By: Oscar Infanzon, Design Engineer & Manager,

Amerikooler Cold-storage rooms may look like simple metal boxes, but their performance is governed by what lies between the inner and outer walls. Insulation determines how efficient the refrigeration is, how much energy is consumed, how long it resists moisture and corrosion, and, ultimately, how reliably it protects food or pharmaceuticals. As energy codes tighten and operating margins shrink, cold storage manufacturers are rethinking everything from the materials they use to the systems that shape them. The industry is moving toward three central priorities: higher performing insulation, precision driven automation, and more sustainable manufacturing practices.

Why Traditional Foam Falls Short

For roughly fifteen years the industry standard has been foamed-in-place (FIP) polyurethane. The chemistry delivers a respectable R-value on day one, yet its micro-cell structure is vulnerable to two forms of degradation. First, the blowing agents that create the foam’s closed cells migrate out over time, a phenomenon known as thermal drift. The result is a steady drop in resistance to heat flow. Second, the open edges and microscopic voids readily absorb water. Operators who disassemble aging walk-ins often discover rust bands and soft, spongy spots where moisture accumulated over time, causing the foam to collapse.

Service technicians see the effects in the field: compressors cycle more often, evaporators struggle to defrost, and energy bills inch upward year after year.

Compounding the risk, most FIP panels ship with no meaningful long-term thermal warranty, leaving owners to absorb repair or replacement costs sooner than expected.

How Extruded Polystyrene Keeps its Chill

Extruded polystyrene (XPS) addresses those weak points at the molecular level. Formed as dense, closed cell boards, XPS locks in its blowing agent early in the manufacturing process, so the R-value stabilizes and remains essentially unchanged for decades. Independent lab tests show water absorption of less than one percent by volume, considerably lower than FIP or expanded polystyrene.

The durability translates directly into operating savings. Panels that resist moisture do not lose R-value to trapped water, and surfaces stay structurally sound instead of degrading near the floor line. When owners run lifecycle analyses, insulation that holds its R-value delivers a clear, long-term drop in refrigeration energy use—often a noticeable share of the walk-in’s annual consumption—compared with panels whose performance drifts as they absorb moisture or lose blowing agents.

No Foam, No Voids: How Automation Supports Material Integrity

Even the highest-performing insulation fails to deliver if installed improperly or manufactured inconsistently. Gaps at joints or thresholds compromise thermal performance and cause long-term energy loss. As a result, the move toward XPS has coincided with advances in panel fabrication, ensuring tighter fits and more reliable energy efficiency.

Some manufacturers have moved away from traditional foaming and toward digitally integrated production lines tailored to board-based insulation. In these facilities, CNC routers cut each XPS panel to a unique digital blueprint, ensuring a precise, gap-free fit. Robotic press brakes form the metal skins to exact dimensions, while barcode tracking and in-line scanning verify each step and improve traceability in real time. This level of precision reduces variability, minimizes errors, and helps maintain the performance potential of high-quality insulation.

These advancements aren’t just about thermal performance; they also improve production timelines. Orders that once took six to eight weeks to fulfill can now ship in as little as two, even for custom walk-ins. As a result, manufacturers are able to meet tighter construction schedules without compromising quality or energy efficiency.

Amerikooler, a leader in commercial refrigeration solutions, was one of the first major walk-in manufacturers to fully adopt XPS as a standard, not just as an option, across all of their custom and quick-ship products. What sets them apart, however, is how their highly automated manufacturing process supports the full performance potential of XPS.

The company’s Miami-based facility has evolved significantly over time, replacing older,

manual practices like jigs, tape measures, and handwritten labels with an almost fully

automated panel production line. Automated systems precisely shape each panel’s insulation board and form metal skins to exact specifications, with quality assurance checks integrated at every stage of production. Advanced barcode tracking and in-line scanners capture detailed data points in real time, providing complete visibility into each job’s progress. This end-to-end automation not only guarantees exceptional quality and tracking, but also enables us to efficiently produce custom boxes to order, which eliminates the need for warehousing preset

panel sizes. Rigorously minimizing variability and safeguarding product integrity allows

Amerikooler to deliver systems that provide exceptional benefits far beyond mere speed.

Building for Efficiency and Responsibility

In cold storage design, energy efficiency is a long-term performance metric. When

insulation maintains its integrity over time, walk-ins require less energy to keep temperature stable. Panels that resist moisture and thermal drift help reduce compressor runtime, limit system strain, and support lower utility costs across the equipment’s lifespan.

