Cold storage installation process cold storage involves 7 engineering steps: site survey and system design, ventilated floor construction, insulated panel installation, door and fittings installation, refrigeration system installation, control cabinet wiring, and commissioning before handover. Each step has its own technical standards, from the 300 mm spacing of the sleeper walls and the PU panel thickness matched to the storage temperature range, through to the nitrogen pressure test carried out before the refrigerant is charged.
An industrial cold store is a sealed system holding a stable temperature anywhere from +8°C (chill room) down to -25°C (deep-freeze storage), used to store food, seafood, fruit and vegetables and pharmaceuticals in volume. Unlike domestic cold rooms, an industrial system integrates screw or piston compressors, evaporative condensers, industrial air coolers and a PLC/SCADA control cabinet into a closed refrigeration cycle.
A mistake at any step leads to heat loss, electricity consumption above the design figure, or equipment failing before its time. With more than 20 years installing cold stores for seafood, food and pharmaceutical plants nationwide, Tan Long has built the cold store installation process these 7 steps from hands-on experience across more than 500 projects, from 50 m² cold rooms to 12,000 MT frozen stores.
This article describes the engineering process. If you are looking for a contractor, see Tan Long's cold storage contracting services — site survey, heat load calculation and a quotation for each individual project.
What is an industrial cold store? How does the installation process affect its service life?
An industrial cold store is a large-scale refrigeration facility, operating on a mechanical vapour compression system to hold a temperature range below the ambient environment inside a fully insulated space. In refrigeration engineering, how long the system runs reliably depends directly on the precision of cold storage installation process. Three items in particular determine its performance: treating the floor against cold bridging, the technique used to assemble the insulated panel envelope, and the tightness of the refrigerant pipework. Following the construction process properly protects not only the equipment but the quality of the goods held in long-term storage.
Telling frozen stores and chill rooms apart by storage temperature range
System industrial cold storage are usually classified by operating temperature, which in turn governs the choice of equipment and materials in cold storage installation process.
- Chilled Storage: Holds a temperature from 0°C to +8°C, the optimal solution for agricultural produce, fruit, pharmaceuticals and dairy products.
- Cold Storage (frozen): Operates from -18°C to -25°C, and down to -40°C on deep-freeze stores used specifically for seafood and export food products.
The difference in purpose determines the specific technical parameters: PU panel thickness rises from 100 mm on a chill room to 150 mm or 200 mm on a freezer store. The capacity of the refrigeration compressor and the defrost heater configuration of the air coolers also have to be calculated from an accurate heat load before construction begins.
Common construction faults that push up operating costs
Drawing on hands-on experience from major projects, Tan Long sees many firms make serious mistakes in cold storage installation process, leading to wasted electricity and equipment failure:
- No floor ventilation system: On a freezer store, failing to build ventilated sleeper walls or to install floor heating elements lets moisture accumulate, causing frost heave that destroys the floor structure and reduces the insulating performance of the panels.
- Substandard refrigerant pipe insulation: Insufficient insulation thickness lets the refrigerant pick up heat along the pipe run, reducing cooling performance at the air cooler.
- Open panel joints: Not tightening the panel camlocks to the correct torque, or skipping the dedicated low-temperature silicone along the joints, creates thermal bridges.
According to figures from Tan Long's engineering department, each small heat leak can make the compressor run 10% to 15% longer than the original design intended. This is why choosing a firm with deep expertise in refrigeration system installation is the decisive factor in optimising a business's operating cost and return on investment.
Step 1: Site survey, system design and technical drawings
In cold storage installation process the survey and design stage is the foundation that determines 80% of the system's operating efficiency and service life. At Tan Long, the engineering team measures the actual site and establishes the storage requirement in detail — the characteristics of the goods, the temperature range required, and the daily intake and dispatch volumes — in order to calculate the heat load accurately.
The cold store heat load is the total quantity of heat the system must remove each hour, usually expressed in kW or kcal/h. An accurate heat load calculation has to account for: heat conducted through the insulated panel walls, heat from the goods themselves, radiant heat from the lighting, the air cooler fan motors, and the heat introduced by operators working in the space. This total heat load is the only basis on which the engineering team can select the capacity of the refrigeration compressor and the air coolers to match, avoiding wasted electricity from excess capacity or an overloaded machine from insufficient capacity.
A worked example: a project cold storage storing seafood over 500 m² at an operating temperature of -20°C, in a hot climate such as Ho Chi Minh City, typically has a calculated heat load in the range of 45 to 60 kW of cooling. To keep the system within a safe margin, a screw compressor with a motor rating of 37 to 45 kW (roughly 50 to 60 HP) is the optimal engineering choice.
