Since EISA was passed January 1, 2009, the U.S. Department of Energy (DOE) has been working to mandate a standardized energy efficiency test for walk-in coolers and freezers.  The first step was taken with an informal meeting on February 4, 2009 to discuss comments and suggestions from industry professionals on determining a testing procedure. After nearly a year’s worth of research, DOE has published their proposed testing procedure for walk-in coolers and freezers. A follow-up meeting was scheduled to discuss these proposed rulings, but due to winter weather the meeting was cancelled and has not been rescheduled at this time.

In accordance with section 312 of the Energy Independence and Security Act (EISA), DOE published a Notice of Proposed Rulemaking (NOPR) for the test procedure on walk-in coolers and freezers. The NOPR is the first published document for the test procedure rulemaking process for walk-ins. DOE proposes the procedures explained in the NOPR be used to test walk-in equipment. Once performance standards are accepted, manufacturers will be required to use the accepted test to determine compliance and for all representations regarding the energy use of the product.

DOE proposes to adopt a test procedure that contains two separate testing methods; one for the insulated box and the other for the refrigeration equipment. Each of the two components, the insulated box and the refrigeration system, will be tested separately. The manufacturer will be responsible for testing their product respectively and must provide compliance with all testing standards. 

Testing the Walk-in Panels

DOE considers the insulated box to include walls, floor, ceiling, windows, doors, lighting and any other components of the walk-in that are not part of the refrigeration. For testing the energy consumption of the walk-in, DOE developed its own testing method which allows for the overall energy performance to be determined. This will include an insulation test and an air infiltration test procedure.

While deciding which testing methods would be most accurate for walk-in coolers and freezers,  DOE has taken into account several concerns from industry professionals such as ageing insulation and water absorption in foam insulation. DOE has researched both of these characteristics that affect walk-in coolers and freezers and have come to industry conclusions.

Neither the EPCA (Energy Policy and Conservation Act of 1975) nor EISA specify when insulation should be tested for R-value rating in walk-in coolers and freezers. A concern was posed that insulation R-values significantly drop after manufacture; therefore depending on when the insulation is tested calculations could be inconsistent.  DOE investigated this issue and found that aged foam insulation made with gaseous blowing agents does change over time.  Furthermore, DOE has concluded that the R-value decrease occurs within the first 5 years after it is manufactured. After careful research, DOE has determined that insulation ageing is an important factor in determining an accurate testing method for walk-ins. DOE has proposed a testing method for ageing foam called the “thin slicing” method. This technique is used to thinly slice the foam so it ages quickly. The results of this test are to determine the aged R-value of foam 5 years after manufacture.

Additionally, DOE has concluded the use of metal skins does not eliminate insulation aging. It has been frequently stated in the walk-in industry that the use of metal skins on the surface of the foam eliminates ageing and the reduction of R-value in polyurethane panels. DOE studied this issue and found research by the NRCC (National Resource Council Canada) suggesting that medal skins do not eliminate ageing but may delay the rate of aging. The relationship between the skins and the rate of ageing foam depends on the protection of the skin’s surface and the bonding between the insulation and the skin. Punctures made in the panel to allow for cam-locks, light fixtures, doors, windows, controls, etc. weaken the R-value of the panel.  According to DOE, walk-in insulation and their skins typically separate overtime due to the shrinkage of the foam material after manufacture, causing significant air gaps. There is no known testing at this time to account for these imperfections in the panel.

Another important aspect DOE has researched is water absorption in foam. DOE reported that polystyrene foam is highly resistant to water absorption, whereas polyurethane is more easily damaged by moisture. Generally, the solution to help decrease moisture in the insulation is to create an air-tight barrier from the insulation.  However, walk-in panels are continually punctured to allow for installation of fixtures and doors, which allow moisture to enter the insulation. Therefore, the more punctures and holes inflicted on the panel the less efficient the insulation will perform.  At this time, DOE has not adopted a standard test to measure the insulation’s water absorption in walk-in coolers and freezers due to the complexity of this issue.

There are two widely used insulation methods in walk-in coolers and freezers today; Expanded Polystyrene and Polyurethane. When testing R-values and energy efficiency in walk-ins, there has never been a consistent testing method. When EISA passed in 2007, it required a testing procedure be in place no later than January 1, 2012. The NOPR is the first published document stating conclusions and proposals for this testing procedure.

View the NOPR document.

Copeland Scroll Outdoor Condensing Units are perfectly suited for walk-in cooler and freezer applications. All units integrate the many benefits of the Copeland Scroll compressor technology, fan speed control and Copeland PerformanceAlert™ diagnostic controls, and are available in 208/230 single-phase and 208/230 three-phase voltage applications.

Scroll compressors offer the highest energy efficiency levels to lower energy bills. With integrated controls that optimize fan motor speed to maximize the heat transfer through over-sized condenser coils, additional energy savings are achieved. The average energy savings for end-users is $350 per year for a 3HP medium temperature unit, however this number could be greater depending on the application.

Advanced protection and early warning against common failure conditions will help lower maintenance costs. To avoid unneeded service, protection against common nuisance conditions is also included. With the fault code retrieval capabilities of the diagnostic controller, accuracy in the diagnosis of field issues is greatly enhanced, accelerating the service process to further reduce repair expenses.

Smooth scroll movement lowers sound and vibration levels. Ultra quiet variable speed fan motors and internal baffling further improve the sound quality, creating a better customer experience and providing additional location options.

In addition to the benefits of lower energy costs, improved reliability and quiet operation, its slim shape and light weight make these units both aesthetically appealing and simplify the installation process.

Copeland Marketing Bulletin

Visit Copeland’s website for more information on their new Outdoor Scroll units.

Currently we are not automatically redirecting mobile users from uscooler.com to uscooler.mobi. Users will have to type in uscooler.mobi or through the “Mobile Website” link on uscooler.com under the heading Company Info. What are your opinions of automatic redirection from standard to mobile websites? Is there any other information you would find useful on our mobile website?

Did you know your walk-in coolers and freezers are potentially capable of doing double-duty?  It’s a well kept secret you may wish to consider.  Depending upon your existing (or hopefully new, from U.S. Cooler) equipment, you may be able to save thousands of dollars annually by capturing the heat rejected from air-cooled condensing units and using it to pre-heat hot water.

Consultant, Eugene Kanning, from Milwaukee, WI has been employing this strategy for many years.  Kanning has used this application in restaurants, schools and recently in a larger project for the Salvation Army in southern Wisconsin.  According to Kanning the systems have repeatedly netted thousands in documentable savings in the cost of heating hot water.  As a general rule of thumb, if the combined horsepower of the condensing systems is between three and five horsepower, and the operation requires hot water for ware washing and general use, then it makes sense to explore.

A conservative estimate would net a payback of $5000 per year in energy cost which in an average installation would be a 1 – 2 year payback.  According to Kanning “It’s not a complicated process and it can be retrofit to existing locations in most cases.”

If you would like to explore and evaluate the potential payback here are some questions you will need to be prepared to answer:

• Operating Hours per day and per week
• Hours of peak hot water usage
• Estimated hot water usage per day/week
• Obtain a copy of your energy bill during one peak month and one slow month
• Water heater size
• Water heater energy
• Recovery rate
• What temperature are you holding water at
• What are the ambient conditions for the geographic region

If you would like more information on this process contact Gene Kanning contact Gene via email at Kanning@sbcglobal.net

LED lighting provides a 68 to 85% energy savings over the fluorescent lights typically used in coolers and freezers. LED’s use only 15 watts for a 5’ model and 18 watts for 6’. But if energy savings was the only advantage, adoption of LED’s wouldn’t be near where it is today. The real difference is the attractive quality of the light it gives off. LED’s give your products a beckoning glow and more uniform illumination than fluorescent.  You can choose between lights that give off a neutral or slight red or blue hue. Conventional wisdom suggests that the more appealing the product presentation, the more likely a customer is to take notice and purchase it.

LED light not only shines brighter than fluorescent, it also offers other benefits. With LED lights you won’t get lamp burn-out, cold start failures or flicker. LED’s work very well in the cold and last over 50,000 hours in a cooler and almost 100,000 hours in a freezer. Additionally, they don’t give off the heat of flourescents, which will decrease the load on your compressor.

With all the benefits of LED retrofitting, it proves to be a smart investment that will pay for itself many times over. Two LED retrofit options are the Anthony Optimax 2 and the SCHOTT Gemtron Crossfire LED.

LED Retrofit Installation Instructions

The new EISA law requires all new walk-ins be equipped with high efficiency motors to be compliant. These cost a little bit more but save you money in the long run. Some suppliers may try to sell you non EISA compliant refrigeration systems. To be compliant with the law and purchase the best lifetime value always ask for EISA compliant equipment.

1. Remote Systems - Remote systems are the least expensive systems to purchase. They consist of a condensing unit, evaporator unit and misc. parts such as expansion valve, site glass, dryer, pump down solenoid thermostat, and on freezers a timer and drain heater to install the system. They require the use of a licensed refrigeration installer since they are pumped down and charged with refrigerant gas on site. The installer will also charge for any other parts needed for the install such as copper pipe, pipe insulation, connectors, and electrical. They are less expensive systems to buy with the walk-in but may cost more over all depending on what the going hourly rate is with the installer and the cost of the parts he provides. They also provide an advantage by allowing the condensing unit to be located outside the building. There the condensing unit can dump its heat without adding extra heat to the building and air conditioning systems.

2. Pre-assembled Remote Systems - Pre-assembled Remote Systems are the same as Remote Systems except all the parts are shipped installed on either the condensing unit or the evaporator coil. Pre-assembled Remote Pre-charged systems come with the condensing unit, the evaporator coil and line set (copper pipes that connect the two units) charged with refrigeration gas. A licensed refrigeration technician will be needed to install the refrigeration system. These systems may or may not be less expensive depending on the cost of the system, the refrigeration service and electronics service charges.

3. Standard Top Mount - Top Mount Systems are self-contained refrigeration systems. They come with all parts, copper lines and refrigeration gases completely installed. A licensed refrigeration technician will be needed to install the refrigeration system. The only downside to these units is that the evaporator hangs down inside the walk-in taking up shelf space and head room in small walk-ins. Some units come with low profile coils that help but do not eliminate this problem.

4. Side Mount Refrigeration System - Side Mount Refrigeration Systems are the same as Top Mount Refrigeration Systems except they are installed on one of the wall panels with bolts that go through the refrigeration plug and wall panel and are attached with nuts on the inside of the walk-in. They also require that a condensation drain hose be connected to a drain nearby. A licensed refrigeration technician will be needed to install the refrigeration system. One downside is that you lose shelf space where the evaporation unit extends inside the walk-in.

