Enhancing Efficiency and Safety with Thermoscreens Cold Store Air Curtain.

A leading supermarket chain was experiencing ongoing issues with ice build-up, temperature instability and excessive refrigeration energy usage within one of its cold store environments. Looking for a more effective long-term solution, the business partnered with Thermoscreens to trial the innovative CS (Cold Store) Air Curtain.

The Overview

Cold store doorways are one of the biggest sources of temperature loss and energy waste in refrigerated environments. Frequent door openings allow warm external air to enter the space, causing temperature fluctuations, increased compressor workload and heavy ice formation around entrances.

To improve operational efficiency and create a safer working environment, Thermoscreens installed its patent-pending CS Air Curtain at a supermarket cold store facility. The project included a full monitoring system to evaluate temperature stability, energy usage and door activity before and after installation.

The Challenge

The supermarket was experiencing substantial hoarfrost and ice build-up around the cold store entrance, creating hazardous slip risks for employees transporting goods in and out of the room.

Frequent door openings were also allowing warm air to enter the cold store, forcing chillers and compressors to work significantly harder to maintain internal temperatures. This led to:

• Increased refrigeration energy usage
• Temperature instability throughout the room
• Excessive compressor runtime
• Higher operational costs
• Ongoing maintenance and defrosting requirements

Traditional climate separation methods previously used on-site were struggling to maintain a stable internal environment during daily operation.

The Solution

Thermoscreens installed a CS Cold Store Air Curtain above the cold store entrance to create an effective climate separation barrier between the ambient and refrigerated environments.

Unlike traditional insulated doors or PVC strip curtains, the CS Air Curtain is specifically designed for cold storage applications where doors are opened frequently throughout the day.

As part of the installation, Thermoscreens also implemented a comprehensive monitoring system which included:

• Internal and external temperature sensors
• Door opening monitoring
• Compressor energy monitoring
• Power usage analysis

This allowed the supermarket to directly compare operational performance before and after the air curtain installation.

The Results

The installation delivered significant operational improvements across temperature control, energy efficiency and workplace safety.

Improved Temperature Stability

Before the installation, cold store temperatures regularly exceeded 7.5°C during operation, with temperature differences of approximately 5°C between different areas of the room.

Following installation of the CS Air Curtain:

• Peak temperatures reduced to -11°C
• Temperature variation across the room dropped to within 1°C
• Door openings caused minimal temperature disruption
• Compressor off-time increased dramatically

The monitoring also showed that when the air curtain was operating, temperature increases during door openings were reduced to less than 3°C.

Reduced Energy Usage

Monitoring data showed a clear reduction in refrigeration energy usage after the installation of the air curtain, despite higher ambient temperatures outside the cold store during the monitoring period.

One of the most significant findings was the increase in compressor off-time, which improved by approximately 1600%. This reduction in compressor workload has major long-term implications for:

• Energy consumption
• Equipment lifespan
• Maintenance requirements
• Overall refrigeration efficiency

Preventing Ice Build-Up

The CS Air Curtain also virtually eliminated the heavy ice and hoarfrost build-up previously forming around the doorway.

This helped to:

• Improve employee safety
• Reduce slip hazards
• Minimise defrosting downtime
• Reduce maintenance intervention
• Prevent damage caused by excessive ice formation

Remarkably, the supermarket reported no significant ice build-up issues for around two years following installation.

A Sustainable Alternative to Traditional Cold Store Methods

Compared to insulated doors and PVC strip curtains, the Thermoscreens CS Air Curtain provided a far more effective and operationally efficient climate separation solution.

By stabilising temperatures and reducing warm air ingress, the system improved refrigeration performance while lowering operational strain on the cold store equipment.

The supermarket also gained several additional long-term commercial benefits, including:

• Reduced evaporator defrost cycles
• Lower maintenance requirements
• Reduced need for equipment replacement
• Potential reductions in evaporator duty requirements
• Improved compressor longevity

The Conclusion

The installation of the Thermoscreens CS Air Curtain transformed the supermarket’s cold store environment, delivering measurable improvements in safety, temperature control and refrigeration efficiency.

By reducing ice build-up, lowering energy usage and creating a more stable refrigerated environment, the CS Air Curtain demonstrated its value as a long-term sustainable solution for cold storage applications.

For businesses operating refrigerated environments with frequent door openings, effective climate separation can have a major impact on operational efficiency, maintenance costs and workplace safety.

Click the link below to read the full case study.

Read the full case study here