Coldstorage Facilities Can Lower Energy Costs by Choosing the Right Door

Industrial facilities today have more door options than ever before. From fabric high-speed doors and steel doors to PVC strip curtains, folding doors, and air barriers, the market is crowded with solutions claiming to improve efficiency.

But with such a wide range of options available – and a growing number of imported products entering the market – choosing the right door for the right application has become increasingly complex.

For facility managers responsible for energy efficiency, safety, and operational productivity, the door you choose can significantly impact long-term operating costs.

With more than 25 years of experience working with many of New Zealand’s largest industrial operators, our team has seen first-hand what works – and what doesn’t – when selecting facility doors.

Below are three key factors every facility manager should consider.

 

1. Seals and Insulation: Critical for Cold Storage Efficiency

One of the most important performance indicators for a cold storage door is how well it seals and insulates the opening.

The better the door’s seal integrity and insulation value, the greater the long-term savings on energy costs.

Why this matters

When a door does not seal properly:

• Cold air escapes
• Warm air enters
• Moisture condenses and freezes
• Ice builds up around the door frame

Ice build-up is often the first sign of energy loss and poor door performance.

The hidden cost of poorly insulated doors

Some facilities install single-layer PVC high-speed roll-up doors in freezer environments. While they may operate quickly, they typically have little to no insulation value (R-value).

To prevent ice forming on these doors, facilities often rely on heat lamps consuming 15-30 kW of power. This creates two additional costs:

• The energy used by the heaters
• The refrigeration load required to remove the heat generated

Over time, these inefficiencies can dramatically increase the total cost of ownership.

The right insulated freezer door can significantly reduce these ongoing energy demands.

 

2. Operating Speed: Faster Doors Reduce Energy Loss

In cold storage environments, the biggest cost occurs when the door is open.

Every-second a door remains open allows warm air to enter the space, forcing refrigeration systems to work harder.

Why high-speed doors matter

Faster doors help facilities:

• Reduce temperature loss
• Maintain cold chain integrity
• Lower refrigeration energy usage
• Improve forklift traffic flow

High-speed doors also reduce the risk of collision. When doors open and close quickly, forklifts are less likely to impact them while passing through.

For busy logistics operations, this can translate directly into energy savings and improved productivity.

 

3. Durability and Impact Resistance

In high-traffic warehouse environments, door impacts are almost inevitable.

Forklifts, pallet jacks, and transport equipment frequently operate around door openings. If a door cannot handle impact, downtime and repair costs quickly follow.

Why impactable doors are valuable

Impactable door designs allow the curtain or panels to disengage safely during a collision and automatically reset or re-feed into the guides.

This means:

• Less downtime
• Lower repair costs
• Reduced disruption to loading operations

For example, doors with auto-re-feed technology can realign themselves after impact, allowing operations to continue with minimal interruption.

The productivity cost of door failure

If a loading dock door is damaged and cannot be used:

• Trucks cannot load or unload
• Staff remain idle
• Warehouse throughput slows
• Revenue is lost

Choosing a durable, impactable door system helps protect both productivity and operating costs.

 

 

Questions Facility Managers Should Ask Before Choosing a Door

Before selecting a door system, it’s worth reviewing your current setup.

Consider:

• How frequently is each door used?
• What type of traffic passes through the opening?
• How often do doors get damaged?
• Are there issues with ice, condensation, or energy loss?
• What operational improvements are you trying to achieve?

Answering these questions helps identify the right door for each application, rather than using the same door type across every opening.

 

Partner With Experts Who Understand Industrial Door Performance

Selecting the right door system isn’t just about the purchase price – it’s about lifecycle performance, operational efficiency, and reliability.

At Ulti Group, we work closely with facility managers, engineers, and operations teams across New Zealand to help identify the best door solutions for each environment, whether that’s:

• Cold storage facilities
• Logistics and distribution centres
• Food production sites
• Retail warehouses

Our team can assess your facility and recommend door systems designed to improve efficiency, reduce energy loss, and keep operations moving safely.