The output of this stage in cold storage installation process is a detailed technical file comprising:
- Layout drawings for the store envelope and the door system.
- Process and instrumentation diagram (P&ID) for the refrigeration system.
- Electrical schematic and automatic control diagram.
- Construction detail for the ventilated sleeper wall floor (for freezing and frozen storage rooms).
Fixing the position of the compressor set, the discharge direction of the condenser and the position of the pressure relief valves on the drawings means the actual refrigeration system installation stage runs smoothly, on schedule and to the highest technical standard.
Step 2: Floor construction, sleeper walls and PU floor panels
In the construction phase proper, the floor is the first item and forms the foundation for the entire system. The store floor has to be absolutely level, with a deviation of no more than 5 mm across the whole surface, before the following steps in cold storage installation process.
Technical standards for building ventilated sleeper walls
A ventilated sleeper wall is a system of concrete ribs beneath a freezer store floor whose function is to create an air circulation void. This entirely prevents cold bridging into the ground, which would otherwise freeze the floor and crack the foundations after long periods of operation. When carrying out cold storage installation process, the sleeper wall specifications have to follow this standards table strictly:
| Specifications | Standard value |
| Spacing between sleeper walls | 300mm |
| Width of each sleeper wall | 100mm |
| Height of each sleeper wall | 100mm |
| Width of the perimeter sleeper wall | 200mm |
| Vent gap at the end of the sleeper wall | 50mm |
| Overall level deviation | ≤ 5mm |
All sleeper walls must be levelled together using a laser level or spirit level. Any height deviation over 5 mm creates uneven load points on the insulated panel system, which readily leads to cracked panels and reduces the performance of the freezer store.
Moisture-proofing and floor insulation
Before the PU floor panels are laid, the team must install the moisture barrier — bitumen, polythene sheet and bituminous paper — exactly as the technical drawings specify. Once the moisture barrier is complete, the floor insulation boards in polyurethane (PU) or high-density EPS are laid tight against one another, leaving no thermal gaps.
The thickness of this insulation layer typically ranges from 100 mm on a chill room up to 200 mm on deep-freeze stores reaching -25°C. The thickness and material density must be chosen from the heat load calculation made at the preliminary design stage, in order to optimise refrigeration system operating costs. This ensures the refrigeration compressor operates at its design capacity and holds a stable temperature range for the goods.
Step 3: Erecting the envelope, wall panels and insulated ceiling panels
Within the sequence of steps, erecting the wall and ceiling panels is the item that takes the longest. Tan Long's engineers normally run these in parallel to optimise the overall schedule of cold storage installation process while still keeping the structure consistent throughout.
Camlock connections and sealing the panel joints
Cold store wall and ceiling panels lock together through a male-female camlock system built into the panel core. The assembly process has to meet three technical conditions: a gap of 3 to 5 mm between adjacent panels for the low-temperature silicone to fill; two beads of sealant applied along the edge rebate before the camlocks are tightened; and a locating V-section of 40 × 40 × 2 mm sheet, 200 mm long, riveted on both faces at every joint.
The silicone used at the panel joints must be a low-temperature grade, either acid-cure or neutral-cure. Opaque white silicone is used on panels clad in Colorbond or PVC-coated steel; clear silicone is used on stainless steel clad panels. Before applying the silicone, peel back the protective PE film on both sides of the joint so that the silicone bonds properly.
PU panel thickness by storage temperature range
Establishing the panel thickness is the decisive step in optimising the performance of a refrigeration compressor and saving electricity in operation. Tan Long applies the following PU panel thickness standards by temperature range:
| Storage temperature | PU panel thickness | Typical applications |
|---|---|---|
| 0°C to +8°C | 100mm | Chill rooms for vegetables, fruit and dairy |
| -5°C to 0°C | 100mm | Pre-freezing rooms |
| -18°C to -12°C | 125mm | Frozen food storage |
| -25°C to -18°C | 150mm | Export seafood freezer stores |
| -40°C to -25°C | 200mm | Deep-freeze stores, industrial ice cream |
Step 4: Installing cold store doors and finishing the fittings
Within the envelope structure, the cold store door is regarded as the weakest point for insulation. It is operated frequently, takes constant mechanical impact from forklifts and foot traffic, and therefore demands cold storage installation process.
Technical requirements for sliding and hinged cold store doors
Depending on the scale of the project and the operating requirement, Tan Long supplies two main door ranges: T-Light manual sliding insulated doors for large stores with forklift traffic, and T-Light hinged insulated doors for smaller rooms. For a cold storage installation process to reach optimal performance, the door system has to meet demanding technical standards:
- Sealing: The cold gasket system around the door leaf must seat perfectly against the frame, allowing no cold air to escape to the outside.
