Food Processing & Cold Storage – PA

A Larger Facility for Processing and Freezer Storage

After outgrowing an existing 30,000-square-foot building, a Pennsylvania operator moved forward with a new 50,500-square-foot facility. The plan combined 25,200 square feet of 30-foot-high cold storage with 18,000 square feet of food processing space, creating two demanding environments within one coordinated construction project.

• The larger footprint had to increase both production and freezer capacity without separating the panel scope across different wall systems.
• Freezer areas required strong thermal performance, while processing areas needed durable finished surfaces suited to regular food production activity.
• The project team already had years of experience with PermaTherm, so the build could move forward with a familiar supplier and a current PolyIso panel system.

Four-Inch and Six-Inch PHF43 Panels for Dual Environments

PermaTherm supplied 4-inch and 6-inch PermaCore PHF43 Light Mesa panels with stucco-embossed, 26-gauge galvanized facings finished in Polar White SMP. The two thicknesses allowed the project team to match the panel package to the distinct requirements of freezer storage and food processing areas.

• Current PHF43 data lists R-8.2 per inch of thickness, giving the 4-inch and 6-inch panels insulation levels suited to temperature-controlled construction.
• The concealed-fastener joint and rigid PolyIso core created a continuous panel assembly across walls serving both the freezer and processing sections.
• When a small number of panels showed delamination, PermaTherm replaced them promptly so installation could continue without reopening the broader material plan.

Smooth Coordination From Estimating Through Delivery

The facility reached completion in September 2025 with 36,298 square feet of PHF43 panel coverage. Refrigeration systems had not yet been commissioned when the original case study was documented, so temperature and energy performance data were not available, but the construction and material process was complete.

• Estimating, ordering, production, and shipping moved through one coordinated PermaTherm panel scope for both major facility uses.
• Prompt replacement of the affected panels kept a limited product issue from becoming a larger schedule problem.
• The finished enclosure gave the operator expanded processing and freezer capacity inside a single 50,500-square-foot building.

Planning a facility with processing and cold storage areas? Talk to a PermaTherm panel expert.