Commercial food manufacturing facilities evolve continuously as production volumes increase, workflows improve, and operational requirements change. Refrigeration systems that performed perfectly during the original construction often require modifications years later to accommodate new production layouts, improve airflow, optimise food safety, and support greater manufacturing efficiency.
Unlike new refrigeration installations, renovation projects require engineers to work around existing infrastructure while ensuring production continues with minimal disruption. Every modification must integrate seamlessly with operational refrigeration systems without compromising temperature control or food safety.
This case study showcases how Glotech Group completed a comprehensive commercial refrigeration renovation for Food Directions at its manufacturing facility in Airport Industria, Cape Town. Rather than constructing new refrigeration rooms, the project focused on upgrading existing cold storage infrastructure, improving airflow distribution, installing new refrigeration equipment, and modifying insulated panel systems to improve overall operational performance.
The project demonstrates Glotech Group’s ability to optimise existing refrigeration facilities while supporting one of South Africa’s leading hospitality and airline catering manufacturers.
ood Directions has built its reputation on delivering premium food solutions to the hospitality and airline catering industries.
As production processes evolved, certain refrigeration areas required modification to improve workflow, temperature consistency, and operational efficiency.
Rather than replacing complete refrigeration facilities, the client required targeted engineering improvements that would maximise the performance of existing refrigeration infrastructure.
Several structural improvements formed part of the renovation programme.
The dairy chiller received a new insulated door together with commercial strip curtains, improving temperature retention while reducing warm air infiltration during frequent staff movement.
Additional insulated panel work included the installation of:
These modifications improved both the structural integrity and thermal performance of the refrigeration rooms while creating a professional hygienic finish suitable for food manufacturing.
As part of the renovation, Glotech Group installed a new medium temperature evaporator inside one of the cold rooms.
The new blower was carefully positioned to integrate with the existing refrigeration system while improving airflow and cooling performance.
Replacing ageing refrigeration components as part of a planned renovation reduces future maintenance while improving overall refrigeration efficiency.
One of the most technically challenging aspects of the project involved the food preparation room.
The preparation area measured approximately 20 metres by 15 metres and was served by two evaporator coils.
Despite both units operating correctly, the client experienced inconsistent temperatures across different parts of the room.
Some areas maintained the required operating temperature while others remained noticeably warmer.
For food production facilities, uneven temperatures create operational inefficiencies and can affect product handling.
Rather than recommending additional refrigeration equipment, Glotech Group investigated the airflow characteristics within the room.
The assessment concluded that the refrigeration capacity itself was sufficient.
The problem lay in how the cold air was distributed throughout the space.
To correct this, the two evaporator coils were repositioned to improve airflow patterns and create more even temperature distribution across the entire preparation room.
This engineering approach delivered a practical solution without unnecessary capital expenditure.
Many refrigeration systems are incorrectly diagnosed as being undersized when the real problem is poor airflow.
Correct evaporator positioning helps achieve:
By optimising airflow rather than increasing refrigeration capacity, the client received a more efficient solution with lower operating costs.
The fifteen-day project included:
Each stage was completed while maintaining the high installation standards expected within food manufacturing environments.
Following completion of the renovation, the refrigeration rooms demonstrated improved thermal efficiency and better overall performance.
The upgraded dairy chiller now experiences reduced cold air loss through the new insulated door and strip curtains.
The repositioned evaporators provide a more balanced temperature throughout the preparation room, eliminating the uneven cooling that previously affected daily operations.
The completed renovation improved both operational efficiency and product protection while extending the service life of the existing refrigeration infrastructure.
The renovation delivered:
Most importantly, the project solved operational problems through engineering improvements rather than unnecessary equipment replacement.
With more than 15 years of experience, Glotech Group designs, installs, upgrades, refurbishes, repairs, and maintains commercial refrigeration systems for food manufacturers, airline catering companies, restaurants, pharmaceutical facilities, supermarkets, seafood processors, butcheries, hospitality businesses, and industrial clients throughout South Africa.
Our expertise includes:
Every project is engineered around the client’s production process, operational requirements, and long-term business objectives.
The Food Directions renovation project demonstrates that improving refrigeration performance is not always about installing larger equipment. By combining structural cold room improvements, upgraded refrigeration components, and careful airflow engineering, Glotech Group transformed existing refrigeration facilities into more efficient and reliable production environments.
This project showcases our ability to solve complex operational challenges inside active food manufacturing facilities while maintaining the highest standards of refrigeration engineering. For manufacturers looking to optimise existing cold rooms, improve temperature consistency, or modernise ageing refrigeration infrastructure, Glotech Group continues to deliver practical, long-term solutions backed by more than 15 years of commercial refrigeration experience.
067 153 8332
info@glotechgroup.co.za
Gotech Group offers emergency repair, replacement and installation of industrial and commercial refrigeration units restoring efficient operations in Hermanus & across Western Cape.