Docket No. EERE‐2008‐BT‐TP‐0014

RIN: 1904‐AB85

To Whom It May Concern:  

DOE is referencing the attached material in support of its assertion that most manufacturers use

the same panel thickness, materials, and construction methods for many of their panels.   The attached

documents are copies of brochures and text from a variety of walk‐in manufacturers’ websites

supporting DOE’s claim.  These documents show that each manufacturer advertised only one or two

types of insulation for their panels. For instance, all of Thermo‐Kool’s, Kysor’s, and Kolpak’s panels were

constructed with polyurethane insulation, and US Cooler constructed panels with polyurethane or

extruded polystyrene insulation. Also, the manufacturers only advertised panels in one size thickness or

offered a limited number of size options. US Cooler and Kolpak only advertised panels with four inches

of insulation, ThermolKool offered two different insulation thicknesses, and Kysor presented three

different insulation thicknesses on its website. Each manufacturer offered modular panels in a standard

set of sizes which would be interlocked together to construct the walk‐in envelope.  The manufacturers

also offered a limited number of framing options to construct their panels. For instance, Kysor used

either wood or high density polyurethane to frame its panels.  DOE believes these manufacturers are

representative of most walk‐in cooler and freezer panel manufacturers and therefore, these documents

support DOE’s assertion that most manufacturers use the same panel thickness, materials, and

construction methods for many of their panels.
' I , . -

-

WALK-IN COOLERS AND FREEZERS
--

---

OPTIONS:

Rain roof, shelving, glass doors, lighting, strip curtains,

viewing windows, alarms and more can be purchased

through our sales department.

CONSTRUCTION:

Modular panels are connected with cam lock

connectors. All walls, ceilings and floor panels

use no wood unless otherwise noted. All walk-ins

are EISA compliant.

INSULATION:

4" extruded polystyrene coolers and freezers

SKIN:

26 go. galvanized, galvalume, painted or 24 go.

stainless steel

FLOORS:

22 go. stainless steel

DOORS:

Self closing, flush mount with magnetic gasket;

chrome latches and hinges; safety release

handle. Automatic self closer, vapor proof light

and thermometer.

REFRIGERATION:

All sizes, remote, side mount, top mount, indoor,

outdoor

WARRANTY:

10 year panels, 1 year parts.

Specifications subiect to change without notice. Item drown may

not be exactly as shipped.

';\ ..' '. '. \ m: ',- ~.. ~: ,. I ~llb'f"""'" '... ' .. .' .. ~'7'I' ... --""-- :. '1 '.' ".' ", <'-~ " '; I • \. "-':. :. \

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401 Delaware, Quincy, Illinois 62301

800.521.2665 Fax 217.228.2424

www.uscooler.com

A OIVISION OF
EXTRUDED POLYSTYRENE 

SPECIFICATIONS

GENERAL 

Walk-ins shall be constructed of prefab, 

precision-formed, modular panels designed 

for accurate, rapid field assembly. 

Walk-ins shall be test assembled at the 

factory. 

DRAWINGS AND INSTRUCTIONS 

Each walk-in shall have a set of installation 

instructions and lay-out drawing. All panels 

shall have panel identification corresponding 

with the lay-out drawing to facilitate rapid and 

accurate field erection. 

PANEL CONSTRUCTION

Each panel shall consist of inner and outer 

metal skins, a 4" insulation core, and be 

equipped with cam-action locking devices. 

The locking devices shall be operable from 

inside the walk-in and a hex-shaped wrench 

shall be supplied. Press-fit plug buttons shall 

be provided to seal wrench holes after 

assembly is complete. Construction shall be 

as approved by the National Sanitation 

Foundation International and shall bear the 

NSF® Seal of Approval. 

All panels shall be connected to one another 

by placing the tongue of the insulation core of 

one panel into the groove of the core 

insulation of the adjacent panel. The 

resultant tongue and groove joint shall be 

sealed at both sides by double barreled 

NSF® approved gaskets. In order to avoid 

future swelling and mold formation, no wood 

shall be permitted in the manufacture of the 

tongue and groove panel profile. 

PARTITIONS 

When specified, walk-ins shall be divided into 

compartments by the use of panels that are 

constructed in accordance with the 

specifications for all panels. 

FLOOR SCREEDS

Floor screeds shall be provided for all 

floorless walk-ins. The screeds shall be 

vinyl, and have NSF® approved cove both 

inside and out. 

PANEL FINISH 

Metal finish of the panels shall be as follows. 