- Heater element system: The door frame must have heater elements running continuously to prevent icing, so the door opens and closes easily and the rubber gasket lasts.
- Operating mechanism: The hanger and sliding track system must be made from rigid material, so it runs smoothly without judder and carries the considerable weight of the insulated panel leaf.
On freezer stores running below -10°C in particular, the condensate drain line at the door recess needs insulating and a heater wire fitting inside it. The heater wire has to extend at least 100 to 150 mm beyond the panel wall to stop the condensate freezing and blocking the line.
Installing pressure relief valves and finishing fittings
Once the envelope is erected, technicians fit the supporting accessories to the design drawings, completing the cold storage installation process properly:
- Pressure equalisation valve: This fitting regulates the pressure difference between the inside and outside of the store when the temperature changes sharply or the door is opened, protecting the envelope structure from distortion.
- Monitoring and safety systems: Install a digital temperature display where it is easy to read, together with an alarm bell and warning light. The emergency alarm switch inside the store is mandatory, to keep operating staff absolutely safe.
- Trim and leak sealing: Purpose-made aluminium V-section trim is used on the internal and external corners. The camlock access holes are capped for appearance and every last gap is sealed with dedicated low-temperature silicone before the cold store envelope is handed over to the plant installation stage.
Following these small details strictly at the finishing stage is what makes the system durable, minimises the risk of heat loss and optimises maintenance costs for the owner.
Step 5: Installing the refrigeration system, pipework and equipment
The refrigeration plant is the heart of an industrial cold store: the compressors, the condenser (or cooling tower), throttle valve electronic components, the air coolers and all the refrigerant pipework. This work requires engineers certified in refrigeration with hands-on experience of high-pressure systems.
Pipe insulation and installation standards
The pipework carrying refrigerant inside the store must run parallel or perpendicular to one another, clamped firmly on supports at even intervals. The whole suction line must be insulated with elastomeric foam or foamed polyurethane in situ, to the thickness shown on the design drawings. The liquid line and the discharge line are not insulated but must be kept away from heat sources and must not touch the store panels directly.
The compressor set, the condenser, the water pumps and the cooling tower must be mounted on a steel frame or a concrete plinth at least 150 mm above floor level. The frame or plinth must be level and have a drainage channel. An air-cooled condenser must stand at least 200 mm off the wall so the hot air can discharge freely, avoiding recirculation of hot air that would reduce condensing performance.
Choosing a refrigerant for an industrial cold store: NH3, R404A or R507
The refrigerant is the fluid circulating through the vapour compression cycle, absorbing heat at the air cooler and rejecting it at the condenser. The three refrigerants most commonly used in industrial cold storage in Vietnam today are:
| Medium | Evaporation temperature | Suitable applications | Safety notes |
|---|---|---|---|
| NH3 (R717 – Amoniac) | Down to -40°C | Large industrial cold stores, seafood plants | Toxic, prone to leaking, requires a sealed machine room |
| R404A (HFC blend) | Down to -40°C | Small and medium frozen stores | High GWP, being phased down under the Kigali schedule |
| R507 (HFC blend) | Down to -46°C | Deep-freeze stores, a replacement for R404A | GWP higher than R404A, on the same phase-down path |
NH3 (ammonia) has the highest cooling efficiency of the group, a low refrigerant cost and no GWP (Global Warming Potential), which suits the trend towards sustainability. However, NH3 is toxic and corrodes copper, so the whole system has to use steel pipe rather than copper, and a separate machine room with leak detection has to be designed in. R404A and R507 are safer for operators but are being progressively restricted by international regulation because of their high GWP.
Step 6: Installing the control cabinet and wiring the electrical system
Control cabinet is the automated operating centre of the cold store, managing the whole cycle of compressor start/stop, air cooler defrost, fault alarms and temperature logging.
The cold store electrical system must be wired entirely to the approved electrical schematic and equipment layout drawings. Cable sizes must match the load and the circuit length; check the actual run length before cutting. The control cabinet goes somewhere cool and dry, easy to see and to operate. If it is mounted on a steel frame, the frame must stand at least 300 mm above floor level.
PLC electrical cabinet (Programmable Logic Controller) for an industrial cold store typically integrates: PT100 temperature sensors at several points in the store; an automatic defrost controller running a programmed cycle; overload, overpressure and phase-loss protection relays for the compressors; and a SCADA connection for remote monitoring by computer or phone. The SCADA system (Supervisory Control and Data Acquisition) retains a real-time temperature history, serving the data retrieval required under HACCP and ISO 22000 for food storage.
