Cold storage isn’t just about keeping things cold—it’s about keeping them consistently cold, safe, and protected from hidden threats. One of the most critical yet often overlooked elements in cold storage construction is the vapor barrier. This thin layer of material may not seem like much, but it plays a massive role in maintaining temperature control, preventing damage, and ensuring product integrity over time.

So what exactly is a vapor barrier—and why is it so essential in cold storage design? Let’s break it down.
What Is a Vapor Barrier?
A vapor barrier (also called a vapor retarder) is a material used to prevent moisture in the form of vapor from passing through walls, ceilings, and floors. It’s typically made from polyethylene sheets, foil-faced insulation, or specially coated membranes, and it’s installed on the warm side of the insulation in a cold storage facility. In simple terms: vapor barriers stop warm, humid air from seeping into the cold, dry environment inside the storage space.
Why Moisture Control Matters in Cold Storage
Cold storage facilities operate at low temperatures, sometimes below freezing. When warm, humid air from the outside environment comes into contact with cold interior surfaces, condensation and frost can form. This can lead to a host of problems such as mold and mildew growth, frost buildup, damage to insulation, slippery floors, and compromised food and product safety. Even small amounts of moisture infiltration can reduce energy efficiency and damage the building’s structure, resulting in expensive repairs and product loss.
The Role of Vapor Barriers in Cold Storage Design
A vapor barrier works as the facility’s first line of defense against moisture. Its job is to keep humid air from reaching the cold side of the wall or ceiling assembly, where it would otherwise condense into water or ice.

Here’s how vapor barriers benefit cold storage environments:

Prevent condensation and ice formation
Preserve insulation performance
Enhance energy efficiency
Reduce maintenance and repair costs
Improve food safety and compliance
Extend building lifespan

Where Vapor Barriers Should Be Installed
For maximum effectiveness, vapor barriers should be strategically installed wherever there’s a temperature difference between warm and cold spaces. This may include behind insulated wall panels, beneath insulated floors, on ceilings (separating conditioned and unconditioned spaces), and around door openings. Keep in mind that proper installation is just as important as the material itself. A poorly sealed or misaligned vapor barrier can lead to air leaks, rendering the entire system ineffective.
Common Mistakes to Avoid
There are a few mistakes that should be avoided at all costs, otherwise you’ll have a false sense of protection for your cold storage facility. First, vapor barriers should go on the warm side of the insulation. In cold storage, that’s the outside of the cold room.

Second, all gaps should be properly sealed. Even the smallest openings around pipes, seams, or electrical outlets can let vapor in, causing problems for your system. Lastly, it’s crucial that the right materials are used. Not all vapor retarders are rated for cold storage use. Use only materials designed for low-temperature, high-humidity environments.
Small Detail, Big Impact
In cold storage design, vapor barriers are not optional—they are essential. This invisible layer helps protect your facility from moisture damage, maintain temperature stability, and ensure long-term energy efficiency. When properly installed and maintained, a vapor barrier can save you thousands of dollars in repairs and operational costs—while helping your cold storage facility meet safety, quality, and compliance standards.

Need help designing a moisture-controlled cold storage facility? Contact Central Washington Refrigeration to speak with one of our experts.

In cold storage design, the right wall system isn’t just about structure—it’s about thermal performance, energy efficiency, durability, and long-term cost savings. Two of the most popular choices in the industry are insulated concrete walls and insulated metal panel (IMP) walls. Each has its strengths and drawbacks, and choosing the right one depends on your facility’s needs, location, and budget.

Let’s break down how insulated concrete walls compare to insulated metal panels when it comes to building high-performing cold storage facilities. For more information about large-scale, cold storage solutions, contact Central Washington Refrigeration today.
Thermal Insulation Performance
Insulated concrete walls are typically made using Insulated Concrete Forms (ICFs)—blocks or panels filled with rigid insulation and reinforced with poured concrete. ICFs offer continuous insulation with high thermal mass, which helps maintain stable indoor temperatures by resisting temperature fluctuations.

Insulated metal panels (IMPs) consist of two metal skins with a rigid foam core (typically polyurethane or polyisocyanurate) sandwiched in between. They offer excellent R-values per inch of thickness and provide high-performance thermal insulation right out of the box.

For pure insulation value, IMPs generally deliver a higher R-value per inch. But ICFs provide thermal mass that improves temperature stability over time—especially useful in very cold or variable climates.
Air and Moisture Resistance
Thanks to their dense composition and minimal seams, concrete walls provide excellent air sealing and moisture resistance. When properly installed, they drastically reduce the chance of air leaks and condensation—critical for cold storage.

IMPs are designed to be airtight, but installation is key. Poorly sealed joints or fasteners can lead to air leakage or condensation inside wall cavities. However, modern systems come with tight interlocking seams and vapor barriers that mitigate these risks.

