📍 Powering the growth of a Saudi halal food enterprise with a custom cold chain solution
A halal food processing and storage company in Riyadh secured a new government contract requiring an urgent expansion of its frozen storage capacity from 500m² to 900m². The critical constraint was an extremely tight deadline: the expanded facility needed to be fully operational within 45 days to fulfill the contract. Conventional construction methods were impossible within this timeframe. Additionally, the system needed to reliably maintain temperature during Riyadh's summer, with outdoor temperatures regularly exceeding 45°C and reaching 50°C+.
Our Solution
To meet this urgent and technically demanding challenge, we deployed a rapid-deployment, prefabricated cold room solution combined with a ruggedized refrigeration system.
► Rapid Prefabricated Construction
- We utilized 150mm thick, high-density PIR panels (λ≤0.022 W/(m·K)) with cam-lock joints for rapid assembly. The 400m² extension was constructed as two modular blocks in 42 days, including floor preparation, panel erection, and door installation. All panels and components were pre-cut and pre-assembled as much as possible off-site.
► High-Ambient-Temperature Optimized Refrigeration
- The expansion was served by a new, independent refrigeration system. The system was equipped with Bitzer compressors fitted with factory high ambient temperature kits, including oversized condensers, enhanced fan motors, and refrigerant cooling for the compressor motor. The system was engineered and tested for stable operation at up to 55°C outdoor condensing temperature.
► Commissioning
- Design, procurement, panel fabrication, and equipment pre-testing were conducted in parallel. On-site work followed a 24/7 shift pattern where permissible. Commissioning was compressed into a 5-day period focusing on core temperature pull-down and stability tests.
Results
✔ On-Time Delivery The expanded 900m² frozen storage facility was operational and handed over in 42 days, enabling the client to meet the critical deadline and successfully secure and fulfill the government contract.
✔ Reliable Performance in Extreme Climate During the following summer, the new storage area consistently maintained the required -18°C to -20°C product temperature, even when outside temperatures averaged 45°C and peaked above 50°C. The system demonstrated stable operation without shutdowns due to high head pressure.
✔ Future-Ready Design The prefabricated design allows for potential future relocation or further expansion with minimal downtime.
Client
Client Feedback "The speed and reliability your team demonstrated were crucial for our business. Completing a 400m² cold store expansion of this quality in 42 days, especially in our summer heat, seemed impossible. Thank you to the team. You not only delivered on time but gave us a system that works perfectly in our extreme climate. This success has given us the confidence to take on larger projects."
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