Project Summary
A Dunnellon Funeral Home needed a larger walk-in cooler to better support its operations, but expanding the refrigerated space created a new challenge: the existing refrigeration system was no longer large enough to cool the new space. Rather than recommend an expensive full system replacement, we engineered a staged two-system refrigeration design that reused equipment the customer had installed just a year earlier while adding only the capacity needed for the larger cooler.
The result was a cost-effective refrigeration solution that delivered reliable 37° operation, protected the customer’s recent investment, and provided built-in redundancy to help safeguard temperature-sensitive operations.
Project Snapshot
Location
Dunnellon, Florida
Industry
Funeral Home
Service
Commercial Walk-In Cooler Expansion & Refrigeration System Upgrade
Equipment
Existing Refrigeration System (Reused) + New Russell Condensing Unit & Evaporator Coil with KE2 Electronic Controller
Timeline
3 Days
Project Overview
The customer needed to replace an undersized walk-in cooler with a new 12′ × 20′ box that could better support daily operations. While the larger cooler provided the additional storage space they needed, it also significantly increased the refrigeration load.
Ordinarily, a project like this would require replacing the entire refrigeration system with a larger unit. However, we had installed the customer’s existing refrigeration system only about a year earlier. Recommending a complete replacement would have meant discarding equipment that still had years of dependable service remaining.
Instead, we engineered a smarter solution.
By designing a staged two-system refrigeration system, we were able to reuse the existing condensing unit and evaporator as the primary cooling stage while installing a second refrigeration system to provide the additional capacity required for the larger walk-in cooler. The result was a properly sized refrigeration system that maximized the customer’s previous investment while providing dependable cooling performance and built-in equipment redundancy.
Work Performed
To complete the project, our commercial refrigeration technicians:
- Carefully removed and preserved the existing refrigeration equipment before dismantling the original walk-in cooler.
- Installed the new customer-supplied 12′ × 20′ walk-in cooler in the existing location.
- Reinstalled the original condensing unit and evaporator coil as the first-stage refrigeration system.
- Installed a new Russell outdoor condensing unit and matching evaporator coil to provide the additional refrigeration capacity required by the larger box.
- Configured both refrigeration systems to operate as staged first- and second-stage cooling, maintaining precise box temperatures while sharing the refrigeration load.
- Installed a new KE2 electronic thermostat with programmable off-cycle defrost for the new refrigeration system.
- Ran new refrigerant piping for the new equipment while reusing existing refrigerant lines where appropriate.
- Installed new PVC condensate drain piping with unions for simplified maintenance on both evaporator coils.
- Added a new pump-down solenoid, thermostatic expansion valve, and pressure controls.
- Pressure-tested both refrigeration systems with nitrogen, evacuated the new system, charged it with fresh refrigerant, and recharged the existing system using recovered refrigerant as needed.
- Completed startup, leak testing, commissioning, and final temperature verification.
Results Delivered
The completed walk-in cooler provides the additional refrigerated storage space the customer needed without requiring the unnecessary expense of replacing equipment that was still in excellent condition.
The staged refrigeration design allows both systems to work together efficiently, delivering the total cooling capacity required to maintain a consistent 37°F operating temperature. Instead of paying for an oversized single refrigeration system, the customer retained their existing investment while adding only the capacity necessary for the expanded cooler.
Equally important, the two-system configuration provides an added level of reliability. If one refrigeration system ever experiences a problem, the second system continues cooling the box, slowing temperature rise until repairs can be completed. For a business where dependable refrigeration is essential, this redundancy offers valuable protection against unexpected equipment failures.
The finished project demonstrates how thoughtful engineering can reduce costs, improve reliability, and deliver a refrigeration system designed around the customer’s operational needs—not simply the easiest equipment replacement.
Project Photo Gallery
Need a Commercial Walk-In Cooler or Refrigeration System Upgrade?
Expanding your walk-in cooler doesn’t always mean replacing everything you’ve already invested in. United Refrigeration Heating & Air designs practical commercial refrigeration solutions that maximize existing equipment whenever possible while delivering the cooling capacity your business requires.
Whether you’re replacing an aging walk-in cooler, expanding refrigerated storage, or upgrading your commercial refrigeration system, our experienced technicians can engineer a solution that improves reliability, protects your investment, and keeps your operation running efficiently.
Contact United Refrigeration Heating & Air today to schedule a consultation for your commercial refrigeration project.