Kolpak And Emerson Team Up To Innovate Food Service Storage

A walk-in is a walk-in is a walk-in.  At least that’s how it’s been for decades.  But now a new design from Kolpak, a division of Manitowoc Foodservice Group, breaks with the old inside-the-box tradition to create a more functional, more flexible unit.  Unveiled at NRA 2002 in Chicago, the new R Series walk-in coolers and freezers offer a variety of innovations that set Kolpak apart from more traditional lines of walk-ins.

The most obvious difference in the new walk-in is its appearance.  Gone is the boxy look.  In its place is a sleek, smooth unit with rounded edges and an array of cosmetic and functional design enhancements.  The new design includes a ramp that can be approached from three-sides for easier loading, a flexible interior storage and work surface solution, and an easy-to-read digital display panel. In addition, the door features a third hinge as standard (for heavy usage applications), is self-closing and has a curved, custom-designed handle with “feel good” grip that extends the entire width of the door.

The new walk-in also features a low profile evaporator that increases headroom and creates more available space inside the unit.  An optional remote refrigeration system diverts noise and heat away from kitchen and service areas.

Historically buyers considered cost, reliability, and storage size or capacity when selecting walk-in units.  But recent changes in the food service industry – namely more stringent FDA regulations on food safety and an across-the-board heightened awareness of energy consumption and costs – are changing the buying criteria.  Kolpak’s R Series walk-ins meet these industry hot buttons, with the help of technology from several Emerson divisions.

On the food safety front, the units are available with an innovative storage solution from Emerson’s InterMetro division, allowing food service operators to create a work friendly environment that provides safe and separate storage of food products.   A sliding shelving system from Metro adds flexibility and maximizes use of valuable floor space.  The R Series’ food storage and handling systems address ergonomic user interface and food preservation issues.

The team considered the entire range of needs a food service kitchen might have, and designed the walk-in layout with as much flexibility as possible. They also incorporated a modular lighting system available in six different options, so lighting can be installed at special angles and even in corners to make the most efficient use of space. 

The R Series incorporates Kolpak’s new, patented “AirShield” for improved energy efficiency..  Unlike traditional air curtains, AirShield disperses air horizontally across the opening, allowing the refrigerated air to re-enter the cooler.  Because it reduces air infiltration and cuts run time on the refrigeration system, AirShield provides added efficiency – and ultimately, reduced energy consumption.

The Einstein controller from Emerson’s Computer Process Controls, Inc. division is one of the more advanced technologies available with the R Series.  This integrated controller, similar to those used in supermarket and retail applications simplifies system operation by monitoring temperatures in each storage area and the refrigeration system components.  Einstein monitors temperature, humidity and controls the lighting, aiding in food safety and energy management efforts.  While the Einstein controller is used primarily for data acquisition on the walk-in, it can be expanded to give food service operators the ability to integrate other pieces of equipment in the kitchen and provide wireless temperature monitoring of additional product coolers or store conditions.

Kolpak and Emerson engineers worked for more than eighteen months on the development of the R Series.  The biggest challenge, according to Michael Chandler, group engineering manager at Kolpak, came from attempting to design a refrigeration system that conserved precious space while still achieving the Btu/hour capacity demanded by a walk-in.

“It was no easy task, but we met these engineering challenges on three different fronts, ” explained Chandler.  “It required a creative approach to the physical design and layout of the walk-in, making key design changes to the refrigeration system, and careful sizing and selection of components to meet the tough performance standards we set for ourselves.”

According to Chandler, redesigning the refrigeration system was perhaps the most tedious part of the project, but also a truly differentiating design in walk-ins. To gain additional headroom and storage space in the unit, engineers redesigned the heat exchange coil and developed a low-profile evaporator that extends just 4” from the ceiling (versus the typical 15” drop). 

The team selected Copeland Scroll® and reciprocating compressors for the condensing units for R Series coolers, with a goal of improved reliability and energy savings.  Other key technologies from Emerson include a White-Rodgers temperature sensor that controls the power for the condensing unit, Alco expansion valves and Emerson air moving motors.

Reshaping the future of walk-ins, literally, is just the first step in what Manitowoc officials see as an ongoing effort to think -- and build -- outside the box.  “We will continue to break the mold with walk-in products that achieve higher levels of performance and flexibility for our customers,” said Tim Kraus, president of Manitowoc Foodservice Group.  “Doing that requires breakthrough technology and creativity.  Emerson Climate Technologies brought a lot to the table in this project, and we definitely see the value in partnering with them on future new product designs.”