Energy use is just one part of the sustainability equation. Forward-thinking manufacturers are also reexamining how panels are built and what happens to the materials that don’t make it into the finished product. Some facilities now bale XPS insulation off-cuts for return to the supplier, where they’re reprocessed into new board stock. Metal scraps are diverted to recycling streams rather than waste bins, and digital fabrication techniques are reducing the number of miscuts or reworks on the production floor.

Precision driven systems also help reduce overfill and chemical waste often associated with foamed-in-place insulation. By adopting recyclable board-based insulation and refining manufacturing to eliminate unnecessary material use, producers are helping end users reduce both operational emissions and embodied carbon. For facilities navigating stricter energy codes and ESG reporting requirements, these improvements in material selection and production control can offer meaningful, measurable benefits across the product’s full lifecycle.

Adapting to new regulations, such as state-level restrictions on certain finishes, updated refrigerant standards, and evolving sanitation codes, has also driven manufacturers to select more durable, corrosion-resistant materials like Acrylume and 304 stainless steel for panels and hardware. These choices not only ensure long-term product integrity but also help cold storage systems meet the highest standards for safety, durability, and compliance. Additionally, our internal R&D engineering department works closely with sales and customer service teams to continuously drive improvements in design, quality, and manufacturing processes.

A New Blueprint for Cold Storage

As the cold storage industry evolves to meet today’s demands, insulation can no longer be treated as a static commodity. The transition away from foamed-in-place polyurethane toward more durable, board-based alternatives like XPS marks a meaningful shift in how cold rooms are designed and built. Yet, material choice is only part of the equation. The rise of precision automation and closed-loop manufacturing is ensuring that insulation performs as promised—not just on day one, but for decades to come.

The next frontier is intelligent cold storage: manufacturers are now investing in smart systems for inventory tracking, humidity and temperature control, automated alerts, and remote monitoring. These innovations promise to further enhance reliability, efficiency, and traceability across the cold chain. At Amerikooler, ongoing R&D is focused on integrating these intelligent features into future product lines, reflecting a broader industry commitment to continuous innovation. By refining processes and embracing new technologies, companies like Amerikooler are helping to set new benchmarks for performance, sustainability, and long-term value as the industry moves toward a smarter, more resilient future.

How Automation is Becoming the Industry's Best Defense

By Juerg Frefel, CEO,

As US trade policy takes a more aggressive turn, food and beverage manufacturers are bracing for new cost pressures and supply chain volatility. The recent announcement of additional tariffs on a number of smaller nations including key agricultural exports in Africa and the Caribbean, is the latest disruption in what feels like a long cycle of geopolitical uncertainty and logistical strain. With production costs rising and sourcing reliability in question, food manufacturers are being forced to rethink operations. Today's supply chain must be adaptable, resilient, and safe in addition to the traditional sole focus on efficiency. As a result, many companies are accelerating their investments in automation to help navigate this high stakes moment. Among the most transformative of solutions is the automated storage and retrieval system (AS/RS). 

Trade tensions and tariffs can ripple through supply chains in unpredictable ways causing ingredient shortages, shipping delays, and cost spikes. By implementing an AS/RS, manufacturers gain the control and flexibility needed to respond quickly to changes in inventory availability, supplier reliability, and consumer demand. 

Automation reduces dependency on manual labor and volatile global sourcing schedules, AS/RS platforms help manufacturers stay compliant, maintain product integrity, and respond dynamically to changes without sacrificing safety or sustainability. 

Key Ways the AS/RS Supports Food Manufacturers

1. Minimized Contamination Risk with Labor Gaps

With tighter budgets and workforce uncertainty, especially in import-heavy segments, many manufacturers face labor shortages that can compromise quality and safety. An AS/RS reduces physical touchpoints, helping maintain high hygiene standards even with fewer human handlers, and lowering the risk of pathogen or allergen contamination.

1. Inventory Visibility for Smarter Decision Making

Tariff induced cost changes often require shifts in procurement or batch prioritization. AS/RSs integrated with warehouse management platforms provide real-time tracking, allowing companies to reallocate stock, manage recalls, and rotate inventory based on origin, expiration date, or lot. This kind of agility is critical when product availability or costs shift quickly due to trade policy. 

