ENERGY SAVING Mind the gap


In the cooling sector, a door is not merely an entryway, but a thermal valve. Here, Adam Mann, Engineering Manager at GB Controls, explores how advanced door controls serve as the primary safeguard against ‘thermal drift’, preventing the catastrophic energy loss and equipment strain that occurs when the cold chain is breached.


T Adam Mann 'These


systems use sensors to monitor door position and trigger an immediate, loud, and sometimes custom-voiced audible alarm if the door remains open past a pre-set threshold time.'


he global cooling sector, spanning food processing, pharmaceuticals, chemical storage, and logistics, is one of the most energy-intensive industries in the world.


To maintain the integrity and safety of countless perishable and temperature-sensitive products, refrigeration systems work nonstop, consuming vast amounts of electricity. While insulated panels, effi cient compressors, and advanced refrigerants are rightly celebrated, the single most critical, yet often overlooked, component in maintaining a stable cold environment is the door control system. A cold room door is not just a physical barrier; it is the most


signifi cant thermal weak point in the entire structure. In a world demanding greater sustainability, lower operational costs, and absolute consistency in product quality, door controls transform a liability into a highly controlled asset. Their importance extends across four pillars: unparalleled energy effi ciency, absolute product integrity, optimised system performance, and regulatory compliance.


The energy effi ciency imperative The primary reason door controls are essential is the dramatic impact a door opening has on energy consumption. The physics of air exchange dictates that cold, dense air inside a chiller or freezer fl ows out immediately upon opening, to be replaced by warmer, more humid ambient air. This air exchange sets off a costly chain reaction: Increased Thermal Load: The warm air entering the cold


room must be cooled back down to the target temperature. This forces the refrigeration unit to run longer and harder, directly increasing electricity usage and driving up utility bills. For large industrial sites, these energy savings can be signifi cant, with some studies suggesting that eff ective control systems can reduce energy consumption by up to 17%. The Problem of Moisture and Ice: The incoming air is not just warm; it is also humid. As this moisture cools, it condenses and then freezes, depositing ice and frost onto the evaporator coils. This is perhaps the single biggest threat to system effi ciency. Ice acts as an insulator, reducing the evaporator’s ability to extract heat from the room, forcing the compressor to work even harder for diminishing returns. The Solution is Time and Design: Door control mechanisms are fundamentally about controlling time. Studies suggest the fi rst 7 to 10 seconds of an opening are the most


22 January 2026 • www.acr-news.com


critical period for heat loss. Consequently, door systems are designed to minimise this exposure. Modern door control technology addresses this through design and mechanism: High-Speed Doors: These are designed with rapid open/ close cycles, sometimes using automated sensors, to ensure the door is only open for the absolute minimum time necessary for passage. Insulation and Seals: Control starts with the door itself. High-quality cold storage doors utilise advanced insulating materials and airtight, perimeter sealing systems to provide a high thermal resistance (low U-value) when closed, preventing energy leakage (air infi ltration). Air Separation: In high-traffi c environments, air curtains or specialist air separation technology create an invisible barrier across the doorway. This mitigates the exchange of air masses, sometimes requiring a warm airstream on the cold side to actively “demist” the doorway and prevent fog or ice formation at sub-zero temperatures.


Safeguarding product integrity and system performance In industries governed by the cold chain, temperature consistency is non-negotiable. Any fl uctuation can have catastrophic fi nancial and safety consequences. Risk of Spoilage: For food and beverage products, an


Download the ACR News app today


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40