EJM Engineered Systems Ltd was appointed by TanRo to design, supply, install and commission the complete refrigeration package for Cube Cold’s new frozen and chilled storage and distribution facility in Theale, Reading.
Delivered in accordance with the performance specification produced by MBA Consulting Engineers, the project required a reliable and energy-efficient refrigeration solution capable of supporting several different temperature-controlled environments.
The completed installation uses natural refrigerants, including CO2 and propane, to provide high-performance cooling across freezer storage, chilled storage, blast freezing and marshalling areas.
Project Overview
The new multi-temperature facility includes two large freezer stores fitted with automated racking systems, a versatile chilled storage chamber and two high-capacity blast freezers.
The chilled storage area can operate between +1°C and +25°C, allowing Cube Cold to adapt the space according to changing product and operational requirements.
The two blast freezers are capable of cooling up to 26 pallets of mixed packaged products from +4°C to a core temperature of -18°C in under 36 hours.
EJM was responsible for the complete refrigeration installation, including the refrigeration plant, mechanical services, electrical infrastructure, safety systems, controls, monitoring and commissioning.
The Refrigeration Solution
EJM designed and installed multiple transcritical CO2 refrigeration packs serving the freezer stores, blast freezers and marshalling areas.
Adiabatic gas coolers incorporating wet-pad technology were installed to improve system performance during warmer conditions. This supports efficient heat rejection while helping to improve the longevity and reliability of the refrigeration equipment.
A propane-based glycol chiller system was also installed to support the chilled storage areas. Warm glycol recovered from the refrigeration system is used for evaporator defrost and underfloor heating, reducing the need for conventional electrical heating.
This integrated approach provides Cube Cold with a highly efficient and adaptable refrigeration solution while reducing the facility’s environmental impact.
Key Deliverables
- Complete refrigeration system design, installation and commissioning
- Multiple transcritical CO2 refrigeration packs
- Adiabatic gas coolers with wet-pad technology
- DX CO2 evaporators serving the freezer stores, blast freezers and marshalling areas
- Propane-based glycol chiller system
- Warm glycol evaporator defrost systems
- Glycol underfloor heating mats
- CO2 detection and alarm systems
- Mechanical ventilation systems
- Munters MX2 40 and IceDry 1400 dehumidification systems
- Refrigeration pipework, insulation and condensate drainage
- Secondary steelwork and equipment supports
- Complete electrical distribution, cabling and containment
- RDM controls, monitoring and data management
- Remote alarm integration
- Full system testing and commissioning
System Performance
The installation was designed to provide precise and reliable temperature control throughout the facility.
The two blast freezers are capable of cooling up to 26 pallets of mixed packaged products from +4°C to a core temperature of -18°C in under 36 hours. Reversible fan technology helps produce a consistent temperature profile across the stored products.
The freezer stores can operate between -29°C and -18°C, while the chilled storage chamber can be adjusted between +1°C and +25°C depending on Cube Cold’s storage requirements.
EC fan technology is used throughout the evaporators and gas coolers, while variable-speed compressors and pumps improve efficiency during part-load operation.
Integrated heat recovery provides warm glycol for evaporator defrost and underfloor heating, further reducing energy consumption.
Project Benefits
- High-efficiency natural refrigerant solution using CO2 and propane
- Excellent temperature stability across freezer, chilled and marshalling areas
- Flexible chilled storage operating between +1°C and +25°C
- High-capacity blast freezing for mixed packaged products
- Reduced energy consumption through warm glycol defrost
- Improved part-load efficiency through variable-speed compressors and pumps
- Efficient heat rejection using adiabatic gas coolers
- Improved equipment longevity through wet-pad technology
- Integrated heat recovery for defrost and underfloor heating
- Comprehensive CO2 detection, alarms and ventilation
- Complete remote monitoring and diagnostics
- Reduced environmental impact through the use of natural refrigerants
- High-quality mechanical and electrical installation delivered under full-time supervision
Controls, Monitoring and Safety
A comprehensive RDM control system provides Cube Cold with complete visibility of the refrigeration installation.
The controls allow temperatures, operating conditions, alarms and equipment performance to be monitored across the facility. Remote alarm integration supports rapid fault identification and allows the system’s performance to be reviewed without requiring constant on-site attendance.
CO2 detection systems, alarm panels and mechanical ventilation were installed throughout the relevant areas to provide a robust and fully integrated safety solution.
The Result
The completed installation provides Cube Cold with a dependable, efficient and environmentally responsible refrigeration system capable of supporting its modern cold-chain and distribution operations.
By combining transcritical CO2 refrigeration, propane-based glycol cooling, heat recovery, adiabatic gas coolers and advanced controls, EJM delivered a complete solution offering operational flexibility, temperature stability and long-term reliability.
The Theale project demonstrates EJM’s ability to design, install and commission complex, large-scale industrial refrigeration systems for demanding temperature-controlled storage and logistics facilities.
About EJM Engineered Systems Ltd
EJM Engineered Systems Ltd specialises in the design, installation, commissioning and maintenance of large-scale industrial refrigeration systems.
Our experienced team delivers complete refrigeration, mechanical, electrical and control packages for cold-storage, food-production, manufacturing and distribution environments across the UK.
To discuss your industrial refrigeration requirements, contact EJM Engineered Systems Ltd today.
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