1. Environmental Control and Waste Reduction

Imported perishables often face longer or unpredictable transit times under new tariff regimes. An AS/RS helps mitigate spoilage risks through tightly regulated temperature and humidity controls. These systems ensure that goods, especially high-risk categories like dairy, produce, and seafood remain within safe parameters while minimizing waste and energy usage. 

1. Compliance and Certification Readiness

The environment is still heavily regulated, where every shipment's origin, storage condition, and traceability must be documented, and automation enables compliance at scale. An AS/RS provides automated logs and environmental records, ensuring seamless  audits and adherence to global food safety standards, even as tariffs and sourcing rules shift. 

1. Precision and Product Segregation

With some ingredients now more expensive due to tariffs, product integrity matters more than ever. An AS/RS enables precise separation of allergen containing items, organic and non-organic SKUs, or temperature-sensitive ingredients. That ensures compliance with labeling regulations and avoids expensive recalls or certification issues. 

A Role for AI in Weathering Uncertainty

AS/RSs incorporate AI and machine learning to further bolster resilience. Predictive analytics tools can assess demand fluctuations tied to trade developments, optimize inventory levels, and prioritize shelf-life sensitive items. AI-driven route planning for AGVs and AMRs also improves warehouse throughput, helping operations stay productive even when margins are squeezed. 

What once may have been considered a "nice-to-have" investment is now a strategic imperative.

As the food and beverage sector faces geopolitical shocks, rising logistics costs, and tougher consumer and regulatory scrutiny, automation is becoming the backbone of operational strategy. Automation helps manufacturers work through today's challenges while also preparing for future unknowns thanks to a reduction in waste, improved traceability, and increased speed and flexibility. In a food supply chain increasingly defined by instability, smarter storage may be the surest path to safety, sustainability, and success.

By: Steve Grant, Product Manager - Pneumatic Conveying at Hapman

In bulk material handling environments, space is often limited, downtime is costly, and operational efficiency is crucial. Traditional mechanical conveyors, while effective, can struggle to meet the evolving demands of modern production lines, especially those requiring easy cleanability, quiet operation, and the flexibility to navigate complex layouts. In response, many industries are turning to vacuum conveying systems for a reliable and low-maintenance alternative.

Vacuum conveyors use suction to move materials through enclosed piping systems, offering a hygienic, low-energy way to transport powders, granules, and other bulk solids. Unlike mechanical systems that rely on belts, screws, or chains, vacuum conveyors eliminate many of the moving parts that contribute to wear, contamination, and maintenance delays. As customer needs grow more complex and regulatory expectations tighten, these systems offer a practical way to maintain performance while reducing risks.

Principles and Advantages

Vacuum conveying works by creating negative pressure within a sealed pipeline. A blower or pump generates this vacuum, drawing material from a pickup point and transporting it through enclosed piping to a receiver. At the receiver, filters separate the conveyed material from the air, allowing for controlled discharge into downstream equipment.

While the core principle has remained consistent over time, today’s vacuum conveyors are significantly more efficient and better suited to complex materials. The enclosed dust-tight design minimizes the risk of material leakage or airborne dust, which is especially important for maintaining product quality and cleanliness in production environments. Because any system leaks are inward, plant and worker safety is enhanced, and the risk of contamination is greatly reduced.

Modern vacuum conveyors incorporate advancements in blower performance, filtration, and system controls, enabling manufacturers to efficiently handle a wider range of materials. These systems can be routed vertically, horizontally, or around obstacles, making them well-suited for facilities with space constraints or complex layouts.

Additional advantages include:

Improved Hygiene and Safety: The enclosed process supports regulatory compliance and reduces exposure to airborne dust and contaminants.

Reduced Maintenance: Fewer moving parts mean less wear and easier cleaning, especially with tool-less access and clean-in-place features.

Energy Efficiency: Optimized air volume and independent blower operation can lower operational costs.

Modular Design: Many vacuum conveyors are modular, simplifying installation and future expansion.

These combined features make vacuum conveying a practical, reliable solution for modern material handling challenges, supporting efficiency, safety, and adaptability.

Addressing Material Handling Challenges

A primary advantage of vacuum conveying is its routing flexibility. These systems can be installed vertically, horizontally, or around corners, providing practical solutions for facilities where space constraints make traditional conveyors unworkable. This adaptability is particularly valuable during plant expansions or retrofits, where seamless integration with existing lines is essential.

Maintenance requirements are another area where vacuum conveyors stand out. With fewer moving parts and easy access to filters and valves, these systems demand less upkeep than mechanical alternatives. Features such as tool-less entry and modular construction further simplify changeovers and cleaning, helping to reduce both downtime and labor demands.