5. Saddle Mount Refrigeration System - Saddle Mount Refrigeration Systems come completely pre-assembled on a bracket that is designed to be mounted over the top of one of the wall panels. These systems must be installed on a panel with slots cut in the top to allow the bracket to go through the wall. These systems are hung over the wall before the installation of the roof. A licensed refrigeration technician will be needed to install the refrigeration system. These units also have the evaporator coil that hangs from the top of the panel but it is more toward the top and doesn’t interfere with the shelving as much as a side-mount unit.

6. Penthouse Refrigeration System - Penthouse Refrigeration Systems are like Standard Top Mount Systems except they do not have an evaporator coil sticking down inside the walk-in. The air inside the walk-in is drawn up through the evaporator coil located with the condensing unit on top of the walk-in to be cooled. A licensed refrigeration technician will be needed to install the refrigeration system. These systems sometimes seem higher in upfront cost but when all things are considered including the fact that they are factory assembled and don’t take up space in the walk-in it is less expensive in the long run.

7. Roll Up Refrigeration System - Roll up Refrigeration Systems are much like Penthouse Refrigeration Systems except they are rolled up to an opening in the side of the walk-in and attached to the unit. One difference is that even though the evaporator coil is located outside the unit it takes up shelf space inside the walk-in because shelving should not be installed in front of the unit. A licensed refrigeration technician will be needed to install the refrigeration system.

Now that you know all about these units don’t let it be confusing. To simplify the selection of refrigeration system, first decide whether allowing the condensing unit to dump heat into the building is unacceptable. If it is then a remote unit is the correct choice. Whether it is pre-assembled pre-charged should be decided by evaluating the difference in cost of having it done in the field or at the walk-in plant.

If dumping the heat inside the building is not a concern then choosing a self contained side mount or top mount refrigeration system verses a penthouse or rollup refrigeration unit should be decided by how important the space in the walk-in is to you. If space is important then a penthouse unit is the choice. If space is not a big consideration then side-mount, top mount or rollup unit may be the choice.

Whatever the refrigeration system you chose it is important to check the efficiency of the unit and the manufacturer’s warranty to make your final choice.

For more walk-in information visit our buying guide.

LED lighting is becoming increasingly popular in the gas station c-store industry. This is not only due to the lower energy consumption of the LED lamps, but the new lighting also makes the beverages in the coolers more visually appealing!

OSRAM Opto Semiconductors recently released their findings from a study on the life-cycle assessment (LCA) of LED lamps. Here is a summary of their findings.

LED life-cycle assessment

Light Emitting Diodes are among the most energy-efficient light sources available on the market. LED lamps are already today more than five times more efficient than incandescent lamps and future technical achievements offer additional potential for the coming years.

At present, artificial lighting accounts for around 19% of global electricity consumption – that corresponds to 2.4% of worldwide primary energy consumption. 70% of the energy used for artificial lighting is consumed by lamps for which there are more energy-efficient alternatives. Simply replacing conventional light sources with LEDs would theoretically halve global electricity consumption for lighting. The potential savings are therefore enormous.

An OSRAM study monitored the life cycle of an LED and an LED lamp. It´s outcome made it clear – LED lamps need less than 2% of their energy consumption for their manufacture – over 98% are used for their task: illuminating the world.

Click here for more information on the detailed process analysis that went into the study and a list of the benefits of LED lighting.

Engine House No. 4 will be featured on the PBS program Illinois Stories at 6:30pm, December 10th (WSEC – Jacksonville/Springfield, WQEC – Quincy, QMEC – Macomb).

Illinois Stories: From the river heritage of Quincy and Hannibal, to the bounty of the richest farmland on earth, Mark McDonald hosts this Emmy award winning series about the people and places of central and western Illinois. PBS

WASHINGTON (Reuters) – A U.S. Senate committee voted unanimously on Wednesday to increase government oversight of food safety but the first significant overhaul in 50 years may not happen until 2010.

Pressure to overhaul the food safety system has grown following several high-profile outbreaks involving lettuce, peppers, peanuts and spinach since 2006 that have sickened thousands and killed several.

However, the full Senate probably won’t vote on the bill until 2010 as Congress is currently mired in debate about overhauling the U.S. healthcare system, said Tom Harkin, chairman of the Senate Health, Education, Labor and Pensions Committee.

“I really, honestly, I just don’t see how we’ll get to it before Christmas,” Harkin said of the food safety bill.

The Senate bill would expand U.S. Food and Drug Administration (FDA) oversight of the food supply and shift its focus toward preventing, rather than reacting, to foodborne outbreaks. FDA would have the power to order recalls, increase inspection rates and require all facilities to have a food safety plan.

“There are very few things that are as important as ensuring that the food we eat and the food we serve our families is safe for consumption,” said Sen. Christopher Dodd, a member of the committee.

The Senate bill is similar to legislation passed by the House in July in many key areas. One area where they differ is the Senate bill does not include a yearly fee to help pay for the increased oversight.

The House would require processing plants to pay $500 per year.

The Senate version could include a fee once the nonpartisan Congressional Budget Office determines the price tag of the Senate bill, Harkin said.

“If this is for public protection, it’s something we all ought to pay for,” he said.

An estimated 76 million people in the United States get sick every year with foodborne illness and 5,000 die, according to the U.S. Centers for Disease Control and Prevention.

The Senate legislation would require FDA to inspect all food facilities at least once every four years and high-risk plants no less than once a year. Currently, many facilities can go several years without being inspected.

Click to read the rest of the By Christopher Doering’s Reuters Food Safety Article

The rubber door gasket on the inside edge of the doors of all your refrigeration equipment is very important. It prevents cold air from escaping, which means the unit will stay colder longer and use less energy. Old gaskets wear out and lose their seal. Even worse, older gaskets can pose a food safety risk because they begin to collect grime and food bits and become a breeding ground for bacteria.

Luckily, it’s easy to replace door gaskets!  There are several different styles of gaskets. To insure you get the proper gasket, gather the following information:

1. Dimension of gasket – Measure from outside corner to outside corner for both height and width.

2. Manufacturer – Get the manufacturer’s name and the model and serial number of the piece of equipment (the serial number may not be needed).

3. Style –  Check to see if the gasket is magnetic or non-magnetic(compression). Almost all newer refrigeration equipment will have a magnetic gasket. A magnetic gasket will be hard and square at the point where it contacts the inside frame of the unit. Magnetic gaskets will also snap shut when you hold the door less than an inch from the frame because the magnet attracts to the metal.

Magnetic door gaskets are the most common.

Compression gaskets usually need a door latch to hold them tight in place to get a good seal. These gaskets are soft and compress easily at the point where they contact the inside frame of the unit.

A compression style door gasket.

Door gaskets are also categorized by how they attach to the door.  There are 3 ways a door gasket mounts on a door: snap in (or dart), push in, and screw in.

How To Replace Refrigerator Door Gaskets By Style

Snap in (or dart) door gaskets

Note the arrow shaped “dart” in the middle. This snaps into a slot on the door.

Removal – Remove the old gasket by grabbing a corner and pulling.  The dart section of the gasket, which fits snugly into a slot in the door frame, will pull out.

Installation – To install the new gasket, soak it in hot water for a few minutes. This will make it more flexible.  Begin by snapping in a top corner first. Then, using a mallet or a block of wood and hammer, tap into place the top of the gasket. Continue by installing the sides from top to bottom, and finally the bottom.

Note: Make sure the hinge side of the gasket does not roll under when you close the door.  If it does, push it into position and you may have to tape the door closed to get the gasket to seat itself. You might also try a hair dryer to heat the gasket as this will help it seat. (Make sure you don’t melt the gasket!)

A push in style door gasket.

Push in door gaskets

Removal – Remove the old gasket by grabbing a corner and pulling!

Installation – Push in gaskets may require vinyl cement. To install the new gasket brush some vinyl cement into the channel and press the gasket into the channel.

Note: Make sure the hinge side of the gasket does not roll under when you close the door.  If it does, push it into position and you may have to tape the door closed to get the gasket to seat itself.  You may also use a hair dryer to heat the gasket as this will help the gasket seat. (Make sure you don’t melt the gasket!)

Screw in door gaskets

Removal – Simply remove screws.

Installation – Screw in the new gasket using retainer strips.

A screw in style door gasket. Note the strip for screwing in the gasket.

Jerry Green blogs about the food service industry at The Back Burner, which is written by the employees of Tundra Specialties, a company specializing in restaurant equipment and restaurant supply.

WASHINGTON — The U.S. Department of Energy (DOE) has announced three new steps to strengthen its ability to enforce energy efficiency standards. DOE has formed a new enforcement team within the Office of the General Counsel; established a program to randomly review manufacturers’ compliance with DOE certification requirements; and is publishing guidance that provides further details about DOE’s energy efficiency enforcement regulations.

In its new guidance, DOE confirms that under existing regulations, it can take enforcement action and assess civil penalties if a manufacturer fails to properly certify a covered product and retain records. Specifically, the agency clarifies that any failure to certify covered products according to DOE’s rules violates the Energy Policy Conservation Act of 1975 and DOE regulations. DOE will randomly select previously filed certification reports for review, request certification records as needed, and hold manufacturers accountable for failing to certify covered products according to DOE rules.

DOE said these new steps are part of its effort to save energy for U.S. residents and businesses by clearing the backlog of energy efficiency standards for appliances and aggressively enforcing those standards. This past summer, DOE initiated investigations of alleged violations against both an air conditioner manufacturer and a freezer manufacturer. Both investigations are expected to be concluded shortly.

This article comes from ACHR The News. Click here for the original article.

If you have already purchased restaurant equipment in 2009, or are planning on doing so before the year is up, make sure you get your accountant to take a special 50% depreciation allowance for all equipment that is purchased, installed and used by December 31st.

This tax provision was extended by President Obama’s stimulus bill from 2008, and it provides an excellent benefit for restaurants that need to purchase new equipment but are tight on cash in a struggling economy.

If you’ve already taken the leap and purchased new equipment this year, congratulations!  You’ll be able to take this 50% write-off on this year’s taxes with no problems.  If you’re not sure if now is the time to buy, maybe this is the thing that pushes you into shopping mode.

That’s because this incentive is only good through the end of the year, and the kicker is that the equipment must be installed and in use by the end of the year.  You can’t just wait for December 30th and order the equipment you’ve been wanting and still qualify for the credit.  So now, with two months left, might very well be the right time to act.

Greg McGuire blogs about the foodservice industry at The Back Burner, which is written by the employees of Tundra Specialties, a company specializing in restaurant equipment and restaurant supply.