(Specify finish desired, combinations may be 

used) 

Interior or exterior walls, ceilings, and exterior 

floors 

• 26 gauge stucco embossed galvalume 

• 26 gauge bright stucco embossed 

 galvanized steel 

• 26 gauge white stucco embossed 

 galvanized steel 

• 26 gauge tan stucco embossed 

 galvanized steel 

• 24 gauge smooth stainless steel 

• 24 gauge smooth white galvanized steel 

Interior floors (When specified) 

• 22 gauge smooth stainless steel 

• 20 gauge smooth galvanized steel (used 

for use with quarry tile application) 

INSULATION

Panel insulation shall be Extruded 

Polystyrene, manufactured in an HFC and 

CFC free process, made from 60% recycled 

materials and 100% recyclable. 

Door insulation may be Polyurethane. 

3/21/11 

401 Delaware, Quincy, Il62301

800.521.2665 217.228.2421 Fax: 217.228.2424 www.uscooler.com

A Division of Craig Industries, Inc.
Coolers

Extruded Polystyrene: All wall and ceiling 

insulation shall be 4” thick, high quality, rigid 

extruded polystyrene, 1.6 lb density. K factor 

of not more than .139 and an R-factor of not 

less than 7.2 per inch, initial fresh R-28.8 

minimum total wall R factor. Vapor 

transmission shall be less than 1 perm and 

foam core material must meet: 

Owens Corning - UL Foam Core 5 flame 

spread rating with average smoke rating less 

than 175. (UL 723) 

Dow – UL Foam Core 15 flame spread rating 

with average smoke rating less than 165. (UL 

723) 

Freezers 

All wall and ceiling insulation shall be 

4" thick, high quality, rigid Extruded 

Polystyrene, 1.6 lb. density. K factor of not 

more than .125 and an R factor of no less 

than 8 per inch, initial fresh R-32 minimum 

total walls R factor. Vapor transmission shall 

be less than 1 perm and foam core material 

must meet UL 5 flame spread rating with 

average smoke rating less 

than 165. (UL 723) 

 

PASSAGE DOORS 

(Standard door is 34"x76"; alternate sizes are 

available upon request). 

Cooler Doors

Door shall be flush mounted, positioned and 

hinged per drawings. Doors shall be 

provided with suitable sweep and magnetic 

gaskets. Door shall be provided with door 

closer, one pre-wired vapor proof light fixture, 

light switch with pilot light, dial thermometer, 

manual internal lock override, chrome plated 

can lift hinges, and chrome plated door 

latches with strike. Doors on outdoor walkins shall have weather protected light switch 

and door drip cap. 

Freezer Doors

Freezer doors shall be identical to coolers 

doors, but with the addition of UL approved 

heater wire on all four sides. Freezer doors 

shall include a heated pressure relief port in 

the adjacent panel. 

Door Options

Customer shall specify requirements for 3 

hinges, view windows, locking bars, internal 

ramps, external ramps, and diamond tread 

plate. 

Optional Doors 

Optional sliding and overhead doors are 

available; customer to specify. 

GLASS DOORS 

(When specified)

Glass door openings shall be provided as 

necessary for the doors being installed. Sill 

height shall be per customer specification. 

Wood framing of the opening shall be 

required to assist with the installation of the 

glass doors. 

RAIN ROOF PACKAGE 

(When specified)

(For use on walk-ins installed outside) 

(Specify whether walk-in is free standing or 

which wall is butted) 

A single-ply membrane roof shall be supplied 

to provide a water resistant covering of the 

ceiling panels. Membrane material shall be 

provided in one complete roll designed for 

the size of the walk-in. No welding of seams 

shall be required for installation. 

SLOPED ROOF PACKAGE 

(When specified) 

(For use on walk-ins installed outside) (May 

be required at certain snow loads; consult 

U.S. Cooler) 

In order to form a sloped roof profile, suitable 

quantities of sloped foam shall be provided. 

The foam shall be cut in a manner that upon 

installation, a 1⁄4":1' slope is obtained. The 

membrane roof shall be increased in size 

appropriately, in order to provide the 

additional material required to properly cover 

the resultant profile. 

401 Delaware, Quincy, Il62301

800.521.2665 217.228.2421 Fax: 217.228.2424 www.uscooler.com

A Division of Craig Industries, Inc.
FOAMED-IN-PLACE POLYURETHANE 

SPECIFICATIONS

GENERAL 

Walk-ins shall be constructed of prefab, 

precision-formed, modular panels designed 

for accurate, rapid field assembly. 

Walk-ins shall be test assembled at the 

factory. 

