The Challenge: Converting an Existing Building Into a Refrigerated Cold Storage Cooler
This produce handling and distribution operator needed to convert an existing building into a large refrigerated cooler while minimizing disruption to ongoing operations and meeting a tight construction schedule. The project required a high-performance insulated envelope capable of maintaining consistent temperatures for produce storage while accommodating modifications discovered during demolition and construction.
The facility was designed as a large cooler measuring approximately 120′ wide by 85′ deep with a 26′ high ceiling, maintaining temperatures between 36°F and 40°F to support reliable produce storage and distribution.
The wall and ceiling system had to deliver dependable temperature control and energy efficiency while standing up to the daily operational demands of a food handling environment.
Construction had to fit within a limited downtime window, and the panel package needed to adapt to field conditions discovered after demolition began, including changes to the tee-bar support layout.
The PermaTherm Solution
The Solution: PermaCore PHF43 Cold Storage Insulated Metal Panels
PermaCore PHF43 hidden fastener panels with a polyisocyanurate core were selected for the cooler envelope. The FM Approved panel system addressed the thermal performance, moisture resistance, and durability requirements of refrigerated produce storage in one integrated package, directly answering the schedule and performance challenges that defined the project.
The high R-value of the Poly ISO core helps maintain stable cooler temperatures while reducing energy consumption, with the moisture resistance and long-term durability needed for refrigerated produce storage applications.
The panels arrive pre-insulated and factory-finished in Polar White, providing an all-in-one insulated building envelope that eliminated the need for multiple construction components and simplified the overall installation process.
PermaTherm worked closely with the contractor throughout design and construction, providing updated layouts, engineering support, freight coordination, and schedule flexibility. When demolition revealed changes to the tee-bar support layout, the team quickly revised the panel package and kept the project on track with frequent, responsive communication.
Results/Outcome
The Results: Faster Panel Installation and Energy-Efficient Cooler Performance
The completed cooler provides a modern, highly insulated environment designed to maintain consistent temperatures for produce storage and distribution. The panel system reduced construction complexity and supported the contractor’s aggressive schedule from production through installation.
Compared to traditional framed wall and ceiling assemblies requiring separate insulation and interior finishes, the PHF43 system allowed crews to enclose large areas significantly faster, with fewer trades and reduced installation time.
Although the schedule evolved several times due to refrigeration coordination and facility planning, PermaTherm manufactured the panel package on an accelerated timeline and aligned production with the customer’s installation window, completing and releasing materials in August 2025.
The project team transformed an existing structure into a high-performance refrigerated facility with strong thermal performance and a durable interior finish suitable for food industry applications, supporting long-term operational growth and product quality.