Storage of Fresh Food in the Refrigerator

The air in a fresh food refrigerator is always quite dry. What moisture there is in the refrigerator tends to collect and condense on the evaporator surfaces. Therefore, food containers should be covered and as air tight as possible to keep food moist.

The temperature inside the fresh food cabinet should be kept at 35 to 45 degrees F. Most fresh foods may be kept from three days to a week at the above temperatures. Unfrozen meat and fish should be stored at as close to 32 degrees F as possible. Fruits and vegetables should be cleaned and prepared for the table before being refrigerated.

For Storage of Frozen Food in the Freezer

The air in a food freezer, as in refrigerator, is very dry. Any moisture in the air of the freezer quickly condenses on the evaporator coil surfaces. It is very important, therefore, that all frozen foods be packaged in moisture proof containers.

When packaging food for the freezer, as much air as possible should be removed from the packaging. Frozen food packages must be tightly sealed. Ordinary paper is too porous for freezer use. If not properly packaged, frozen food will develop ”freezer burn”.

Freezer burn is indicated by a change in color of the food. Food value is not affected but there is a change in color and outside appearance.

Most frozen foods, if kept at temperatures of 0 to -10 degrees F may be kept for several weeks. Food to be kept for a year or more should be frozen at -20 degrees F or lower. Some frozen foods keep better than others; beef keeps better then pork.

It is a good idea to keep a thermometer in the refrigerator and freezer to make sure you don’t have any refrigerator repair issues. We give free thermometers to our customers who need GE refrigerator repair Tucson, AZ.

View the original Dependable Refrigeration Article

Many businesses have already been impacted by the Spring 2009 H1N1 flu outbreak. Steps can be taken now to slow the spread of the flu. It is also possible that flu conditions may become more severe, so it is important to plan now for how to respond under those circumstances.

Why you should be concerned about the spread of the flu in the workplace.

The work place may act as a “point of spread”, where employees can easily spread flu to their fellow employees as well as others in the community. The flu can have a major impact on business operations, causing workers to stay home because they are sick or they have to take care of other sick family members.

For more information and how to plan for H1N1 and the seasonal flu from the CDC review their toolkit.

Source:http://www.cdc.gov/H1N1flu/business/toolkit/pdf/Business_Toolkit.pdf

How to Prepare your Restaurant for a Swine Flu Outbreak

NRA, CDC & Ecolab offer recommended steps for foodservice operators.

WASHINGTON – Responding to the prediction by medical experts of a return of the H1N1 virus (swine flu) this fall, the National Restaurant Association together with the U.S. Centers for Disease Control and Prevention and Ecolab are recommending steps that foodservice operators can implement to help control the spread of the virus, Nation’s Restaurant News reports.

Among the recommendations:

• Base all prevention and response strategies on information from state and local health officials, and communicate your plans to employees.
• Encourage your employees to be vaccinated against the flu.
• Keep workers exhibiting flu-like systems to remain homebound for at least 24 hours after the fever has passed. Expect workers in such situations to be out for three to five days, and implement sick policies that are flexible, not punitive.
• Remind employees to cover their mouth and nose when they cough or sneeze. Provide tissues for both employees and customers.
• Advise employees to wash their hands regularly.
• Cross-train personnel in critical areas in the event that key employees are sick.
• Increase cleaning and disinfection frequencies.

Source: http://www.nacsonline.com/NACS/News/Daily/Pages/ND0915093.aspx

Government Urges Flu Preparations for Small Businesses

The U.S. Department of Homeland Security wants small companies to come up with a plan for when employees are out sick with swine or seasonal flu.

WASHINGTON – The U.S. Department of Homeland Security wants small businesses to be prepared for the H1N1 flu, The Washington Post reports. On Monday, the agency urged small companies to develop contingency plans for when employees are out sick with H1N1.

Half of the country’s private-sector workers are employed at small businesses, and the federal government strongly recommends those companies have plans in place to keep the economy going.

“We are already seeing an uptick in cases across the country,” said Homeland Security Secretary Janet Napolitano. “We expect that to continue throughout the fall and winter.”

Already, the government has issued guidelines for school campuses, asking that they stay open and allow sick students to do their work from home. But some small business owners have not devised a flu plan yet and are not convinced one would help their business.

“I think you’ll see a lot of business owners stretched to the max,” said Molly Brogan, spokeswoman for the National Small Business Association. “You’ll see stores shut down a day or two. In this economy, you can’t afford that. Unfortunately, there aren’t a lot of other options.”

The agency wants small businesses to think about a worst-case scenario, with many of their employees out of the office at a time. Officials estimate people sick with the flu will be out for three to five days. Visit www.sba.gov/flu for a complete list of the government’s guidelines.

For more on flu resources at NACS Online, visit the “Industry Resources” section.

Source: http://www.nacsonline.com/NACS/News/Daily/Pages/ND0916091.aspx

More information on Swine Flu. http://news.yahoo.com/s/ap/20090830/ap_on_he_me/us_med_swine_flu

Taken right after the tornado hit Casey's General Store in Williamsville, IL.

After the store clean-up.

Additional pictures of the damage.

By leasing your walk-in, you avoid having to come up with the complete purchase price necessary to buy it outright. Instead, with leasing, the cost is spread out comfortably over a fixed period of time, and only a small initial down payment is required. Leasing removes the need for equity financing. It also allows you to acquire and use an asset without having to make a substantial down payment. Thus, minimizing the affect on your cash flow and working capital.

U.S. Cooler has partnered with Advantage Leasing to provide our customers with a financing program for their walk-in equipment. For more information on the program visit the leasing program page on our website or contact Advantage Leasing for details.

The biggest mistake people make when filling out a bill of lading is they simply put a basic description of the product like “plastic figurines”.  The problem is that plastic figurines are a density item according to the NMFC and can be classified at any class from a 70 to a 400 (which is a difference of about 250% in price).

Without a classification number, the carriers have every right to bill out at a class 400 if “plastic figurines” is all they are given.  The proper way to describe this item on a bill of lading is to write a description which includes the NMFC issued number.  This is a perfect way to describe this item “Plastic Articles, NMFC #157320 Sub 8, Class 85.”

Elizabeth LaFleur, freight auditor for Logistics Management, Inc., says shippers will cut down on a lot of headaches if they followed this simple process.  LaFleur says, “When a carrier see’s a poor description, they red flag it and can classify it at a much higher class.  If the description on the bill of lading is vague, a lot of times there is nothing that can be done to fight it.  However, if the item number is on the bill of lading then there, is no problem.”

Not only can this be a hassle, the cost can be significant to a shipper.  The way it is nowadays in the freight world is if a shipper does not fill out their bill of lading accurately they get nailed not only with the difference in the freight class but also with a “Weight & Inspection” fee which can be as high as $30.00.

What a Bill of Lading Should NOT Look Like

Recently I visited a prospect that was getting overwhelmed with Weight & Inspections from carriers.  They pulled their bill of ladings for me and on them was the description for “tools”.  There was two problems with this description.  First, “tools” is too vague of a description and second, they were actually shipping drive shafts and other engine parts for race cars.

Don’t laugh, they are not alone.  In fact, many shippers have similar scenarios.  What is a familiar story at a lot of companies is that some carrier rep provided a description 20 years ago and that is the way bill of ladings have been filled out ever since.

There is no descriptions in the NMFC for just “tools” so this description would trigger dock workers to perform a W&I to change the class.  You can bet they will change it to the highest possible class for a tool.

What was interesting in this example is that when we properly classified their products, most of the engine parts were actually a lower class than the class the carriers were billing them at under “tools”.

By doing nothing more than helping this customer to fill their bill of lading properly this customer lowered their freight cost by about 12%.  Of course, the president of that company and I are friends for life now.

What can you do?

There are two things that you can do to eliminate carrier inspections.  First, get the weight right.  Once the carriers determine you to be one who “guesses low on weight”, then you are flagged in their system.  You will be nailed every time by W&I teams.

Secondly, and most important: be as accurate as possible with your description.  Make sure you have the most up to date NMFC number followed by the description (the way it is read in the NMFC).  When your bill of lading is properly filled out, the clerk at the carrier is more likely to move to the next bill of lading.

What a Bill of Lading Should Look Like

This is the text book way to fill out a bill of lading.

Now it is very important to follow these instructions more than ever.  Not only are the carriers looking for the extra cash, the NMFC guide is changing all the time.  Sometimes they are making change which make the classes higher.  Sometimes they are actually changing them to be lower.  The most important part is get with someone who is very familiar with the NMFC guide and get them to properly fill out your bill of lading the correct way.

Article written by Tim Walsh

Tim Walsh Logistics Management Inc. 908.879.2940 twalsh@lmiservices.com

Truckload…Flatbed…Rail Shipments : 800.426.8896 # 5

Game Lockers (also known as meat lockers, game coolers, deer boxes, or deer coolers) are a perfect solution to preserving and storing meat after the hunt. Game Lockers come in two sizes: 6’ x 6’ x 8’ and 6’ x 8’ x 8’. These meat coolers are sold as a package including refrigeration and overhead rail system with hooks. Both models have available space for shelving to help organize your inventory in the cooler. They are now available to purchase online from our dealer sites.

Now is the time to start looking into Game Lockers for this upcoming hunting season. Visit this page for more detailed information regarding Game Lockers.

]]> http://blog.uscooler.com/index.php/2009/game-meat-locker-coolers-hunters/feed/ 0 http://blog.uscooler.com/index.php/2009/zero-ozone-depleting-polystyrene-insulation/ http://blog.uscooler.com/index.php/2009/zero-ozone-depleting-polystyrene-insulation/#comments Wed, 19 Aug 2009 20:23:41 +0000 Freezer http://blog.uscooler.com/?p=705

Toledo, Ohio – Owens Corning (NYSE: OC), a global leader in building materials and energy efficiency solutions, today announced it has started manufacturing zero ozone-depleting FOAMULAR^® Extruded Polystyrene (XPS) rigid foam insulation. The new blowing agent technology developed by Owens Corning meets the requirements of the Montreal Protocol which requires the phase-out of the hydrochloro-fluorocarbon (HCFC) 142b, an ozone-depleting compound, by January 1, 2010.

Owens Corning’s new Gresham plant is the first facility in the Western U.S. to meet the requirements of the Montreal Protocol and expands the company’s XPS foam production capabilities. The company also has converted its Rockford, Ill., insulation plant to use the new blowing agent, and all FOAMULAR products will meet the requirements of the conversion deadline.

“High performance homes and buildings are an ever-growing segment of the construction industry, and Owens Corning is committed to helping architects, builders, contractors and specifiers consistently meet and prosper from this demand,” said Joe Ochoa, Foam Business general manager, Owens Corning. “Our customers trust FOAMULAR insulation to deliver energy efficiency solutions that help reduce building life-cycle energy costs. With the addition of our Gresham facility, we are providing our customers across the U.S. greater access and flexibility.”