DRAWINGS AND INSTRUCTIONS 

Each walk-in shall have a set of installation 

instructions and lay-out drawing. All panels 

shall have panel identification corresponding 

with the lay-out drawing to facilitate rapid and 

accurate field erection. 

PANEL CONSTRUCTION

Each panel shall consist of inner and outer 

metal skins, a 4" insulation core, and be 

equipped with cam-action locking devices. 

The locking devices shall be operable from 

inside the walk-in and a hex-shaped wrench 

shall be supplied. Press-fit plug buttons shall 

be provided to seal wrench holes after 

assembly is complete. Construction shall be 

as approved by the National Sanitation 

Foundation International and shall bear the 

NSF® Seal of Approval. 

All panels shall be connected to one another 

by placing the tongue of the insulation core of 

one panel into the groove of the core 

insulation of the adjacent panel. The 

resultant tongue and groove joint shall be 

sealed at both sides by double barreled 

NSF® approved gaskets. In order to avoid 

future swelling and mold formation, no wood 

shall be permitted in the manufacture of the 

tongue and groove panel profile. 

PARTITIONS 

When specified, walk-ins shall be divided into 

compartments by the use of panels that are 

constructed in accordance with the 

specifications for all panels. 

FLOOR SCREEDS

Floor screeds shall be provided for all 

floorless walk-ins. The screeds shall be 

vinyl, and have NSF® approved cove both 

inside and out. 

PANEL FINISH 

Metal finish of the panels shall be as follows. 

(Specify finish desired, combinations may be 

used) 

Interior or exterior walls, ceilings, and exterior 

floors 

• 26 gauge stucco embossed galvalume 

• 26 gauge bright stucco embossed 

 galvanized steel 

• 26 gauge white stucco embossed 

 galvanized steel 

• 26 gauge tan stucco embossed 

galvanized steel 

• 24 gauge smooth white galvanized steel 

• 24 gauge smooth stainless steel 

Interior floors (When specified) 

• .100 Aluminum 

INSULATION

Panel insulation shall be foamed in-place 

polyurethane, manufactured with a HFC and 

CFC free process. 

 3/21/11 

401 Delaware, Quincy, Il62301

800.521.2665 217.228.2421 Fax: 217.228.2424 www.uscooler.com

A Division of Craig Industries, Inc.
Coolers

Foamed in-place polyurethane: All wall and 

ceiling insulation shall be 4” thick, high 

quality, foamed in-place polyurethane, 2.2 lb 

density. K factor of not less than .141 and an 

R-factor of not less than 7.1 per inch, initial 

fresh R-28.4 minimum total wall R factor. 

Vapor transmission shall be less than 1 perm 

and foam core material must meet: UL Foam 

Core 25 flame spread rating with average 

smoke rating less than 450. (ASTM E-84) 

Freezers 

All wall and ceiling insulation shall be 

4" thick, high quality foamed in- place 

polyurethane, 2.2 lb. density. K factor of not 

more than .125 and an R factor of no less 

than 8 per inch, initial fresh R-32 minimum 

total walls R factor. Vapor transmission shall 

be less than 1 perm and foam core material 

must meet: UL Foam Core 25 flame spread 

rating with average smoke rating less than 

450. (ASTM E-84) 

 

PASSAGE DOORS 

(Standard door is 34"x76"; alternate sizes are 

available upon request). 

Cooler Doors

Door shall be flush mounted, positioned and 

hinged per drawings. Doors shall be 

provided with suitable sweep and magnetic 

gaskets. Door shall be provided with door 

closer, one pre-wired vapor proof light fixture, 

light switch with pilot light, dial thermometer, 

manual internal lock override, chrome plated 

can lift hinges, and chrome plated door 

latches with strike. Doors on outdoor walkins shall have weather protected light switch 

and door drip cap. 

Freezer Doors

Freezer doors shall be identical to coolers 

doors, but with the addition of UL approved 

heater wire on all four sides. Freezer doors 

shall include a heated pressure relief port in 

the adjacent panel. 

Door Options

Customer shall specify requirements for 3 

hinges, view windows, locking bars, internal 

ramps, external ramps, and diamond tread 

plate. 

Optional Doors 

Optional sliding and overhead doors are 

available; customer to specify. 

GLASS DOORS 

(When specified)

Glass door openings shall be provided as 

necessary for the doors being installed. Sill 

height shall be per customer specification. 

Wood framing of the opening shall be 

required to assist with the installation of the 

glass doors. 

