Building your Own Walk-in Cooler

[jvandenbrink]

Hey all -
So I did a quick search to see if I could find anything on this already and wasn't able to find anything...so here is my question..

Who out there has built their own walk-in cooler? How big is it? What did you use to cool? And how did you do it? Are you using the 'air-conditioner' method or a commercial cooling system?

I'm trying to figure out if it is worthwhile, or if it will be more pain in the long run with moisture problems and such.

Thanks all
Joel

[beerbros]

We built our for our brewpub and it's roughly 7x14x20. We had a local refridge guy do the r-value math and tell us what size unit to put in it. We found 2 large used walkin doors and framed them in. We did a layer of plastic for vapor lock and finished it with cement wall panels and then marine grade plastic paint. We ended up using foam for insulation. Works like a charm.

Duffy

[South County]

I'm pretty sure there is a thread on here that covers this topic. Like Duffy we are building our own. Were are framing it out using a vapor proof interior w/ plastic vapor barrier and then either spray foaming or using foam board (cost will determine). I would recommend a minimum R-21 for the walls and check your local commercial HVAC company for prices on used and new equipment. Also you have to decide what your desired temp is. There are two system types so to speak, one that handles to 35 degrees (ref) and one that goes below 35 degrees (freeze). I hope someone can chime in on which temp range is good, bad , or indifferent.

[nohandslance]

What size are you looking to build? Are you a Production brewery or brewpub?
I purchased a used Refrigerated Container. And it performed great. 10X40'.

[SRB]

Hey duffy that sounds like a well designed high performance cooler. Nice. I look forward to heading up to the pan handle to check it out, but maybe your beer first ;)
South County feel free to bounce some prices your getting for spray foam. Sounds like your on the right track. Our cooler is designed for 32 F +.
There are some great pointers on this thread. (http://www.probrewer.com/vbulletin/showthread.php?t=11477&highlight=walk+cooler)
Our custom cooler is nearly complete. Grundy's patiently waiting bunched inside our 14x16x8 foot print. 2x6 fir walls and 2x12 BCI rafters. 6 inches open cell spray foam in walls (approx. R-21 and primo moisture and air movement performance). And 1" (R-7) Dow polystyrene foam board screwed into walls and ceiling to break thermal bridging ..Total R-27 in walls and R-40 in the ceiling. Spray foam is at cost for us so remember at 1 " your at 80% performance...6" of foam you are at approx 96% and at 8" your at 98%.
99% at 12 inches...ie diminishing returns on depths. I get the stuff at cost so we sprayed a little heavy. 8" recommended, 6" min. With blueboard screwed into the studs you could actually get away with less foam in between the bays. 700 sqft of blue board cost $450 or so. Aint cheap.
I also plan to staple/caulk 6 mil plastic to the outside walls of the cooler for vapor drive control. The ceiling roof outside has raft like rubber welded together compliments of Mike the roofer and new friend. Gotta love local roofer putting in time for future beer and loads of scrap roof supplies given to "help the cause" :D The engineers at Icynene (spray foam manufacturer) recommended vapor barrier on the out side based on our average climate. Primary vapor drive in not out. But in the other thread I think Canyon is right that spray foams moisture performance makes vapor barrier in a cooler unnecessary. Save a $100 and time. But Im not an engineer. Freezer different story I think.
We poured four inches of fiber reinforced concrete on top of rebar on top of 2 inches Dow polystyrene foam. (R-14)
Trench drain (state plumbing inspector, health inspector approved)
(thx beertje46)
We went with 7/16ths plywood (thx Glacier) coated with oil based primer and 1 coat 2 part epoxy paint. (Death rolling it on!...but shiny and bomber after 7 day cure) **Frankly speaking here this paint coupled with the acrylic/silicone caulking I applied is essentially a vapor barrier on the inside of the cooler. OMG call the vapor drive police Im going mad!**
We just off loaded our evaporator and compressor. We spent extra on brand new for this equipment. We have a mechanical expert we have hired that sized our equipment. We commence on custom cooler door this week. 2x6 fir, spray foam etc. Big hinges and 4 ft wide.... (thx Glacier) and one ATTB lock! Custom shelves for our hops hanging from chains are being welded by my partner this week as well. Soon we vac seal our whole hops.(we bought a commercial vac sealer) Thats going to be fun.
Hope this helps...have fun!

[HumanFish]

What size are you looking to build? Are you a Production brewery or brewpub?
I purchased a used Refrigerated Container. And it performed great. 10X40'.

great idea. I am also looking to do this in an effective but cheap way. I have a vacant block of land next door and now have a plan to get hold of an old refrigerated container, and a normal container also just as a store and away we go.

thanks !


M

[brewsoda]

I have a bunch of walk in panels and a door that I am looking to sell. The panels do NOT all match up, but they would be good material to work with if you are building your own cooler. This is all located in central vermont. I need to sell this stuff in the next month.... send me a PM if anyone is interested. I don't have any refrigeration to go with it (we used the air conditioner method).

[v2comp]

I have a bunch of walk in panels and a door that I am looking to sell. The panels do NOT all match up, but they would be good material to work with if you are building your own cooler. This is all located in central vermont. I need to sell this stuff in the next month.... send me a PM if anyone is interested. I don't have any refrigeration to go with it (we used the air conditioner method).

how many is lot? i need enough to build an 8 x 10 cooler with a door....