Key Technological Enhancements

Recent developments have increased the appeal and utility of vacuum conveyors. One important advancement is the use of regenerative blower technology. Unlike systems that rely on plant air, regenerative blowers operate independently, helping companies reduce utility costs and avoid tapping into high-demand compressed air resources.

Another advancement is reverse-pulse filter cleaning. This feature sends timed bursts of air through the filters to dislodge accumulated dust, helping maintain performance without frequent manual intervention. It reduces filter maintenance and helps sustain airflow during extended operation.

Additionally, improved inlet and discharge configurations, such as rotary valves and metering devices, have expanded the range of materials these systems can handle. From fragile granules to more aggressive particulates, vacuum conveying is now a viable option for many applications once thought incompatible.

Vacuum Conveying in the Food Processing Industry

In the food processing sector, hygiene and throughput are both top priorities. Vacuum conveyors provide an enclosed, dust-tight system for moving dry materials like flour, sugar, and powders, helping processors comply with food safety regulations while maintaining production efficiency.

By relying on negative pressure within sealed piping, vacuum conveyors prevent exposure to contaminants and reduce airborne dust in the plant. Their routing flexibility allows them to fit into mixing areas, processing lines, and packaging lines with minimal disruption to layout.

Fast cleaning capabilities are another benefit. Tool-less filter access simplifies sanitization between batches, which is crucial for allergen control and organic-certified production. These features reduce changeover time and support compliance with FDA guidelines.

As global food production scales to meet demand, vacuum conveying provides a scalable, clean, and low-maintenance way to move ingredients while protecting product integrity.

Planning for Integration

For first-time adopters, integrating a vacuum conveyor starts with careful planning. While the system’s routing flexibility is a strength, unnecessary bends or height changes can reduce efficiency and increase power requirements. Simple, direct routes are best.

Before selecting a model, material testing is also recommended. Understanding bulk density, flowability, and reactivity can help determine the right inlet design, filter type, and discharge configuration for each unique application.

Manufacturers typically offer a range of vacuum conveyors to meet different operational needs:

Compact models for tight spaces

High-capacity systems for long runs

Safety-rated units for explosive dust applications

Selecting a vacuum conveying partner with deep application expertise and a comprehensive product line is essential for ensuring your system meets both current and future operational demands. Hapman, a leader in custom bulk material handling equipment, offers a full range of vacuum conveyors tailored to address diverse challenges in modern production environments. The Hapman MiniVac model is ideal when maximum routing flexibility is required, allowing materials to be conveyed vertically, horizontally, and around corners-even across multiple levels-with minimal maintenance. The LP Series is specifically designed for installations where space is limited, providing efficient conveyance rates in tight or hard-to-reach areas without sacrificing performance. For environments where combustible dust is a concern, the E-Line model offers enhanced safety features, including pressure-rated filter/receivers that can be used with explosion venting or suppression systems. A full range of options allows companies like Hapman to deliver flexible, safe, and scalable material movement solutions tailored to the unique requirements of each facility.

Choosing the Right Vacuum Conveyor Partner

Selecting the right vacuum conveyor involves more than simply choosing equipment; it requires a system that aligns with operational goals for cleanliness, efficiency, and long-term reliability. The most effective solutions are those developed in close collaboration with customers and in response to evolving regulatory standards. For example, at Hapman, ongoing customer feedback and shifting industry requirements directly inform product development, ensuring that each conveyor addresses the real-world challenges manufacturers face.

When evaluating available options, several best practices should be considered:

Start with the space: Facility constraints should be carefully assessed, and routing designed accordingly.

Understand the material: Testing bulk density, abrasiveness, and flow characteristics helps determine compatible inlet and discharge options.

Prioritize cleanability: For food processing applications, systems offering tool-less access and optional clean-in-place (CIP) features are recommended.

Minimize operational costs: Preference should be given to systems that do not rely on plant air and that offer self-cleaning filter mechanisms.

Plan for growth: Modular systems that can scale alongside production needs provide long-term value.

Whether upgrading an aging conveyor or launching a new production line, vacuum conveying provides a flexible and low-maintenance solution. When paired with an experienced partner, organizations gain not just equipment, but a thoughtfully engineered system designed to support production goals for years to come.