RAIN ROOF PACKAGE 

(When specified)

(For use on walk-ins installed outside) 

(Specify whether walk-in is free standing or 

which wall is butted) 

A single-ply membrane roof shall be supplied 

to provide a water resistant covering of the 

ceiling panels. Membrane material shall be 

provided in one complete roll designed for 

the size of the walk-in. No welding of seams 

shall be required for installation. 

SLOPED ROOF PACKAGE 

(When specified) 

(For use on walk-ins installed outside) (May 

be required at certain snow loads; consult 

U.S. Cooler) 

In order to form a sloped roof profile, suitable 

quantities of sloped foam shall be provided. 

The foam shall be cut in a manner that upon 

installation, a 1⁄4":1' slope is obtained. The 

membrane roof shall be increased in size 

appropriately, in order to provide the 

additional material required to properly cover 

the resultant profile. 

401 Delaware, Quincy, Il62301

800.521.2665 217.228.2421 Fax: 217.228.2424 www.uscooler.com

A Division of Craig Industries, Inc.
Walk-in

Coolers & 

Freezers
STRUCTURAL-FRAME PANEL

Kysor Panel Systems - Structural-Frame Panels are made to last in the tough commercial

environment. Strong and durable. Structural-Frame Panels will give you years of quality service.

FEATURES

Available in 3-1/2”, 4” and 5”

panel thicknesses

Poured-in-place urethane

insulation, CFC Free.

Cam-Lock wall-to-wall and

ceiling-to-ceiling joints for

ease of installation.

Sturdy wood perimeter or

high-density rail.

Heavy-duty bulb-type

compression gaskets on

panel edges.

Flexible designs from simple

rectangles to complex-angle

configurations.

A variety of metal types and

colors are available.

Panel lengths of up to 26’, in

door clear ceiling spans of

up to 20’.

z

z

z

z

z

z

z

z

Kysor Panel Systems uses only the

highest quality hardware and components.

APPLICATIONS

General Storage Meat Preparation Dairy
STRUCTURAL-FRAME PANEL

Kysor Panel Systems - Engineered to work and keep working in heavy traffic and high-abuse

environments. No other swing door has the strength, quality, durability, or component quality

of a Kysor Panel Systems Door.

APPLICATIONS

Floral Merchandising Deli

1

2

3

4

Recessed inside safety release

Heated sweep gasket - Eliminates the need for

under-threshold heater wire

Double-lined PVC magnetic core door gasket

Full-door jamb guards with thermal break

1

2

3

4

FEATURES

(

- I

.' I'
Due to continuous improvement programs, specifications are subject to change without notice.

Insulframe (800) 633-3426 Section 2 Page 1 

10/08

WALL PANELS

MAXIMUM AVAILABLE SINGLE PANEL HEIGHT= 26'-0"

PANELS WALLS

INSIDE OUTSIDE

 Design based on deflection criteria: 

LIVE LOADS - PSF

FINISH

THICKNESS

WEIGHT 

DEAD LOAD 

PSF

R VALUE

5

70 MPH 

13

80 MPH 

17

90 

MPH 

21

100 MPH 

26

110 MPH 

31

ALUM 3 1⁄2’

4”

5”

1.99

2.63

3.34

28

32

40

18’ 10”

20’ 6”

26’ 0”*

14’ 4”

15’ 0”

20’ 0”

13’ 0”

13’ 9”

18’ 4”

12’ 3”

12’ 9”

17’ 4”

11’ 6”

11’ 11”

16’ 0”

10’ 9”

11’ 3”

15’ 0”

GALV 3 1⁄2’

4”

5”

2.90

3.36

4.25

28

32

40

21’ 0”

22’ 0”

26’ 0”

15’ 4”

16’ 0”

21’ 9”

14’ 0”

14’ 8”

19’ 10”

13’ 2”

13’ 10”

18’ 6”

12’ 4”

12’ 10”

17’ 3”

11’ 7”

12’ 1”

16’ 2”

Panel Systems·

HIGH DE

URET

COR

PANEl

PA LJOINT

112

STAND~RD PANELS

P L SIZ I LV. YOM T

SPECIFICATION CRITERIA

JOI GASKET

GROOVE

CAM·LOCK

FASTE ER

f/180
Due to continuous improvement programs, specifications are subject to change without notice.