Both systems perform well when installed correctly, but concrete has fewer potential failure points when it comes to air and vapor intrusion.
Structural Strength and Durability
Concrete offers superior structural strength and longevity. It’s resistant to impact, fire, pests, and extreme weather and is ideal for facilities that need high durability and low maintenance over decades.

IMPs are strong but not as impact-resistant as concrete. They can dent or deform under heavy impact, and depending on the environment, they may require more frequent inspections for corrosion or panel damage. Without a doubt, concrete walls win in terms of durability and long-term structural integrity.
Installation and Construction Time
ICF systems are labor-intensive. They take longer to install and cure, and require coordination between insulation, formwork, and concrete pouring.

Metal panels are prefabricated and quick to install. They arrive ready to go, allowing faster assembly and reduced labor costs. This can significantly shorten project timelines. For those working on a time-sensitive project, IMPs are faster and more efficient.
Cost Considerations
With concrete walls, you can expect higher up-front costs due to labor, materials, and longer construction timelines. However, reduced energy costs and low maintenance can make them cost-effective in the long run.

IMPs are generally more affordable up front. The panels are factory-made and easy to install, which helps reduce overall construction costs. Maintenance and replacement, however, may add to the long-term expense. Therefore, concrete may offer better long-term value depending on the application.
Sustainability and Energy Efficiency
Insulated concrete walls are known for energy efficiency due to continuous insulation and thermal mass. Some ICF systems use recycled materials, and their energy-saving potential contributes to LEED certifications.

Metal panels also support energy efficiency, especially in designs that prioritize continuous insulation and airtight construction. Many are recyclable and made from sustainable materials. Whichever system you choose, you can expect energy efficiency and eco-consciousness.
Conclusion: Which Should You Choose?
The best choice between insulated concrete and insulated metal panel walls depends on your project priorities:

Choose Insulated Concrete Walls if:

Durability and longevity are top priorities
You need superior thermal mass
Your facility is in a region with harsh or variable climates

Choose Insulated Metal Panel Walls if:

Speed of construction and lower up-front cost matter
You need a flexible, lightweight system
Your facility design benefits from modular construction

Both systems offer excellent insulation and protection for cold storage facilities. The right pick comes down to performance needs, budget, and project timeline. Whichever you choose, ensure it’s installed by experienced professionals like Central Washington Refrigeration. We understand the unique challenges of cold storage environments and are happy to evaluate your options based on your facility’s location, use case, and budget.

Consumers demand fresh, high-quality products, making cold storage an essential link in the global supply chain. For operators and logistics providers, the question isn’t just whether to build or maintain a cold storage facility—it’s knowing when and how to upgrade or expand existing capacity. Below, we’ll explore the signs that indicate it’s time to upgrade, outline best practices for planning an expansion, and discuss how to keep operations running smoothly during the process.
Recognizing the Need to Expand
Capacity Constraints
One of the clearest signs it’s time to expand is when you’re consistently hitting capacity limits. Turning away potential business or struggling to accommodate new product lines means you’re missing out on revenue opportunities.
Seasonal or Market Shifts
Rapid shifts in consumer habits—like increased demand for frozen meals, plant-based proteins, or year-round availability of specific produce—can create sudden spikes in storage needs. Keep an eye on emerging trends and future projections to anticipate any upcoming bottlenecks.
Customer Requests
Existing clients may ask for dedicated space for long-term inventory or request custom storage conditions (such as controlled atmosphere). If you can’t fulfill these requests, your competition might.
Aging Infrastructure
Equipment that’s frequently breaking down or can’t meet modern energy-efficiency standards can cost you more in maintenance, downtime, and energy bills than an upgrade would. Recognizing the tipping point between “fixing” and “replacing” is crucial.
Planning Your Expansion
When planning an expansion, start with a needs assessment. This involves evaluating your current and future needs. Will you need more freezer space, refrigerated space, or controlled-atmosphere chambers? Will your product portfolio shift in the coming years? How do products move in and out, and will a new design better accommodate this?

Next, start talking to architects, engineers, and refrigeration specialists early. They can help you determine if your existing building can be expanded, or if a new facility is more cost-effective. Additionally, break down the budget for construction, new equipment, and potential downtime. Weigh immediate capital expenditure against future revenue gains and operational efficiency.
Designing for Efficiency and Future Growth
Upgrading mechanical systems and insulation during expansion offers the chance to incorporate high-efficiency refrigeration units, LED lighting, and solar or other renewable energy options. Building modular cold rooms or using prefabricated panels can also help reduce construction time and cost.