Nationwide, Owens Corning FOAMULAR XPS insulation products are designed for use in a variety of above- and below-grade and load-bearing applications to provide exceptional thermal and moisture resistance and long-term energy efficiency. Benefits of FOAMULAR insulation include:

• Virtually impervious to moisture penetration, preventing loss of R-value
• Twenty-year thermal performance warranty
• Recyclable and reusable
• Minimum of 20 percent certified recycled production content
• GREENGUARD Indoor Air Quality Certified^® and certified under the even more stringent GREENGUARD Children & Schools^SM

Utilizing FOAMULAR insulation can help builders achieve green building certifications including the Environmental Protection Agency’s ENERGY STAR® certification, the National Association of Home Builders’ National Green Building certification, and the U.S. Green Building Council’s Leadership in Energy and Environmental Design certification. FOAMULAR products also are eligible for the Federal Tax Credit for existing homes under the American Reinvestment & Recovery Act of 2009.

To learn more about Owens Corning FOAMULAR insulation and applications that can benefit from XPS insulation, please visit: www.OwensCorningXPS.com.

About Owens Corning

Owens Corning is a leading global producer of residential and commercial building materials, glass fiber reinforcements and engineered materials for composite systems. A Fortune 500 company for 55 consecutive years, Owens Corning is committed to driving sustainability through delivering solutions, transforming markets and enhancing lives. Founded in 1938, Owens Corning is a market-leading innovator of glass-fiber technology with sales of $6 billion in 2008 and about 16,500 employees in 30 countries. Additional information is available at www.owenscorning.com.

First off, the NMFC stands for National Motor Freight Classification. It is a guide used to classify all the commodities shipped and handled by motor carriers in North America.  The commodities are assigned one of 18 different classes – from a low of 50 to a high of 500 – based on four transportation characteristics:  density, stowability, handling and liability.

It also includes rules and packaging requirements for each type of commodity to ensure adequate protection for products moving in the LTL motor carrier service.

The NMFC constitutes industry standards which are developed and maintained by the National Classification Committee (NCC), an autonomous committee of 100 carrier representatives who are elected to represent the more than 1,000 motor carriers participating in the NMFC. The NCC’s activities are regulated by the US Surface Transportation Board which is part of the Department of Transportation (DOT).

The NMFC is published by the National Motor Freight Traffic Association (NMFTA), a nonprofit organization based in Alexandria, VA.

Defining Freight Class

Although, classes are determined by density, stowability, handling and liability, the biggest factor in determining the class is the density. The denser the commodity is, the lower the freight class. Always remember that!

Here is a “rule of thumb” we folks in the freight industry use to do a quick guestimate to determine a particular freight class. Of course this should be backed up by the NFMC but you can a pretty accurate idea of a freight class by following this chart.

FREIGHT CLASS CHART

The first column shows the pounds per cubic foot (PCF). The second column shows freight class. So when the PCF is greater than the number in the first column, than the class will likely be the number in the second column.

PCF     Class
50        50
35        55
30        60
22.5     65
15        70
13.5     77
12        85
10.5     92
9         100
8         110
7         125
6         150
5         175
4         200
3         250
2         300
1         400
< 1     500

Article by George Muha and Tim Walsh

Tim Walsh and George Muha are NJ based employees of  Logistics Mangement, Inc (LMI).

Contact Tim today for a FREE Freight Evaluation to see how much savings is available to your company!

Tim can be reached at twalsh@lmiservices.com or (908) 879-2940.

To give you a rough estimate of how much it cost to operate a walk-in cooler or freezer, using the national average of 11.89 cents per kilowatt, look at the chart below.

*These numbers were figured using the $.0999 kilowatt hour cost. According to the Energy Information Administration this is the average cost in the United States for commercial electricity.

This chart was created using several assumptions that can affect your actual operating cost.

1. The type of insulation in the walk-in.
2. Efficiency of the refrigeration system.
3. Inside and outside temperature of walk-in.
4. Where the walk-in is located.
5. The temperature and the weight of the product entering the walk-in.
6. How often the door is opened.
7. The age of the walk-in.
8. Cost of electricity.

This is just to name a few.  If you would like to be more accurate using your electric rate, follow the instructions below.

Most walk-in refrigeration systems are designed to run 80% of the time or between 16 and 18 hours per day. For a quick estimate of the cost to run your walk-in use the chart and formula below.

For standard sized walk-ins, we have estimated the average kilowatt hours used to run the selected sized walk-ins.  To figure out your monthly cost, select the walk-in you want to calculate and multiply the associated AKWH (Average kilowatt hours) by your cost per kilowatt.

AKWH * C = Average Monthly cost

For example, an 8×10 cooler would be figured by multiplying 1,113.86 by your monthly kilowatt rater per hour.  In this example we used our AKWH of 11.89 cents per KWH.

1,113.86 (AKWH) * $.1189 = $132.44 per month

If you would like to calculate an estimate on a different sized walk-in, follow the provided formula below. You will need to get a BTU (British Thermal Unit) requirement for the walk-in you would like to calculate.  You can get this information from calling your dealer, U.S. Cooler Company at 1800-521-2665 or go to U.S. Cooler’s refrigeration sizing program to size your walk-in.  If you have your dealer or U.S. Cooler on the phone you will also need to get the voltage and amperage of the refrigeration system that will match your BTU requirement.  When you have the amperage and volts of your refrigeration unit, follow the equation below for your average monthly electricity cost. Make sure you have the amperage and volts for both the condensing unit and evaporator coil.

Cooler: (((TW *16)/1000)*30.42)*C = Monthly Energy Cost

Freezer: (((TW)*18)/1000)*30.42)*C = Monthly Energy Cost

16 = Design run time for a Cooler per day

18 = Design run time for a Freezer per day

30.42 = Average days in a month

A = Amperage

V = Total Voltage of refrigeration unit

C = Your cost per kilowatt in dollars (This could be found on your electricity invoice.)

TW = (A*V) for condensing unit + (A*V) for evaporator coil

This takes the amperage (A) times the voltage (V) of the condensing unit plus the amperage (A) times the voltage (V) of the evaporator coil to get the total watts (TW) of the refrigeration system. The amount of watts used is then multiplied by the number of hours the system will run per day. For coolers the average is 16 hours and freezers average 18 hours per day. This will give you the daily amount of kilowatts required daily.  Multiply the daily required kilowatts by 30.42 which is the average days per month to get the monthly required kilowatts.  Multiply that number by the Kilowatt cost of electricity in your area to get your cost per month. This will give you an estimate of what the walk-in will cost to run per day in your area.

Example:  8×10 cooler, Condensing Unit A = 9.5, V = 230, Evaporator Coil A = .9, V = 115

C = $.1189

9.5*230 = 2,185 condensing unit watts

.9*115 = 103.5 evaporator unit watts

TW = 2,185 + 103.5 = 2,288.50

((((2,288.50)*16)/1,000)*30.42)*$.1189 = $132.44

As discussed above these formulas will give you an idea of the cost to run your walk-in and are not to be considered exact figures.  If you would like more accurate figures you need to contact a licensed mechanical engineer to design and calculate your system.

As of January 1, 2009, all walk-in manufacturing companies must sell their refrigeration units with Electronically Commutated (EC) motors. EC motors lower energy costs and significantly improve the walk-in cooler or freezer performance. These energy efficient motors are offered as a complete unit or as a drop-in replacement. Whichever your use is, if you are not familiar with the EC motor it may seem odd when you initially start it up.
When starting an EC motor, the motor must know where the rotor is located in order to start and continue to run. When power is first applied to the motor, the controller will apply a gradually increasing amount of current to all three windings in the motor over a period of 2 seconds. This will cause the rotor to move to a known location. This move will range from no movement at all if the rotor has stopped in the location needed for the next start or may be a much larger movement if it was a longer distance  from where it needed to be. With a fan blade attached, it may even overshoot and move backwards to get to the right location. After that 2 second “positioning” period the controller will start applying power to different phases in a slow rotating pattern that increases in speed over the next 2 seconds until the rotor is moving fast enough for the controller to be able to detect its location. This second phase of the start cycle usually happens so quickly that you cannot really see what is happening. Within 3 to 5 seconds of applying power, the motor should appear to be running normally, but during those first 2 seconds the movements may seem as though the unit is having troubles starting or is broken.

CrossFire delivers a less than two year payback on your LED investment.  Reducing compressor run time, reducing wattage, eliminating maintenance cost, while providing the most light output of any other LED on the market.

This energy efficient CrossFire™ design can save you up to 85% of your current energy cost and also remove the amount of heat that is added to your cold environment, therefore reducing compressor run times.  The SCHOTT Gemtron CrossFire™ design has an exclusive power supply integrated into the light bar.  When you add up all the benefits of the CrossFire™ LED lighting systems you will enjoy a fast payback on your lighting investment.

For more information, please view this SCHOTT Gemtron pdf:  http://gemtrondoors.com/PDF_Files/SCHOTT%20Gemtron%20CrossFire%2009-08.pdf

Does your company manufacture a commercial refrigeration product or accessory you’d like us to feature? If so, email Kristin[at]uscooler.com with details on your product, quality images, and links to more information.

1. Make Your Menu More Efficient.

Are your menu items being prepped and cooked as efficiently as possible? Items that need to be thawed for daily food service can be defrosted in a refrigerator overnight instead of under running water reducing energy usage and conserving water. Review your menu to see if there are common ingredients or items that can all come from one source. Minimizing the number of individual deliveries you receive weekly will add to your conservation practices and reduce your delivery expenses as well as receiving time when you can be going in and out of cold storage using additional energy to bring it back to safe temperatures.

2. Switch to energy efficient light bulbs.

Subway recently switched all their light bulbs to energy efficient bulbs in all of their 2000 US franchise locations. Switching to an energy efficient light bulb can save up to $22 per bulb per year. This can add up to quite a savings over time. Also keep lights off when you don’t need them. If you don’t start serving lunch until 11 o’clock there is no reason to turn the dining room lights on until then.

Areas such as walk-in coolers or your dry store room don’t need to be illuminated all day long. Turning off lights as you leave typically unused areas is a great way to save money on your energy bill. Electrical timers can be used in these areas especially if they are commonly forgotten and left on overnight.

