Results/Benefits Delivered:
- Future-ready refrigeration system enabled by CO2 DX technology, eliminating refrigerant phaseout risk and supporting long-term sustainability goals.
- Continuous operations supported by advanced defrost strategies and high-performance air cooler design, minimizing downtime and temperature disruption.
- Improved energy efficiency through optimized CO2 DX air coolers, EC fan motors, and enhanced refrigerant distribution.
- Maximized usable storage space through a penthouse evaporator solution that preserves interior volume while delivering uniform airflow across high-bay ASRS racks and convertible temperature rooms.
Executive Summary:
A leader in third-party cold storage logistics expanded its presence in the Chicago market with a high-rise automated storage and
retrieval system (ASRS) cold storage facility offering 40,000+ pallet positions. To meet the unique cooling system requirements,
Colmac Coil developed air coolers (evaporators) for convertible temperature cold storage rooms and dock areas.
The facility was designed with a CO2 direct expansion refrigeration system, selected for its superior efficiency at low temperatures,
removal of refrigerant regulatory phaseout risk, and to meet long-term sustainability goals. Colmac Coil’s customized evaporator designs
supported both fixed-temperature zones and convertible rooms capable of switching between freezer, cooler, and tempering modes,
while also reducing defrost cycle time and ensuring continuous operation, delivering an energy-efficient and future-ready solution.
Introduction:
A major cold storage company faced several engineering and operational challenges
when designing its high-bay automated storage and retrieval (ASRS) facility in
Hebron, Indiana. The project required air coolers that could operate reliably under
high-pressure CO2 direct expansion conditions while fitting into the compact
footprint of an automated warehouse. The facility also included convertible rooms
capable of shifting between freezer, cooler, and tempering modes without
compromising food safety or hygiene.
In addition, the dock area featured a pitched roof, requiring insulated penthouse
evaporators to be custom designed with a pitched base to match the roof slope
while maintaining optimal airflow, clearance, and serviceability. Finally, the
equipment needed to maximize runtime and minimize defrost interruptions to
support continuous 24/7 operation.
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