Author: Tony Fleming, Managing Director, JS Air Curtains
The benefits of air curtains for cold stores
In cold storage environments, temperature fluctuations can cause a range of problems - from product spoilage and rising energy bills to safety risks from ice forming at entry points. Without effective control measures, maintaining a consistent internal temperature becomes a daily challenge - one that affects both operational efficiency and the bottom line.
Acting as an invisible barrier across open doorways, an air curtain helps keep cold air in and warm air out, even during busy periods.
Every time a cold store door opens, warm air enters and cold air escapes - causing internal temperatures to rise by as much as 10°C. This puts extra strain on refrigeration systems as they work to bring the temperature back down. A well-positioned air curtain can limit that increase to just 1°C, helping reduce heat loss by up to 90%.
By maintaining a more stable internal environment, air curtains ease the load on chillers and condensers. That not only cuts energy consumption but also reduces wear and tear on equipment, lowers maintenance needs, and extends the lifespan of your systems.
In many cold stores, strip curtains or fast-acting shutter doors are used to retain cold air. But they can slow down operations and require regular maintenance. Air curtains offer a cleaner, more efficient solution, allowing for open-door access with uninterrupted visibility.
This is especially useful for forklift operators, who no longer need to stop and activate doors throughout the day. With fewer door openings, maintenance costs drop, and overall workflow becomes faster and more efficient.
Air curtains help eliminate temperature fluctuations - or hot spots - near doorways, which are often a problem in cold stores. This creates a more consistent environment, reducing the risk of spoilage for items stored near entrances.
The result? You can make better use of your storage space, reduce waste, and boost profitability by utilising areas that would otherwise be too warm for sensitive products.
Improve safety and reduce ice
With clear, open doorways, air curtains improve visibility and reduce the risk of collisions - especially in high-traffic areas. They also help minimise condensation and ice build-up on floors by limiting warm air ingress, reducing the risk of costly injuries through slips, trips and falls. That makes for a safer, more comfortable working environment for staff moving goods in and out of the store.
In addition to temperature management, air curtains act as a barrier against airborne contaminants like dust, smoke, and fumes. They also deter pests such as insects, and there is evidence that rodents may be discouraged from entering the space - an important consideration for cold stores handling food, pharmaceuticals, or other sensitive goods.
By reducing energy usage, air curtains help lower carbon emissions while also cutting down on service visits and maintenance of centralised plant. This makes them a practical solution for companies looking to reduce their environmental impact while keeping operations efficient.
When considering air curtains for cold storage, cost-effectiveness is often a key concern. While the exact return on investment (ROI) will vary depending on several factors - including local climate, the number and duration of door openings, electricity costs, and the presence of other energy-saving measures - air curtains have consistently demonstrated strong payback potential.
...energy losses can be reduced by over 65% with a correctly specified and installed air curtain.
Rapid return on investment
Industry guidance, including research from the Institute of Refrigeration and FETA, suggests that in facilities where cold store doors are open for more than 1,000 hours per year, energy losses can be reduced by over 65% with a correctly specified and installed air curtain. In many cases, this results in a full return on investment within two years.
The savings come not only from reduced energy consumption, but also from lower maintenance costs, improved equipment lifespan, and increased operational efficiency. For cold storage operators looking to balance performance, sustainability, and long-term cost savings, air curtains represent a smart and measurable investment.
Air curtains are a simple, effective upgrade for cold stores, helping to save energy, improve safety, reduce product loss, and streamline day-to-day operations. Whether you're running a warehouse distribution centre, food plant, supermarket, or hospital facility, the benefits are clear.