3. Pre-cut and freeze many of the common vegetables you use in your restaurant or cafe.

Onions: Buy in bulk and on sale. Peel and slice or dice. Freeze one layer thick on a cookie sheet. When frozen transfer to plastic jars with screw on lids. Immediately put back in the freezer. Don’t forget to label the jars! When you need some onions in a cooked dish just shake out what you need. If they clump together shake really hard to loosen. Some of the ways we use frozen onions: sautéed or grilled on hamburgers, in omelets, in any dish that the customer asks for “extra onions” that will be cooked or at least heated. Bell peppers, Mushrooms

4. Train your staff.

Teach your staff to sort recyclables, turn off lights, and let you know if there is a leaky faucet in the wait station. Ask them to bring in their own take-home containers instead of using the restaurant take-outs.

Busy kitchen staff may often forget to do the simplest of energy efficient steps. Leaving oven doors open releases vast amounts of heat. Each time you open an oven door the temperature can drop by as much as 25o F.; watch the clock and use a timer instead. Don’t leave the convection oven or steamer door open too long or it will just continue to release heat, burning unnecessary energy to retain the proper cooking temperature.

The walk-in cooler is another door that needs to be shut at all times or cooling becomes a continuous energy pit. If doors such as the walk-in cooler are consistently left open, place spring hinges on the doors and it will automatically close, eliminating the opportunity for staff to forget to shut the door.

5. Turn down the thermostat.

You can still be comfortable at 68 degrees rather than 72 degrees.

6. Switch from plastic to glass.

Green restaurants have been following this tip for years. If restaurant uses disposable plates, flatware or cups, considering a onetime investment for china, glass and silver. You will save on garbage (good for the environment as well as the restaurant budget) and save money over time.

7. Reduce Water Consumption

Install low flow faucets and toilets. This will save between 20 to 40 percent of water usage. You can find a list of endorsed products on the official Green Restaurant Association web site. Rather than running hot water over them to loosen dried food, fill a sink and let them soak. Also, only run the dishwasher when it is completely full. This cuts down on water usage, soap and energy costs.

8. Turn It Off.

Just like leaving the lights on in your home, leaving equipment to run idly will cost you hundreds of dollars for unused energy. By turning off your inactive equipment, it saves energy and plenty of cash on your next gas, electric, or water bill. For those times when you forget to turn off equipment after closing, electrical timers can be placed on outlets to automatically flip off equipment when you aren’t around.

Typical equipment left on overnight or during idle kitchen hours are griddles, French tops, ranges, convection ovens, and dish machines. These can all have timers placed between their power outlets and cords to turn them off when you forget.

You can’t turn the whole griddle off, but you can turn off some of the burners during slower business hours. Turn off all the griddle burners except leaving one burner on for off-peak hours. This will save you energy while still keeping kitchen services available.

9. Keep Equipment Properly Maintained.

Keeping equipment properly maintained has valuable cost efficient benefits. Although a habit for some restaurant owners to let equipment run until a major problem arises, having equipment serviced regularly can catch operational problems. Small problems can become high cost issues through poor performance or a need for greater amounts of energy to maintain required temperatures for cooking, or cooling foods. Keeping equipment maintained also helps eliminate break downs that cause down time where you may need to use an inefficient cooking method as an alternative until your equipment is repaired or replaced.

De-lime your steamer regularly to save energy by making your boiler run as efficiently as possible and extending your equipment life.

10. Always Keep Equipment Clean.

Setting up a nightly cleaning routine will help you keep equipment running properly so ranges, ovens, and refrigerators perform at their peak efficiency. Clogged burners, for instance, use more energy to heat and cook food. By unclogging burners, you keep your range using less energy to work at maximum performance.

Gaskets on kitchen ovens become cruddy and build up residue that intrudes on the seal between the rubber and the metal. Allowing outside air to enter the oven requires more energy to keep the oven temperature set. Keep ovens and their doors clean to allow them to heat more efficiently.

Vacuuming refrigerator coils keeps the cooling machinery operating at maximum efficiency. Cleaning coils and keeping dust and materials from building up around them will keep your refrigerator running more efficiently and use less energy.

11. Optimize Equipment Capacity.

Smaller volume kitchens can use smaller capacity equipment. For instance, steaming small portions of vegetables can be done in the microwave instead of a large capacity steamer. When choosing from the variety of product manufacturers and standard size equipment, purchase only the size that you need to maximize output while minimizing energy usage. Large production equipment isn’t needed if the kitchen doesn’t have a high volume of customers.

12. It Pays to Save Money.

Many cities and counties offer energy saving incentives for individuals and corporations who choose to go green. Besides saving hundreds of dollars on your utility bills, you can get money back rebates from the government. To find out more information, visit http://www.energystar.gov or contact your local city government for a list of rebates offered by federal and city governments.

Sources:

http://restaurants.about.com/od/finances/a/Dave_Money.htm

http://www.ehow.com/how_4707662_fresh-vegetables-save-money-restaurant.html

http://www.micronanotronics.com/science/energy/top-10-tips-to-start-saving-money-and-energy-in-your-commercial-kitchen-today.html

The USDA is now offering a grant and loan program to improve energy efficiency in rural areas. The REAP/RES/EEI (Rural Energy for America Program Grants/ Renewable Energy Systems/ Energy Efficiency Improvement Program) Grants Program will provide funds to architectural producers and rural small businesses to purchase and install renewable energy systems and make energy efficient improvements.

The program is designed to assist farmers, ranchers and rural small businesses that are able to demonstrate financial need. Small businesses that are located in rural areas can also apply. Most rural projects that reduce energy use and result in savings for the agricultural producer or small business are eligible as energy efficient projects. These include projects such as retrofitting lighting or insulation, or purchasing or replacing equipment with more efficient units. One of the main requirements of the grant program is that the new equipment must be more energy efficient than the current equipment. An ‘energy audit’ will be performed comparing the energy usage of the old equipment to the new anticipated energy efficient equipment.

Walk-in coolers and freezers qualify for this grant program. Older walk-ins are not as efficient as new units built today. Some of the recent changes in the industry include the requirement to provide higher insulation r-values and refrigeration units with EC motors, which are much more energy efficient than older units. These upgrades will prove your new equipment to be more energy efficient, which will save you money on energy costs.

Nationwide there is $16 Million available for this program, which is divided among each state. The grants are awarded on a competitive basis and can be up to 25% of the eligible project cost, not to exceed $250,000 for energy efficiency improvements. At least 20% of the grant funds awarded must be for grants of $20,000 or less.

Application due date is July 31, 2009. To apply for funding for the Grant Program contact your Rural Development State Office.

If you are in need of new refrigeration equipment and meet the requirements above, why not take advantage of the government money set aside for these improvements.

For more info: www.rurdev.usda.gov/rd/energy

http://www.rurdev.usda.gov/rbs/busp/9006grant.htm

Truth: For over 40 years walk-ins have been manufactured by either gluing insulation to metal skins (laminated) or pouring urethane (foamed-in-place) between two metal skins.  Contrary to most beliefs, both systems provide equal performance in adhesion if applied correctly.  This is important because in walk-ins the structural strength of the unit is dependent on this adhesion performance.  When metal skins are glued or foamed to insulation a composite panel is created.  This created panel performs much like a steel I-beam. I-beams by design are very strong for their weight and are used in building structures that need a lot of strength without the weight, such as skyscrapers. A steel I-beam is two flanges of steel connected and separated by a center steel web.  In a walk-in panel, the two flanges are light gauge metal skins and the web is the foam insulation.  All I-beams lose their strength if the flanges separate from the web. If the I-beams separate, skyscrapers would collapse. This is similar to walk-ins that could fail if the skins separate from the foam insulation.

Both of these manufacturing processes, glued panels and foamed-in-place panels, if applied correctly have the same ability to adhere to the metal skins. They both use polyurethane as the bonding agent but use different processes in manufacturing. Urethane panel production requires much more attention to following procedures than laminated panels do. In the foamed-in-place process, blowing polyurethane foam in between the metal allows it to hold itself to the metal skins. When R-12, now outlawed, was used as the blowing agent in foamed-in-place polyurethane, it would adhere to almost any material and could be applied at a broad temperature range, while providing a high level of product strength. There was little need to watch the manufacturing process. As the old foamed-in-place blowing agents were replaced by new blowing agents, the manufacturing procedures became more demanding. Today, the foam needs to be applied and cured at a much more restricted manufacturing process temperature. The fixtures that hold the panel need to be accurately temperature controlled to accomplish this.  Any variation of the temperature during the manufacturing process can cause the panel adhesion to fail in the field.  Many manufactures do not have the right equipment or quality procedures to meet these demanding manufacturing requirements.  Glued panels however, do not use blowing agents and do not require as stringent manufacturing procedures.  The glue used for laminated panels is made specifically for this application and is produced to attach foam to metal. The equipment to apply the glue correctly is readily available and the ability of the glue to adhere to different materials is evident in its wide use in the recreational and housing industry.

In addition to the manufacturing process and the adhesive, there are two other key factors that must be considered: foam characteristics and human error. In the case of extruded polystyrene (slab), because it is a closed cell structure the glue sits on top of the foam and forms a bonding layer between the foam and the skins. The foam must be strong enough to hold the panels together. Since polyurethane is made of chemicals and gasses, when the foam is blown in between the metals, gasses release and form voids in the insulation. The voids, or open spaces, against the metal can cause the metal to detach from the foam. Although it is uncommon, delamination is repeatedly due to human error, not product performance. For foamed-in-place panels, if the foam was not cured accurately or at the correct temperatures there is a possibility of delamination occurring.  For laminated panels, if the panels were not pressed or glued correctly there could be a risk of delamination.

Delaminated Ceiling Panels

Even though delamination is rare, it is still possible in both forms of manufacturing. If your unit delaminates, it can cause severe expense and inconvenience to a business relying on their walk-in to keep their product cold or frozen.

In conclusion, it has always been identified that the application of quality controlled manufacturing processes determines the products quality to the customer.  Can both manufacturing processes meet the punishing requirements of walk-ins in the field?  The answer is yes, but glued panels are now more forgiving in manufacturing than foamed-in-place polyurethane units due to the changes in blowing agents.

Existing equipment using R-22 can continue to be serviced with R-22. However, chemical manufactures will no longer be able to produce R-22 after January 1, 2020. After 2020 the servicing of existing equipment will rely exclusively on re-claimed and recycled supplies of R-22.

If your equipment is more than ten years old, you may save significantly on your cooling energy cost by replacing it with a new more efficient model using R-404a or Scroll compressor technology.

Energy efficiency, system performance, hourly run time of equipment, reliability, and actual cost to operate (amp draw, run time, etc.) should be considered when deciding to purchase new equipment.

To help speed the transition away from ozone depleting refrigerants, choose a system that uses ozone friendly refrigerants.

The AHRI (Air-Conditioning, Heating, and Refrigeration Institute) is trying to raise awareness about what this act mandates among distributors, installers, and consumers. They have created a checklist of the standards walk-in coolers & freezers are required to meet that can be found at ACHR The News. Use this checklist to ensure the walk-in unit you are about to purchase meets the EISA standards.