Step 7: Charging refrigerant, pressure testing and commissioning
The final step before handover is the most important verification stage, confirming that the whole system operates as designed before it goes into actual use.
Nitrogen leak testing and evacuation before charging
Verifying the system before charging involves three technical steps in a mandatory order. The first is the pressure test: dry nitrogen (N₂) is pumped into the entire pipework system up to the test pressure required by the design, typically 15 to 25 bar depending on the refrigerant, held for at least 24 hours and checked for leaks with soapy water at every weld and joint. The second is evacuation: a vacuum pump draws moisture and air out of the system, reaching a vacuum below 500 microns (0.067 kPa) and holding it for at least 30 minutes to confirm the system is completely tight. The third is charging the refrigerant to the exact design charge weight in kilograms — neither over nor under, because both states reduce efficiency and damage the compressor.
Checking the operating parameters after commissioning
After charging, the system is run continuously for at least 4–8 hours and the following operating parameters are recorded:
| Parameter | Measurement method | Reference value (freezer store at -20°C) |
|---|---|---|
| Suction pressure | Manifold pressure gauge | Equivalent to an evaporating temperature of -25°C to -30°C |
| Discharge pressure | Manifold pressure gauge | Equivalent to a condensing temperature of +35°C to +45°C |
| Suction gas temperature at the compressor | Contact thermometer | From -15°C to -20°C (with 5–10°C of superheat) |
| Compressor motor current | Ammeter | Not exceeding 90% of rated current |
| Air temperature inside the store | PT100 sensor | Reaches the design temperature after 12–18 hours |
A cold store meets the handover standard when it holds the design temperature steadily for at least 4 consecutive hours with no leak, no electrical overload and no unexpected shutdown.
What determines the cost of installing an industrial cold store?
In practice there is no fixed market price for cold store construction. The total investment in a project depends closely on six groups of technical and commercial factors that the contractor has to calculate right from the survey stage in cold storage installation process standard.
| Factor | Effect on capital cost |
| Store area and volume | Directly proportional to the quantity of materials and the plant capacity |
| Operating temperature | A freezer store (-25°C) typically costs 40% to 60% more than a chill room (+5°C) |
| Refrigerant type | An NH3 system saves electricity but has a higher upfront capital cost than freon |
| Equipment brand | Compressors from Bitzer, Carlyle or Mycom (EU/US/Japan) cost 20% to 35% more than Chinese equivalents |
| Project location | Projects in mountainous or island regions raise transport and accommodation costs |
| Specific requirements | HACCP standards or a pharmaceutical store call for a stainless steel envelope and GxP monitoring |
Cold store construction in Vietnam currently runs at roughly 3.5 million to 8 million VND per m³ of store volume. That range depends heavily on the technology chosen and the specification set out in the design documents.
Drawing on experience across many large projects in Tan Long's capability record, we always advise investors to require a detailed cost breakdown from the contractor. That is what keeps cold storage installation process transparent, by itemising each element: insulated panels, refrigeration equipment (compressors, condensers, air coolers), the electrical control system, the store doors and the installation labour. Comparing contractors in that detail is what lets a client optimise their return on investment and secure the long-term durability of the system.
Why choose Tan Long to build your industrial cold store?
Tan Long has established itself as a leading firm in the design, manufacture and installation of industrial refrigeration systems in Vietnam. Built on more than 20 years of experience and formally incorporated in 2005, we own a modern equipment manufacturing plant in Duc Hoa 1 Industrial Park, Tay Ninh Province. Tan Long is proud to be among the first five businesses in Vietnam to master industrial freezing equipment manufacturing technology, giving us control and quality assurance at every stage of cold storage installation process.
Proven delivery capability on major projects
Tan Long's reputation is demonstrated by a series of large-scale refrigeration systems built for multinational food and seafood groups. Flagship projects include:
- Kyokuyo Vina Foods Co., Ltd: A complete NH3 refrigeration system together with 08 high-speed IQF belts, contact plate freezers and flake ice machines.
- Lotte F&G Vietnam Co., Ltd: Design and installation of the refrigeration system at Long Hau Industrial Park, Tay Ninh (formerly Long An).
- C.P. Vietnam Livestock JSC: Turnkey delivery at Tan Phu Trung Industrial Park, Cu Chi.
- Frescol Tuna Vietnam Co., Ltd: Project delivered at Nghi Loc, Nghe An.
Delivery experience ranging from 500 MT storage rooms to complex integrated systems of tens of thousands of MT allows Tan Long to optimise cold storage installation process for each client's specific requirement.