Additional technologies to consider incorporating into your design are:

Automated Storage and Retrieval Systems (AS/RS): Maximize vertical space and boost throughput.
IoT Sensors and Monitoring: Real-time temperature and humidity tracking for improved quality control and regulatory compliance.
Automated Guided Vehicles (AGVs): Help streamline internal product movement and reduce labor costs.

Maintaining Operations During Expansion
A frequent concern is the disruption that an upgrade or expansion can cause to operations. A common approach to avoiding significant downtime is to build the new space in phases. For instance, you might complete new sections first, then move inventory over before starting upgrades to the existing areas.

If an expansion requires partial shutdown of your facility, consider renting temporary storage units. This helps ensure minimal disruption to client orders. Lastly, notify all stakeholders—employees, clients, and suppliers—about construction timelines. Frequent updates help prevent misunderstandings and allow everyone to plan accordingly.
Upgrade Your Cold Storage Facility
Upgrading or expanding a cold storage facility is a significant undertaking that demands careful planning, expert guidance, and a strategic vision for the future. Whether you’re driven by rising demand, the potential for new business, or outdated equipment that needs an overhaul, the right approach can lead to substantial long-term gains.

Ready to explore a cold storage expansion? Contact Central Washington Refrigeration at 509-248-4600 to learn more about designing and installing a new refrigeration system.

We service beyond Central Washington: to Virginia, New York, Michigan and Pennsylvania.

In an era of global supply chains and year-round demand for fresh produce, cold storage solutions have become indispensable. Two primary methods often come up in discussions of large-scale storage and shipping: Controlled Atmosphere (CA) and Standard Refrigeration. Both keep products cold, but they work in different ways and serve different needs. This post delves into how each system operates, their benefits and drawbacks, and which industries benefit most from each.
Standard Refrigeration
Standard refrigeration lowers the temperature in a storage space using mechanical cooling systems. It’s the most common method for preserving everything from dairy products and meats to pharmaceuticals and beverages.

Basic refrigeration units are typically powered by compressors and refrigerants, maintaining a set temperature range. Some advanced systems also manage humidity, but the primary focus is on keeping goods at a consistent, cold temperature. Because it primarily involves temperature control, standard refrigeration is relatively straightforward to install and maintain.
Controlled Atmosphere (CA) Storage
Controlled Atmosphere (CA) storage goes beyond temperature control by adjusting the composition of gases (such as oxygen, carbon dioxide, and nitrogen) within the storage environment. The goal is to slow down the biological processes that cause spoilage, extending the shelf life of specific commodities—most notably fruits and vegetables.

CA storage is also ideal for long-term storage needs, such as keeping crops market-ready for extended periods or sustaining flowers, seeds, and nuts. Apples, pears, kiwis, and other fruits with respiration-sensitive shelf lives can also see their marketable life doubled or tripled under proper CA conditions.
Key Differences at a Glance

Aspect
Standard Refrigeration
Controlled Atmosphere

Primary Focus
Temperature control
Temperature + gas composition control

Complexity
Generally simpler setup and maintenance
Requires specialized sealing, gas monitoring, and regulation

Typical Product Range
Meats, dairy, pharmaceutical, beverages
Produce (fruits, vegetables), flowers, seeds

Storage Duration
Short- to medium-term
Extended storage (often months)

Capital & Operating Cost
Lower upfront and simpler to operate
Higher installation costs and specialized equipment

Sealing Requirements
Standard insulation and vapor barrier
Airtight sealing to maintain specific oxygen & CO₂ levels

Pros and Cons
Standard Refrigeration
The benefit of standard refrigeration is that it has straightforward temperature settings and no intricate gas monitoring. Less specialized equipment and sealing requirements contribute to its lower cost, and it’s suitable for a broad range of products. The downsides are that standard refrigeration does not slow the natural respiration of fruits and vegetables as effectively as CA, and energy consumption can still be high, even at low temperatures.
Controlled Atmosphere
With CA, the pros include significant shelf life extension—perfect for preserving perishable goods for weeks or months—optimal product quality, and reduced waste. Products are typically able to maintain flavor, texture, and nutritional value in CA storage. The drawbacks are higher complexity and cost and stringent monitoring (e.g., gas levels, temperature, humidity). Also, not all foods benefit from CA storage, including pre-packaged frozen foods or dairy.
Choosing the Right System
Product Type
Consider the products you are looking to store. CA is usually the better choice for fruits and vegetables with a high respiration rate. If you’re storing frozen foods, meats, or dry goods, standard refrigeration should suffice.
Storage Duration
Standard refrigeration is usually enough to manage short-term needs. If you need to maintain peak freshness for several months, however, CA may be worth the investment.
Budget and Infrastructure
Standard refrigeration has fewer specialized requirements, making it more cost-effective for smaller operations or those with broad product ranges. While CA has higher upfront and operating costs, it can deliver substantial returns by reducing spoilage and extending the selling season for high-value produce.
Operational Complexity
Routine checks are required for standard refrigeration systems, but they are generally straightforward. Operating a CA facility demands expertise in gas management, sealing techniques, and advanced monitoring.
Upgrade Your Cold Storage Today
Both controlled atmosphere and standard refrigeration have essential roles in today’s cold storage landscape. Your choice depends on the nature of your products, how long they need to stay fresh, and how much you’re willing to invest in specialized infrastructure. Considering a move to CA or upgrading your existing cold storage? Contact Central Washington Refrigeration to learn more about your options.