DOORS
• Automatic door closers that firmly close all walk-in doors if they are within 1 inch of the closed position. This requirement does not apply to doors wider than 3 feet 9 inches or taller than 7 feet.
• Strip doors, spring-hinged doors, or other measures to minimize air infiltration when doors are open.

LIGHTING
• Lighting with an efficiency of 40 lumens per watt or more, including ballast losses or occupancy sensors that turn lights off within 15 minutes if the walk-in is unoccupied.

INSULATION
• Insulation of walls, ceiling and doors of at least R-25 for coolers and R-32 for freezers.
• Floor insulation of at least R-28 for freezers.

MOTORS
• For evaporator fan motors under 1 horsepower (hp) and less than 460 V, use either electronically commutated motors (brushless direct current motors) or three-phase motors.
• For condenser fan motors under 1 hp, use either electronically commutated motors, permanent split capacitor-type motors, or three-phase motors.

GLASS
• For coolers, use double-pane with heat-reflective treated glass and gas fill or triple-pane with either heat-reflective treated glass or gas fill.
• For freezers, use triple-pane with either heat-reflective treated glass or gas fill.

ANTISWEAT HEATER ON TRANSPARENT REACH-IN DOORS
• Walk-ins with antisweat heaters on transparent reach-in doors, but without antisweat heat controls, must have a total door rail, glass and frame heater power draw of no more than 7.1 watts per square foot of door opening for freezers and 3.0 watts per square foot of door opening for coolers.
• Antisweat heat controls on walk-ins with antisweat heaters on transparent reach-in doors and a total door rail, glass and frame heater power draw of more than 7.1 watts per square foot of door opening for freezers, and 3.0 watts per square foot of door opening for coolers must reduce the unit’s energy use in an amount corresponding to the rh in the air outside the door or to the condensation on the inner glass pane.

U.S. Cooler is fully compliant with the 2009 EISA requirements.

“A final rule is expected to be adopted in January 2012 that will establish a performance-based standard.”¹

Source: ¹ACHR The News article “Coolers, Freezers Subject of Concerns”

The two main elements that effect energy and cost savings while running a walk-in are the refrigeration and insulation.  To get the optimal results from your refrigeration it must be sized correctly taking in consideration the size of box, if it is a cooler or freezer, and what will be stored inside. (There are many other factors that are considered when sizing refrigeration.) Insulation is the key to energy savings because it is responsible for holding the cool temperature in the box so the refrigeration does not have to work overtime. Insulation quality is measured by R-value; the resistance to heat flow through an object. Since EISA was implemented January 1, 2009, all walk-in manufactures are required to have an R-value of R-25 for coolers and R-32 for freezers. Now that all manufacturers follow the same requirements, the performance of the insulation is what differentiates the walk-in.

The two common types of insulation used are polyurethane and extruded polystyrene.  Each type of insulation brings with it strengths and weaknesses that must be evaluated for each individual application.

U.S. Cooler uses both insulations. Through experience and research, U.S. Cooler believes extruded polystyrene is the best insulation for the walls, ceiling, and floors of coolers and freezers. Polyurethane is better to insulate the doors of their walk-ins. According to a study performed by the U.S. Corps of Engineers, they found that over a five year period extruded polystyrene retains 75% of its R-value while polyurethane retains 25%.¹  This is one reason why U.S. Cooler believes extruded polystyrene provides the most value and the best option for walk-in insulation.

Polyurethane & Extruded Polystyrene

Retaining a high R-value is important in saving energy costs. The higher the R-value, the less the refrigeration will have to work to hold the required cold temperatures. As a result, the less the refrigeration works the less your energy costs will be.

When considering the actual performance of walk-in coolers and freezers, being informed can pay substantial long-term benefits. You pay for the walk-in once, but if the insulation and refrigeration are inefficient, it will cost you every month for the life of the walk-in. Acquisition price should not be the only consideration when purchasing your walk-in. Initial purchase savings can be quickly eliminated by unnecessary operational costs over the lifetime of the walk-in.

To see how much you could save on an Extruded Polystyrene walk-in, check out our Energy Savings Calculator.

¹ U.S. Army Corps of Engineers (CRREL) test data. “New Wetting Curves for Common Roof Installations,” by Wayne Toblasson, Alan Greatorex and Doris Van Pelt; Cold Regions Research and Engineering Laboratory, Hanover, New Hampshire 1991.

Lower infiltration [of warm air] means the air is coming out at a lower velocity, said Navaz. “Previously, air came out of the upper vent (or grille) of a specific display case at 90 feet per minute. We calculated the optimal speed as 65 feet per minute as an optimal discharge air velocity to yield lower infiltration rate,” he said.

By reducing the velocity by 30 percent, infiltration was reduced by 12 percent and the power required was reduced by 13 percent.

Increasing the temperature at the discharge air grille by about 1 degree (F) and lowering the velocity of air resulted in lower suction pressure at the compressor inlet which reduced the compressor usage and therefore less energy consumption.

Infiltration represents 83 percent of the cooling load and is the biggest draw on energy of refrigerated display cases. Less energy use translates into real cost savings to the tune of about $13 million for the state of California alone, according to Navaz.

In addition to energy savings, lowering the pressure on the compressor also extends the life of the compressor and creates more cost savings over the long term.

Click here to read the entire Kettering refrigeration study.

Copeland Scroll Refrigeration Compressor

Also, remember to clean the condenser coil every month, to get rid of dirt and grime that can cause higher condensing temperatures and further reduce condensing performance. A 5% increase in ambient change reduces performance by 3%. Purchasing newer energy efficient equipment along with U.S. Cooler’s new cooler meeting 2009 standards will be a wise move, smoother running and a more profitable operation.

EC Motor Startup

How Scroll Works

More on Copeland Scroll

Also for your convenience, we now have a version of this blog designed for mobile phones. Simply visit mobile.uscooler.com from your mobile device. If you have a QR Code enabled phone, you can scan this picture to be taken to our mobile site. If you don’t have QR Code application on your phone, you can visit http://reader.kaywa.com from your phone’s browser to download Kaywa Reader.

Cooler Connection QR Code

Convenience store chains can slash operating costs by as much as 10% with sound maintenance and general improvements to its refrigeration systems.

Operators looking for greater energy efficiency should cast an eye on their coolers, where centralized controls, lighting adjustments, basic ongoing maintenance and employee training can save them money.

“Coolers are typically an opportunity for improvements in maintenance and operational practices,” said Jerry Lawson, national manager for Energy Star Small Business and Congregations Network, a division of the U.S. Environmental Protection Agency in Washington. “With all the different types of equipment in the c-store, coolers are a key piece of the energy equation, and they are typically the most expensive to run. With the right improvements, there is an energy efficiency dollar saving opportunity.”

Where to begin? Start with the obvious.
“Keeping them clean is the biggest thing,” Lawson said. “Coolers have to breathe. Keeping those coils clean allows them to breathe; they take the air in and expel air out.”

When taking care of monthly cooler cleaning, Lawson liked to pull off the back panel and take a cloth or other type of non-steel brush to it and clean it off, then vacuum or sweep the junk up off the floor. “That’s the biggest thing to keep them running efficiently.”

Matt Lauck, director of marketing for Retail Solutions in Kennesaw, Ga., a subsidiary of Emerson Electric, said that central facility management systems can be a major tool for achieving energy efficiency in coolers. Such systems give the operator the ability to optimize energy reduction by, among other things, tracking temperatures to make sure they stay within operational norms, which obviously also has implications for food safety. “Think of it as a programmable thermostat,” he said.

Read the full article from Convenience Store Decisions

Funds have been allocated to each state education department. Funds vary by state and range from $215,000 to $12 million. The grants are competitive which means preparation is important. The window of opportunity is very narrow so this is an actionable item. The funds are intended to be dispersed within three months.

Items the schools may wish to consider include the repair, replacement or addition of walk-in coolers and freezers. Some of the reasons these qualify include: improving food safety, reducing operating costs translating into energy savings, increased storage capacity to handle expanded breakfast, lunch and snack programs. The link below contains detailed information regarding all qualifying food service equipment. A general rule of thumb is that the equipment must support the reimbursable meal program and not specifically targeted to an ala carte program.

Here is a link to the National School Nutrition Association website where school food service directors can find the most current USDA issued communication related to this process. There are links to each individual state where the food service director can view the requirements and download the required forms.

School food service directors are welcome to call on U.S. Cooler to assist with specification, sizing etc. Contact information is easily accessed via our interactive territory map.

*Participation is measured at the building level rather than the District Level. If the equipment is for a central kitchen, all buildings served by the central kitchen are listed and included in the calculation.

In this political environment there are many grants available for small businesses, especially when it comes to making your business more energy efficient. The following is a list of websites where you can find and apply for grants in your state (most are linked to the state’s business website but some are linked to specific energy grants). There is also an online government grant and loan search available. Different grants have different requirements and payouts (for example, some will require you to reduce energy usage by at least 20% and the state will foot 25% of the equipment bill).

Economic Development Websites:

Alabama, Alaska, Arizona, Arkansas, California, Colorado, Connecticut, Delaware, Florida, Georgia, Hawaii, Idaho, Illinois, Indiana, Iowa, Kansas, Kentucky, Louisiana, Maine, Maryland, Massachusetts, Michigan, Minnesota, Mississippi, Missouri, Montana, Nebraska, Nevada, New Hampshire, New Jersey, New Mexico, New York, North Carolina, North Dakota, Ohio, Oklahoma, Oregon, Pennsylvania, Rhode Island, South Carolina, South Dakota, Tennessee, Texas, Utah, Vermont, Virginia, Washington, West Virginia, Wisconsin, Wyoming

Some systems, whether they are coolers or freezers, are designed only to hold the temperature of the product coming in and are not designed to pull-down the temperature of the product to the desired holding temperature. Pull-down happens when there is product entering the cooler or freezer that is warmer than the desired temperature and needs to cool in a short amount of time. For example, when a restaurant owner has a large pot of soup that needs to be cooled quickly to avoid bacteria growth, the refrigeration must be able to cool the soup to the desired temperature in a reasonable and safe time while maintaining the holding temperature in the cooler/freezer. Systems designed for holding only and not to pull down the temperature of the product coming in will only work properly if products entering the box are already at the desired temperature, either cold or already frozen.

The industry standard design temperature for freezers is at -10° F. Some online companies are selling their freezer refrigeration at a holding temperature of 0° F. If you try to run a walk-in designed for 0° F holding temperature and set the thermostat to -10° F, it will run constantly trying to meet the -10° F temperature it was not designed to hold. This will shorten the life of the compressor and may cause the coil to freeze and consequently warm up the box to melting temperature, damaging the food stored inside.

