larger operations.

The main factors to consider are application size, budget, environment, and how much flexibility is needed. If mobility or quick installation is a priority, self-contained units are the way to go. Remote systems have higher upfront costs usually tied to the complex installation that may involve additional piping, electrical work, and labor; however, over time they may offer more savings in operational costs.

The American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) classifies refrigerants based on their potential hazards, using a numbering system that begins with R-, followed by the ASHRAE assigned number. The most common refrigerant classifications fall under three buckets:

1. Environmental impact, rated by Global Warming Potential (GWP) and Ozone Depletion Potential (ODP); lower GWP values are better for the environment
2. Flammability, broken down by A1 (non-flammable), A2 (mildly flammable), and A3 (highly flammable)
3. Toxicity, classified as either A (low toxicity) or B (high toxicity, such as HFCs, and rarely used)

Read also:

• Refrigerants and Compliance: Understanding the Choices in a Changing Landscape
• What is the AIM Act & Its Impact on Foodservice

The most common types of refrigerants currently used in walk-in coolers and freezers include:

R-290 is the Future:

With the phase-down of HFCs underway, refrigeration manufacturers are adapting to meet regulations. R-290 (propane) is a top choice many are considering, given its environmental friendliness and energy efficiency. It’s a hydrocarbon refrigerant with an ultra-low GWP (3) and excellent cooling performance, often outperforming synthetic refrigerants in systems designed for its use. It’s especially great for small, self-contained refrigeration systems commonly used in foodservice operations. R-290 is also a natural refrigerant.

Norlake is leading the charge to help operations adapt quickly to the regulated phase-down of HFCs. We’re one of the only manufacturers with self-contained walk-in coolers and freezers available with R-290 refrigeration, all manufactured in-house in the U.S.A. to future-proof operations from potential supply chain shortages.

See all Norlake refrigeration system options.

Norlake: Your Trusted Partner of Choice in Cold Storage Solutions

Norlake is the trusted partner of choice in cold storage solutions. We offer the best warranty on walk-in coolers and freezers in the industry—15 years on panels and 18 months on parts and labor—to ensure you can feel confident with your purchase.

We’re here to see you through from start to finish, from worry-free installation to aftercare support. Our commissioning program takes out all the hassle of installation—we handle all the startup and inspection details, thoroughly testing newly installed equipment, checking temperatures and pressures, ensuring all connections and construction meet manufacturer specifications, and providing a detailed report with photos and select repairs and warranty services at no extra cost, leaving you free to focus on your business.

Our units are completely customizable to meet your needs and the only walk-ins available with environmentally friendly R290 refrigerant manufactured in-house, future-proofing your operation against supply chain shortages. We offer three levels of customization:

1. Kold Locker™: The total package in two days! More than 14,000 configurations available that can ship out in two days – the fastest shipping in the industry!
2. Fast-Trak®: Fast and flexible options – featuring coolers, freezers, and combo units in additional sizes.
3. Fineline™: What you need, we can build. Any size, shape, and finish – Fineline units are completely customizable.

Elevate your cold storage with Norlake. For more information, contact us here.