We service beyond Central Washington: to Virginia, New York, Michigan and Pennsylvania.

Effective cold storage is essential in beef processing facilities to preserve product quality, maintain food safety, and optimize operational efficiency. From temperature control and zoning to regulatory compliance and worker safety, each aspect of cold storage design has a major impact on the smooth functioning of a beef processing plant. Below are key considerations and best practices for designing an effective cold storage layout.
Assess Storage Requirements
Before finalizing your design, conduct a thorough assessment of daily and seasonal production volumes. Consider the peak output (e.g., during high-demand periods) and ensure sufficient storage to handle these surges without compromising temperature control or workflow.

Also plan for future growth and potential changes in market demand. Building a flexible design—whether through modular storage units or the ability to integrate additional refrigeration capacity—can save time, money, and downtime when expansions become necessary.
Temperature and Humidity Control
Beef cold storage typically falls between 28°F (-2°C) and 32°F (0°C), balancing the need to keep the meat cold without risking partial freezing. These cooler environments slow microbial growth and preserve freshness.

Proper humidity levels (typically around 85-90% for beef) also help prevent product weight loss from dehydration. Monitoring systems should track humidity continuously and trigger adjustments or alerts when levels move outside the optimal range.
Layout and Zoning
Your cold storage facility should have a clearly defined receiving area for incoming beef products. This zone should allow for quick temperature checks, inspection, and the initial labeling of products before they enter storage.

Avoid cross-contamination by establishing distinct areas for raw carcasses versus packaged or ready-to-ship products. Ideally, each zone will have separate entry and exit points, physical barriers, and dedicated handling equipment.

Additionally, thoughtful traffic flow reduces bottlenecks and preserves product quality. Aisles and pathways should be arranged so employees, forklifts, and pallet jacks can navigate easily without compromising safety or risking damage to stored goods.
Sanitation and Maintenance
All surfaces in cold storage areas—floors, walls, and ceilings—should be constructed from materials that are durable, impermeable, and easy to clean. Central Washington Refrigeration often opts for stainless steel or aluminum racking systems due to their corrosion resistance and ease of sanitization.

Non-slip, waterproof flooring with proper drainage is also critical. Standing water increases the risk of bacterial growth and can create safety hazards. Furthermore, be sure to implement regular cleaning and sanitizing schedules once your cold storage is complete. This includes daily spot cleaning as well as comprehensive, routine deep cleaning to ensure facility hygiene remains up to standard.
Regulatory Compliance
Beef processing facilities in the United States must comply with USDA and FDA guidelines, which set strict parameters for handling, labeling, temperature regulation, and record-keeping.

Proper record-keeping is also vital for food safety audits. We recommend using digital tracking systems to log product temperatures, movements, and storage times. This visibility enhances recall capabilities and demonstrates regulatory compliance.
Energy Efficiency
Investing in high-quality insulation for walls, floors, and ceilings can significantly reduce energy consumption. A reputable manufacturer will ensure all doors, loading docks, and any other openings are well-sealed to prevent temperature fluctuations.

You should also pay attention to the placement and type of refrigeration units based on facility size and production capacity. Energy-efficient compressors, variable-speed fans, and automated defrost cycles can greatly reduce operational costs. LED or other energy-efficient lighting with motion sensors can also help reduce energy usage.
Worker Safety and Training
Prolonged exposure to low temperatures can pose risks to employee health. Provide appropriate protective clothing and regular breaks in designated warmer areas to avoid cold stress.

Train staff on the safe operation of forklifts, pallet jacks, and other heavy equipment in cold environments, where surfaces may be slick. Clear signage and floor markings can also help reduce accidents. Finally, regularly update your team on the latest sanitation procedures, temperature control methods, and regulatory changes.
Cold Storage for Beef Processing Facilities
Designing a cold storage layout for beef processing facilities involves balancing multiple elements: temperature control, workflow efficiency, sanitation, regulatory compliance, and energy management. By carefully assessing storage requirements, you can create a safe, efficient, and cost-effective cold storage environment that preserves the integrity of your beef products. For a free quote on a cold storage facility for your beef processing plant, contact Central Washington Refrigeration today.

We service beyond Central Washington: to Virginia, New York, Michigan and Pennsylvania.