Before purchasing, you must understand the difference and what implications it could have on your business. Most perishable items that are stored in a freezer are not frozen to start with and will need to freeze and stay frozen for a period of time. If the box is designed for holding temperature only and is set at 0° F, the refrigeration will work harder and longer to pull the temperature inside the box back down to 0° F once warm food is stored in the freezer. Frozen products, such as ice cream, hold up better at -10° F rather than 0° F. When a freezer goes into defrost it can raise the box temperature by 10-15°. If your box is set at 0° F, a 10-15° temperature swing can cause some products to be damaged or melted. When dealing with food it is imperative to make sure the holding temperature in the freezer is low enough to keep products frozen, protecting from bacteria or other hazards that spread through food not refrigerated correctly. (Check with your local health codes for the required holding temperature of your walk-in cooler and freezer.) It is also important to note that when refrigeration is working longer and harder, your energy costs will increase as well as the chances of your refrigeration breaking down or having inefficiencies.

Every state has requirements for storing cold food; here is an example of Illinois’s Administrative Code.

Extruded polystyrene is the most efficient insulation available on the market. Over time, extruded polystyrene resists moisture while other insulations start absorbing it. One must consider a real life application to understand moisture absorption.

Freezers normally operate at -10° F inside, but may have an exterior temperature of up to 95° F or even more. With the extreme difference in temperatures, the insulation is vulnerable to retaining moisture in the structural voids. When water starts collecting inside walk-in insulation, the R-value drops and moisture inside the insulation starts to freeze.

When moisture is absorbed and R-values start to decrease, refrigeration systems start working harder and longer to make up for the heat transferring into the walk-in. A refrigeration system working overtime means higher energy bills. By using extruded polystyrene, consumers can save that money.

Extruded polystyrene is unique; the insulation is a closed-cell product, meaning the cells of the material are so tightly packed together that moisture has a difficult time penetrating, which is optimal for moisture resistance and keeps the R-value from decreasing.

Using studies performed by the U.S. Army Corps of Engineers (CREEL), U.S. Cooler demonstrated extruded polystyrene saved consumers over $5,000 in energy costs over the first five years of operation. The savings again are due to extruded polystyrene’s ability to resist moisture and to retain its R-value better than other insulators.

When buying and selling walk-ins, consider more than the initial cost of the walk-in-consider energy costs. Educate yourself about how to save money; to find out more about extruded polystyrene and energy savings, call 800.521.2665 or visit www.uscooler.com.

U.S. Cooler will be exhibiting at the NRA Show in Chicago, May 16-19.

Since last NRA, U.S. Cooler has been busy working on new and innovative processes to reduce waste, inventory, time, and costs while increasing productivity. All of these factors together equal savings for dealers and consumers.

Providing customers with quality, affordable walk-ins in a convenient amount of time has always been U.S. Cooler’s highest priority. Earlier this year, we launched our new Hybrid panel for walk-in coolers. The hybrid panel is the best designed and engineered, competitively priced panel in the market.

U.S. Cooler, through their discount dealer program, passes savings on to consumers via the internet. Quick delivery, quality product, and competitive prices have drawn customers from across the nation to buy walk-in coolers and freezers from U.S. Cooler’s internet dealers online. Recently, prices were discounted even further, saving consumers even more money. Check out www.fastcooler.com, the internet’s best resource for discount walk-in cooler and freezer dealers.

Stop by U.S. Cooler booth 1834 to learn more about our discount internet program and how U.S. Cooler can save you money.

1. Receiving your walk-in: When your walk-in cooler or freezer is delivered by the freight company, it is critically important that you inventory the items delivered.

a. You must be sure when you sign the delivery receipt, you have received the freight in good condition and not damaged in anyway. The person signing the delivery receipt is responsible for inspecting the freight.
b. If you see any damage to the container or boxes, this is a good sign that you may have hidden damage. If you have a camera, take pictures of any damage to your freight, even before it is taken off the truck. Call U.S. Cooler and ask for Customer Service if you see a problem with your shipment. When you call, have your order number available. The order number allows us to pull up all details needed to answer your questions.
c. Insist that the driver does not leave until your satisfied all freight damage has been noted on the delivery receipt before the driver signs the delivery receipt.

2. Take time to read the instruction manual and review drawing: Before you get started take out the installation instructions and drawing package. Inventory your parts against the drawing to be sure you understand the layout. If you have any questions on how to assemble the walk-in call U.S. Cooler and ask for Customer Service.

3. Make sure your area where the walk-in will be installed is flat: Level is critical when installing a walk-in cooler or freezer. Before installation you should get an exact tolerance of the entire space you are planning to install the walk-in. The longer the box, the more important it is to have a level area. Floorless boxes should be shimmed inside the vinyl screed to prevent gaps and air infiltration. A liquid leveling compound is very useful for floors that are not completely level.
4. Threshold bar:  On all standard walk-ins, a threshold bar must be installed in the floor panel below the door panel before the door can be set in place. This allows for the door threshold to be anchored to the floor.

5. Line up top corners evenly: When installing panels, make sure the top of the panels are level with the adjacent panels before locking them in place. This ensures the ceiling fits properly on the routes and will keep the box square as the panels are being installed.

6. With the exception of PRO3 and Apex, all refrigeration units must have a condensation line run to the outside of the walk-in. When running any utilities, including those for refrigeration, drill into the wall panel; not the ceiling. After running all utilities, caulk around drilled holes. Follow all local building and electrical codes during installation.

View our Test-Assembly Webcam

California was one of the first states to set energy regulations for walk-in coolers and freezers. They previously required an envelope insulation rating of R-28 for refrigerators and R-36 for freezers. California was also one of the first to require electronically commutated motors or permanent split capacitor-type motors for refrigeration. Before more states could pose their own requirements on energy consumption, the federal EISA (Energy Independence and Security Act) agreement was signed in 2007. California has fully accepted the EISA requirements, amending their previous appliance energy code.

To review the entire California Code of Regulations, click on the link below. The walk-in cooler and freezer section starts on page 120 of the document.

http://www.energy.ca.gov/2008publications/CEC-400-2008-021/CEC-400-2008-021-15DAY.PDF

The defrost termination/fan delay control is a temperature-activated, single pole-double throw switch controlled with a remote sensing bulb (Fig. 1). The control can be an adjustable type. One example of the installation of an adjustable defrost termination/fan delay control is on a walk-in freezer’s evaporator (Fig. 2).

fig. 1

The control is wired into the refrigeration circuit. The control’s remote sensing bulb is located high on the evaporator where the frost is likely to clear last. The function of this temperature-activated switch is to terminate defrost when the evaporator coil has been defrosted, and to delay the evaporator fans from coming on immediately after defrost.

fig. 2

Defrost time clocks can be programmed for certain defrost duration periods. This is a time duration set at the time clock in minute increments. For example, a defrost time clock on a freezer could be programmed to defrost every six hours (four times daily), and have defrost durations of 40 minutes. However, there will be times throughout the year where the coil does not need the entire 40 minutes. These times could be from low usage of the freezer where the door openings are minimal, or when the humidity is low and not much frost accumulates on the coil. This is where the defrost termination part of the control comes into play.

Read the full article to learn how the defrost termination & fan delay systems work

Here are some ways to help you save energy costs on your walk-in cooler or freezer.

• Properly seal all penetrations in walk-in.
• Replace worn or damaged door seals.
• Install refrigeration away from doors.
• Keep condenser coils clean.
• Do not prop door open for an extended period of time.
• Add strip curtains or air curtains to your walk-in for extra protection from air infiltration when door is open.
• Make sure the lights are off when exiting the walk-in. Lights produce heat, which will cause your unit to run more to hold its optimal temperature.
• Periodically, check gaskets between panels to make sure they are not cracked or weathered. If so, check with your local health codes for the correct procedure to follow as far as repair and replacement.
• Make sure there is nothing stacked around the coil to restrict airflow.
• Make sure fan motors are balanced and running at optimum speed. Clean fan blades to reduce drag.
• Use an evaporator with an EC Motor.
• Utilize Smart Defrost Kits.
• Set defrost frequency at minimum requirements.

Click here for more information on Smart Defrost Kits.

Check out their savings calculator that demonstrates how much money you could save by installing a Smart Defrost Kit.

Bright lights, glass doors and windows can make an old drab corner turn into an inviting alcoholic beverage oasis. It is proven that bright lights and colorful graphics grab people’s attention attracting more customers to the product. Customers like to see all their choices right in front of them. The beer cave consolidates all beer and alcoholic beverages in one area so it is easy for people to find what they are looking for, grab and go.

Since the majority of beer sold in convenience stores is cold, why not put your beer stock in the cave (eliminating time spent on restocking)? Instead of shoving cases of beer on the shelves that only fit a few cases, have your inventory stocked together so you will always know when you are running low.

Wouldn’t you like to be known as having the “coldest beer in town”? Customers enjoy being able to walk-in, feel the cold air and know their beer will be cold and refreshing.

U.S. Cooler can provide for all of your walk-in needs in your convenience store. A beer cave can give you the opportunity to increase sales and produce a creative, inviting destination for your customers. To get a quote on a beer cave call U.S. Cooler at 800-521-2665.

Polystyrene is a dense closed-cell structure that is very resistant to moisture and holds its R-Value longer than other competing insulations found in walk-ins, such as Polyurethane. This allows less water infiltration in the insulation, which in turn saves energy and money. When water starts seeping into the insulation’s pores, the R-value drops dramatically causing the refrigeration to work harder to hold its respective temperature. Refrigeration working overtime means higher energy bills. Polystyrene is less water vapor permeable; therefore, water vapor does not infiltrate through the material as quickly or easily as it does other insulations. Using studies performed by the U.S. Army Corps of Engineers (CRREL), U.S. Cooler demonstrated extruded polystyrene saved consumers over $5,000 in energy costs over the first five years of operation. The savings again are due to extruded polystyrene’s ability to resist moisture and to retain its R-value better than other insulators.

Polystyrene used in walk-in coolers and freezers is made from “at least 20% pre-consumer recycled polystyrene.” (Owens Corning, Technical Bulletin: Recycle Content Claims Must be Reliable and Verifiable) Polystyrene found in walk-ins is also 100% recyclable. Manufacturing companies that produce these insulation materials, reproduce the resources in new insulation material. Alternatively, it is important to note that Polyurethane is produced from chemicals and is not made from any recycled materials nor can it be recycled or reused.