Conclusion

Vacuum conveying systems have become an essential tool for manufacturers seeking efficiency, cleanliness, and flexibility in material handling. As production environments evolve and regulatory standards grow more stringent, the ability to adapt conveying solutions to new requirements is increasingly important. Looking ahead, the industry will see continued emphasis on cleanability and serviceability, with manufacturers like Hapman regularly reviewing and refining system designs to meet customer needs and regulatory expectations.

A Personal Perspective

Charlotte Langley

As someone who has worked closely with Canada’s food industry, I have seen firsthand how much potential we have in processing our own raw materials into finished goods. We are a nation rich in agricultural resources, yet we often fail to capture the full economic value of what we produce. Instead of keeping production local, we export raw materials and import finished products, losing jobs, innovation, and economic security along the way. One of the least engaged and least owned areas of our economy is food processing—an industry that could and should be a cornerstone of Canadian economic strength.

So, how do we make food processing attractive again? The answer is simple: we build systems that care for workers, invest in infrastructure, and create opportunities that make this industry sustainable and desirable. When we prioritize people—through fair wages, paid leaves, healthcare, mental health support, and training programs—we don’t just improve the lives of workers; we strengthen the entire economy.

Investing in the Workforce: The Key to Strengthening Our Economy

For too long, food processing has struggled with high turnover, labor shortages, and a reputation for being a low-wage, high-burnout industry. If we want to change this, we need to invest in the workforce and in the systems that make this industry valuable to both workers and the economy.
1. Paid Leave and Health Care: A healthy workforce is a productive workforce. By ensuring workers have access to healthcare and paid leave, we improve retention, reduce absenteeism, and create more stability in the industry. When employees feel secure in their jobs, they invest more in their work, leading to higher efficiency and better-quality products.
2. Improvement Models and Skill Development: Innovation in food processing doesn’t happen in a vacuum. By providing training, technology upgrades, and pathways for career growth, we empower workers to be part of the industry's evolution. Skilled workers create higher-quality goods, making Canadian products more competitive in both domestic and international markets.
3. Fair Wages and Economic Incentives: Paying workers fairly isn’t just a moral obligation; it’s an economic necessity. Fair wages stimulate local economies, increase consumer spending, and reduce reliance on social support systems. When people earn a living wage, they reinvest in their communities, further strengthening our economic foundation.
4. Mental Health Resources and Workplace Culture: Food processing is a demanding industry. If we want people to stay, we need to create environments that support their well-being. Providing mental health resources, safe working conditions, and a positive workplace culture helps reduce turnover and ensures long-term industry stability.

Langley Foods and the Role of Smaller Co-Packers

At Langley Foods, we recognize that large-scale change happens when businesses work together. That’s why we are actively collaborating with smaller co-packers to find solutions that keep production local, innovative, and economically viable. By supporting smaller processors, we help decentralize food production, making the industry more resilient and better able to respond to market demands.

Covered Bridge Chips: A Model of Perseverance and Value Creation

A shining example of what’s possible in Canadian food processing is Covered Bridge Chips. This family-run business has faced challenges, but through perseverance, worker investment, and community support, they have built a thriving brand that delivers both economic and social value.

Just one year ago, Covered Bridge Chips experienced a devastating loss when a fire destroyed their factory. For many businesses, this could have meant the end, but Covered Bridge proved that resilience and collaboration can keep an industry moving forward. With the help of small co-packers, industry partners, and their dedicated team, they were able to continue production while rebuilding their facility. This extraordinary display of strength and solidarity is a testament to what is possible when the industry supports its own.

Covered Bridge Chips doesn’t just make great snacks—they create jobs, strengthen their local economy, and prove that Canadian processing can be both profitable and sustainable. Their journey is a powerful reminder that investing in people and partnerships leads to long-term success, even in the face of adversity.

Building a Stronger Economy Through Food Processing

By reinvesting in food processing, we don’t just create jobs—we create higher-value goods that boost our economy. When we process our own raw materials, we increase the worth of our agricultural sector, keep profits within our borders, and strengthen our economic resilience. Canadian-made food products should be known for their quality, innovation, and ethical production standards. If we put in the work now—through fair labor practices, workforce investment, and industry support—food processing can become one of Canada’s greatest economic strengths.

It’s time to change the narrative. It’s time to make food processing an industry that people want to work in, that communities benefit from, and that our economy depends on. The path forward is clear: invest in people, invest in infrastructure, and keep production local. Canada has everything it needs to be a leader in food processing—it’s time we take ownership of it.