EJM Engineered Systems Ltd has completed a major refrigeration installation for Cube Cold’s new frozen and chilled storage and distribution facility in Theale, Reading.
Appointed by TanRo, EJM was responsible for the design, supply, installation and commissioning of the complete refrigeration package for the new multi-temperature facility.
The project demonstrates EJM’s ability to deliver complex industrial refrigeration systems that combine natural refrigerants, energy-efficient technology, reliable temperature control and comprehensive monitoring.
A Complete Multi-Temperature Refrigeration Solution
The purpose-built Cube Cold facility incorporates several temperature-controlled environments designed to support demanding cold-chain and logistics operations.
These include two large freezer stores fitted with automated racking systems, a flexible chilled storage chamber, marshalling areas and two high-capacity blast freezers.
The chilled storage area can operate between +1°C and +25°C, allowing the space to be adjusted 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.
Using Natural Refrigerants
The refrigeration installation uses a combination of CO2 and propane, providing Cube Cold with a highly efficient solution based entirely around natural refrigerants.
Multiple transcritical CO2 refrigeration packs serve the freezer stores, blast freezers and marshalling areas, while a propane-based glycol chiller provides cooling for the chilled storage areas.
This approach supports strong operational performance while helping to reduce the environmental impact associated with the facility’s refrigeration requirements.
Improving Refrigeration Efficiency
Adiabatic gas coolers incorporating wet-pad technology were installed to improve heat rejection and system efficiency, particularly during periods of warmer outside temperatures.
Variable-speed compressors and pumps allow the system to respond efficiently to changing refrigeration loads, while EC fan technology is used throughout the evaporators and gas coolers.
Integrated heat recovery also allows warm glycol generated by the refrigeration system to be used for evaporator defrost and underfloor heating.
This reduces the reliance on conventional electrical heating and helps lower the overall energy consumption of the installation.
High-Capacity Blast Freezing
The blast-freezing requirements formed an important part of the overall project.
Two blast freezers were installed, incorporating reversible fan technology to support an even temperature profile across the stored products.
The system is 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.
This provides Cube Cold with the capacity and flexibility required to process a wide range of frozen products efficiently.
Reliable Temperature Control
The freezer stores have an operating range between -29°C and -18°C, while the chilled storage chamber can operate between +1°C and +25°C, subject to Cube Cold’s storage requirements.
Careful system design, optimised refrigeration pack selection and advanced controls provide excellent temperature stability throughout the freezer, chilled and marshalling areas.
This supports product integrity while providing Cube Cold with the flexibility required to respond to changing customer and storage demands.
Advanced Controls and Remote Monitoring
A comprehensive RDM control and monitoring system provides visibility across the complete refrigeration installation.
Temperatures, alarms, operating conditions and equipment performance can be monitored throughout the facility, while remote alarm integration supports rapid fault identification and diagnosis.
The controls provide Cube Cold with greater oversight of its refrigeration plant while helping EJM’s service team identify and respond to potential issues quickly.
Safety Systems and Dehumidification
Robust safety measures were incorporated throughout the project, including CO2 detection, alarm panels and mechanical ventilation systems.
Munters MX2 40 and IceDry 1400 dehumidification systems were also installed to help control moisture within key areas of the facility.
Effective dehumidification can help reduce frost and ice formation, improve working conditions and reduce the frequency and energy requirements associated with evaporator defrosting.
A Complete Mechanical and Electrical Installation
EJM delivered the complete mechanical and electrical package required to support the refrigeration system.
The scope of works included refrigeration pipework, insulation, condensate drainage, secondary steelwork, electrical distribution, cabling, containment, controls and remote monitoring.
The project was delivered under full-time supervision and in accordance with the performance specification prepared by MBA Consulting Engineers.
Supporting Modern Cold-Chain Operations
The completed installation provides Cube Cold with a robust, flexible and energy-efficient refrigeration system capable of supporting modern frozen and chilled storage operations.
By combining transcritical CO2 refrigeration, propane-based glycol cooling, heat recovery, adiabatic technology and advanced controls, EJM has delivered a solution designed around operational reliability and long-term performance.
The project further demonstrates EJM’s ability to manage the design, installation and commissioning of complex industrial refrigeration systems for large-scale distribution and cold-storage facilities.
Read the full Cube Cold refrigeration installation case study:
Refrigeration Installation for Theale Distribution Centre
Industrial Refrigeration from EJM
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 facilities throughout the UK.
To discuss an upcoming industrial refrigeration project, contact EJM Engineered Systems Ltd today.
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