Polystyrene in walk-in coolers and freezers is the most cost effective and environmentally friendly insulation used in walk-ins today. Not only is polystyrene in walk-ins made with recycled materials and is 100% recyclable but it is energy efficient and can save a great deal of money in energy costs and reduce carbon footprint over the life-cycle of the walk-in.

In this issue we detail NAFEM 2009, the Department of Energy Meeting, New Hybrid Panels and more.

This will be a monthly newsletter and future editions will have more focus on news from around the industry.

If newsletters aren’t your style, you can always check this blog for the latest info, or sign up for our RSS feed.

If the video isn’t working, there are problems with the youtube server and you can view the video through the google server.

Ellis Craig (Owner) and Luke Craig (VP of Operations) represented U.S. Cooler by attending the meeting in Washington, D.C. at the beginning of February. The meeting represented just the beginning steps of arriving at a standardized testing method for the walk-in cooler and freezer industry.

February 5, 2009 Orlando, FL — Although the attendance at the NAFEM Show was lower this year, the quality of the people who stopped by our booth was the best we have seen. This year at the NAFEM Show, U.S. Cooler placed two Smart Cars atop one of our 7’7” x 20’ walk-ins. The Smart Cars were successful in grabbing attention and were visible from across the showroom.
We borrowed the cars from The Smart Center in Orlando. On one side of the cooler, we showed a cutout in the wall, displaying our three types of foam insulation; Extruded Polystyrene, Hybrid and Polyurethane. Many people found it useful to compare the insulations side-by-side and to discuss the characteristics of each. Overall, the show was a huge success!

Click here to view the U.S. Cooler PDF Installation Manual.

If the video isn’t working, there are problems with the youtube server and you can view the video through the google server.

How to keep your walk-in operating efficiently.

• Close door when not in use. Do not block or prop door open for extended periods of time. Make sure door is closed at all times except when entering and exiting the walk-in.
• Periodically, minimum of twice a year, clean evaporator and condensing coil. If located outside, the coils should be cleaned more often.
• Make sure fan motors are running at optimum speed.
• Clean fan blades to reduce drag.
• Make sure there is nothing stacked around the coil to restrict airflow.
• Occasionally have service technician check all electrical connections to make sure they are good and tight. Loose wires could cause high amperage, which will cause your unit to use more energy.
• Check for damage or decay in the insulation on suction lines between condensing unit and evaporator coil. Replace as needed.
• Check door sweep for tears and make sure sealing properly.
• Hinges should be lubricated once a year to keep closing properly.
• Make sure the lights are off when exiting the walk-in. Lights produce heat, which will cause your unit to run more to hold its optimal temperature.
• On outside condensing units, maintain clear and adequate airflow. For example, do not allow trash or weeds to accumulate around walk-in.
• Do not pile anything on top of the walk-in. This could cause damage to the ceiling panels.
• Periodically, check gaskets between panels to make sure they are not cracked or weathered. If so, check with your local health codes for the correct procedure to follow as far as repair and replacement.

How to keep your walk-in clean.

• Soap and water is the best cleaning method for your walk-in. Do not use harsh chemicals as it may react and harm the metal surface of your walk-in.
  For chemicals not to use read this pdf.
• Minimum of twice a year use a self-rinsing cleaner, soap and water or stiff bristled brush to clean your evaporator and condensing coils.
• Drain lines – at least once a year, work with a service tech to make sure the drain lines are clean and not clogged with any debris.
• Door gaskets – Regularly wipe down with soap and water. If door gaskets are damaged, cracked or stiff magnet will not seal and will need to be replaced.
• Sweep or mop floors to make sure floors are kept clean.

Mistakes operators most commonly make.

• Turning holding temperature too low for product, this causes the refrigeration to overwork.
• Walk-in manufacturers install a thermostat on the outside of the door that reads the internal temperature of the walk-in. There could be a chance that the thermostat is faulty. Always have a backup thermometer in the walk-in to make sure the walk-in is holding the optimal temperature.
• Stacking boxes or food too close to the door thermometer-sensing bulb or thermostat-sensing bulb can cause a false reading of the temperature in the walk-in.

Advice on safety related issues.

• Make sure you clean up any liquid spills as soon as they happen. This is especially important in freezers as the liquid will start to freeze immediately and can be dangerous.
• Non-skid strips are available for the floors, to ensure a non-slip environment.
• Keep isles clear and do not overload walk-in by stacking too much in your cooler or freezer. Stack things neatly to make sure you are able to take good inventory of your stock.
• Power outage – A typical walk-in will maintain temperature for about 12 hours as long as door is kept closed. If the power outage lasts longer than 12 hours, consider a back-up generator.

* This offer is through dealers only.

To address this issue, AHRI is launching an initiative to educate distributors, installers, and equipment owners about the new standard and its requirements. The association has developed a simple checklist that installers and equipment owners can use to make sure the walk-in cooler or freezer being specified or installed complies with federal law. The checklist is available at www.ahrinet.org/ARI/util/showdoc.aspx?doc=1202.

In addition to customer education, manufacturers believe the solution is the development of a certification program for walk-in coolers and freezers that would clearly identify those units that have been independently tested to verify they achieve a federally established minimum performance rating.

AHRI said the federal government is working with industry to develop a testing methodology for this equipment by 2010. In addition, a final rule is expected to be adopted in January 2012 that will establish a performance-based standard.

The full article can be found here.

U.S. Cooler Sales Territory Map

 Navigate to the U.S. Cooler Territory Map.

KNOXVILLE (WATE) — Knox County health inspectors were forced to temporarily close a North Knoxville deli this week over a walk-in cooler that was way too warm.

When the inspector found the walk-in refrigerator at 60 degrees and not working properly, she ordered a lot of food thrown away including ham, turkey, meatballs, pepperoni, bacon, eggs, and cheese.

Nearly 100 pounds of food were ordered thrown away because they weren’t safe to eat. Garelli’s was closed until the refrigerator was repaired.

Plus, the inspector found a roach crawling on the kitchen floor. Garelli’s pest control company was ordered to pay a visit.

Maybe the roach was attracted to the moldy grapes, celery and rotten tomatoes the inspector found in the refrigerator.

Mold was also found in the ice machine and water was leaking onto the kitchen floor.

Garelli’s is open again.

Make sure your walk-in has insulation that will retain it’s r-value well over time. And always make sure your refrigeration unit is functioning properly. Find the whole wate.com article here.

But those of you who don’t require a custom size can choose to buy from our selection of standard nominals through one of our authorized dealers. (find on in your area by typing in your zip code in the form below)

Sizes Include:

6′ X 6′ X 7′ 6″ Nominal (5′ 10 1/2″ X 5′ 10 1/2″ X 7′ 6″ Actual Size)

6′ X 8′ X 7′ 6″ Nominal (5′ 10 1/2″ X 7′ 10″ X 7′ 6″ Actual)

8′ X 8′ X 7′ 6″ Nominal (7′ 10″ X 7′ 10″ & 7′ 6″ Actual)

8′ X 10′ X 7′ 6″ Nominal (7′ 10″ X 9′ 9 1/2″ & 7′ 6″ Actual)

Options:

Cooler (with or without floor), Freezer (with floor)

Refrigeration:

For Indoor boxes – no refrigeration, indoor remote ref, outdoor remote ref, top mount ref, saddle mount ref (cooler only), penthouse ref

For Outdoor boxes- no refrigeration, outdoor remote ref

Maintaining your walk-in coolers and freezers is pretty simple. For starters, a clean walk-in is an efficient one. Your staff is likely are trained to keep both the interior and exterior clean and sanitary (use a mild soap detergent and damp mop), but key components can sometimes be overlooked. Pay particular attention to:

Door gaskets. Keep clean and pliable. Replace when worn.

Hinges and door closers. Check regularly for proper opening.

Condenser and fan. Keep clean and free of grease so they can do a more effective job of transferring heat. Since most of you will use remote refrigeration systems, that will mean a trip up to the roof for someone on a regular basis.

Condenser and drain lines. Keep them clear and schedule checks of the seals where they enter the building.

Beyond checking these areas, it makes sense to schedule servicing every three months if your system is self-contained and every six months if it’s remote.

These tips come from the February 2009 issue of Foodservice Equipment Magazine. Find the full article here. The article also details the new government EISA rules and new innovations in walk-in component technology from glass doors to compressors.

For more cleaning and maintenence tips view this post.

All the files are in pdf format. You will need a pdf reader to view them.

These are the current items U.S. Cooler is selling on Ebay.

Quincy, IL, December 23, 2008–U.S. Cooler is introducing their new green Hybrid panels for walk-in coolers.  U.S. Cooler’s new product launch will be January 1, 2009. The Hybrid panel is a 4” thick panel, consisting of 3” Extruded Polystyrene and 1” Expanded Polystyrene, which exceeds EISA requirements.  This combination provides the customer with the strength and moisture resistance of Extruded Polystyrene and the insulation economics of Expanded Polystyrene.  With these crucial characteristics, the Hybrid is the best designed and engineered competitively priced panel in the market.  U.S. Cooler will offer the Hybrid cooler in addition to their leading line of 4” Extruded Polystyrene coolers and freezers.  Unlike Polyurethane walk-in manufacturers, U.S. Cooler’s panels are 100% recyclable and are made from over 60% recycled materials.

When purchasing a new walk-in cooler or freezer, the initial cost of the walk-in is almost always the deciding factor. With U.S. Cooler’s new Hybrid Cooler you will receive a high-quality box at a reduced price. In addition to the up-front cost savings, the Hybrid will also save you money over the lifecycle of your walk-in. The Hybrid cooler is ideal for the customer that wants the most efficient and competitively priced walk-in cooler in the industry. Its overall product lifecycle cost will prove that this walk-in is one of the best walk-in coolers available.

The goal of U.S. Cooler’s high quality walk-ins is to obtain and maintain the highest possible R-value, ultimately resulting in energy and cost savings. Both Expanded and Extruded Polystyrene are a closed-cell structure that is free of voids preventing both air and moisture infiltration which allows it to sustain a high thermal opposition through the life of the walk-in.

Congress passed the Energy Independence and Security Act of 2007 to help reduce energy consumption in the United States. The Act requires commercial walk-in coolers and freezers under 3,000 square feet to contain an insulation R-value of at least R-25 for coolers and R-32 for freezers. U.S. Cooler’s products exceed the government requirements. U.S. Cooler’s new Hybrid cooler has an R-value of 25.8 while their freezers have an R-value of 32.4, both exceeding government standards.

Our New Hybrid Insulation

You can also read about the differences between extruded polystyrene and polyurethane.

They are as follows:

Restaurant Coolers & Freezers

Convenience Store Reach-in Display Coolers

Cold Storage Warehouses

More walk-in application pages will be added to this list when completed.

This will be U.S. Cooler’s new blog.