Handover procedure and warranty policy after installation
What sets Tan Long apart is the responsibility we take after completing cold storage installation process. Once the system has been commissioned and confirmed to meet every design parameter, we carry out a structured handover comprising:
- Detailed as-built documentation: Including as-built drawings, equipment data records and the full set of acceptance reports.
- Operational training: Written technical instructions supplied, plus hands-on training for the plant's own personnel.
- 24/7 Technical Support: Our after-sales team in Ho Chi Minh City is ready to attend on site within 2 hours. We also apply PLC and SCADA control connected to the internet, for remote monitoring and technical support.
Tan Long provides free technical consultation, including a preliminary heat load calculation and a recommended configuration for the compressors and compressor packs best suited to your project.
Contact information for consultation and price quotation:
- Technical hotline: (+84) 933 357 058 (Mr. Thinh).
- Headquarters: 86 Dong Den, Tan Binh Ward, Ho Chi Minh City.
- Website:tanlongvn.com – where our full capability record and refrigeration equipment specifications are kept up to date.
See also the conditions for construction by region: cold store installation in Hanoi and Cold storage installation in Da Nang.
Frequently asked questions about the cold store installation process
How long does installing an industrial cold store take?
The build time depends on the size of the store and the complexity of the system. A 50–100 m² cold room is typically finished in 7–10 days. A 500–1,000 m² cold store needs 20–30 days. An integrated system over 2,000 m² with an NH3 compressor set and IQF belts can run to 60–90 days from the start on site.
Does a cold store need a construction permit?
A new industrial cold store of 1,000 m² or more, or one inside an industrial park, usually requires a construction permit and fire safety approval under local regulations. The contractor is responsible for advising and supporting the owner through these procedures.
How many years do cold store PU panels last?
PU panels manufactured to standard, installed correctly and operated properly last 15 to 20 years. What shortens panel life: moisture getting in through open joints, mechanical impact from forklifts, and incorrect cleaning (directing high-pressure water straight at the panel joints).
Is NH3 dangerous to use in a food store?
NH3 is safe when the system is designed and installed to standard, fitted with adequate leak detection sensors and with a machine room completely separated from the food storage area. Thousands of food and seafood plants worldwide — including many Japanese and European businesses operating in Vietnam — use NH3 as their primary refrigerant and hold HACCP/ISO 22000 certification.
Roughly what does annual cold store maintenance cost?
Scheduled maintenance on an industrial cold store typically runs at 2–5% of the original capital value per year, covering: compressor oil changes, cleaning the air coolers and condensers, checking system pressures, topping up refrigerant if there is a small leak, and checking the electrical control system. Maintaining on schedule extends equipment life and keeps the system performing.
Frequently asked questions about the cold store installation process
What steps does the cold store installation process involve?
Site survey and design, floor construction, erecting the panel envelope, installing the cold store doors, installing the refrigeration system and pipework, electrical and control wiring, commissioning and acceptance, then handover with operating instructions.
Why is the survey and heat load calculation the most important stage?
Because every piece of equipment is selected from the calculated heat load. Calculate it low and the store never reaches temperature; calculate it high and the investment is wasted while the plant cycles on and off constantly — both are expensive and hard to correct once installed.
What special treatment does a cold store floor need?
The floor has to be insulated and waterproofed in the correct layers; a deep-freeze store also needs protection against floor freezing, which can cause heave and structural cracking over time.
How long does installing a cold store take?
The time depends on the scale, the temperature range and the site conditions. Tan Long will give you a specific schedule after surveying your site.
What has to be checked at cold store acceptance?
Leak testing the envelope and doors, commissioning to check the pull-down time and temperature stability, checking the defrost cycle operation, checking the protection devices, and handing over the technical documentation with operating instructions.
Does Tan Long deliver cold stores on a turnkey basis?
Yes. Tan Long delivers turnkey, from survey and design through equipment manufacture to installation, commissioning and post-handover maintenance.
Related pages
- Cold storage for eel preserves all nutrients and safety
- How to arrange goods in cold storage for effective preservation
- Ice cream cold storage: standard temperature, construction and installation cost
- Construction and installation of reputable and quality cold storage for wine preservation
- cold store design consulting by product type
Kỹ sư Nguyễn Toàn Thịnh (Giám đốc Kỹ thuật)
Hơn 18 năm kinh nghiệm thực chiến chỉ đạo tư vấn thiết kế và thi công hệ thống lạnh công nghiệp nặng, kho tự động ASRS và cấp đông IQF qua hơn 29 đại dự án quốc gia.
