Turning Cold Storage Challenges into Long-Term Performance Gains
Challenge
A leading private-label cheese manufacturer operates 22 manufacturing facilities and distribution centers across more than 3.1 million square feet of refrigerated space. This scale created a need to address moisture-related challenges without disrupting production.
To improve overall facility performance, the organization needed to address moisture-related challenges. Left unresolved, ongoing humidity and condensation issues could increase refrigeration energy demand, create maintenance burdens, and elevate food safety risks.
Working alongside the manufacturer’s facilities team, Mantis uncovered the root causes behind the problem. What initially appeared to be an insulation issue was revealed to be a more complex mix of air infiltration, HVAC negative pressurization, and thermal transmission through the building envelope. This diagnosis set the stage for a targeted solution.
Solution
To create a sustainable, long-term solution, Mantis implemented a clear three-step strategy. The approach moved from assessment and diagnosis to roadmap development, then execution and validation. It was designed to support long-term performance gains.
- Assess and diagnose facility conditions by establishing performance baselines and identifying root causes.
- Develop a roadmap with prioritized corrective measures, budgets, ROI analyses, and implementation plans.
- Execute and validate improvements through engineering design, procurement, project management, commissioning, and ongoing performance tracking.
This structured approach helped the manufacturer address humidity challenges at their source while improving energy efficiency, supporting food safety objectives, and strengthening the client’s long-term facility performance. Together, these efforts began to show measurable operational gains.
Results
By addressing the underlying drivers of humidity and refrigeration inefficiency, the manufacturer avoided recurring costs, operational disruptions, and compliance concerns associated with ongoing moisture-related issues. This produced a more resilient cold storage environment that supports energy efficiency, predictive facility maintenance, food safety performance, and long-term operational reliability.
Performance Outcomes
- 20+ years of engineered design life achieved.
- 20% reduction in refrigeration energy load.
- 6+ years with no reported food safety violations.
- Reduced maintenance and roof leak response activities.