Insulframe (800) 633-3426 Section 2 Page 2 

10/08

TOP PANELS

MAXIMUM AVAILABLE SINGLE PANEL LENGTH = 26' 0" 

PANELS TOPS

INSIDE OUTSIDE

Includes 2 PSF for Membrane or Standing Seam Roof, add 10 PSF for 

ballasted. Design based on deflection criteria:

LIVE LOADS – PSF

FINISH

THICKNESS

WEIGHT 

DEAD LOAD 

PSF

R VALUE

10 20 30 40 50 60 70 80 90 100

ALUM 3 1⁄2’

4”

5”

1.99

2.63

3.34

28

32

40

14’ 1”

14’ 11”

20’ 0”

10’ 0”

11’ 4”

15’ 0”

9’ 8”

10’ 0”

13’ 7”

8’ 0”

9’ 2”

12’ 0”

8’ 5”

8’ 7”

11’ 6”

7’ 9”

7’ 8”

1 ’ 4”

7’ 9”

8’ 1”

10’ 0”

7’ 5”

7’ 9”

10’ 5”

7’ 1”

7’ 6”

9’ 11”

6’ 10”

7’ 2”

9’ 8”

GALV 3 1⁄2’

4”

5”

2.90

3.36

4.25

28

32

40

15’ 6”

16’ 1”

21’ 0”

11’ 8”

12’ 2”

16’ 3”

10’ 4”

10’ 0”

14’ 7”

9‘ 6”

9’ 11”

13’ 0”

8’ 10”

9’ 3”

12’ 5”

8’ 9”

9’ 1”

12’ 3”

8’ 4”

8’ 8”

11’ 8”

8’ 0”

8’ 4”

11’ 2”

7’ 8”

8’ 0”

10’ 9”

7’ 5”

7’ 9”

10’ 5”

Gl...--_D

j 23" l • •

Gl-_~

j 23" I . ..

POURED IN PLACE URETHANE

STARTER PANELS

CIJ

bJ

Gl---- D

I. 47" ..I

Panel Systems·

~INTERIOR METAL

STANDARD PANELS

INTERMEDIATE PANELS

(C]

bJ

GL--

j

• 47" •I

el240
Due to continuous improvement programs, specifications are subject to change without notice.

Insulframe (800) 633-3426 Section 2 Page 3 

10/08

FLOOR PANELS

 

MAXIMUM AVAILABLE SINGLE PANEL LENGTH= 12'-0"

RECOMMENDED FLOOR DESIGN 

FOOT TRAFFIC: METAL OVER FOAM – UNIFORM LOAD = 600 PSF

HAND TRUCK: 1⁄2” PLYWOOD UNDER METAL – UNIFORM LOAD = 900 PSF

PALLET JACK: 1⁄2” PLYWOOD UNDER METAL WITH FIELD APPLIED 3/16” 

 ADT-UNIFORM LOAD = 2500 PSF

Panel Systems·

STANDARD PANELS

STARTER PANELS INTERMEDIATE PANELS

0 d 0 CIS d

bJ L 23" J bJ L 23" J

d 0 d

J. 47" .l J. 47" .l

OPTIONAL FIELD INSTALLED OVERLAY

(INSTALL PERPENDICULAR TO JOINTS)

3/16" DIAMOND TREAD ALUMINUM

OR 14 GA. DIAMOND TREAD STEEL

END

CAPS I~--

___~--_EXTERIOR

~~~ MEffiL

~~~:~~~;~~:~~~i:::~__WOOD STRIP

SCREED

1/2" C-D-X

PLYWOOD

HIGH

URETHANE

DENSI~TY:~::;;;:== 1Iiiiiii::::::::~~
Three ways to 

get Kolpak quality 

in your kitchen
Unsurpassed quality - Host of standard features

Polar-Pak coolers and freezers are made with the same rugged, high performance construction 

that has made Kolpak the leader in walk-in refrigeration. The Polar-Pak modular panels of 4” 100% 

foamed in place non-CFC urethane foam offer superior insulating capabilities. The exterior and 

interior of top-quality galvanized metal offer an attractive and rugged finish. Polar-Pak also offers 

superior air circulation around the coils making it both economical and efficient to run.

• Top-mount refrigeration is flush to the interior

• Hot gas condensate evaporator

• Superior door construction to seal in cold, prevent condensation

• Posi-Loc panel fasteners for a perfect airtight fit

• Adjustable hinges and durable handle

• Interior safety release to prevent accidental entrapment

• Coved corners on floor panels for easier cleaning, greater sanitation

• Heated air-vents on freezers to eliminate vacuum and pressure build-up

No other manufacturer offers you greater flexibility

Polar-Pak is flexible enough to be used in virtually any configuration. There is no need for 

numbered panels. Some standard 7’6” high units are part of our Polar-Pak program, and will ship 

within 7 working days after your order has been received. Orders specifying options will require 

standard lead times.

100% usable storage space

Flush fit ceiling coil design allows full use of walk-in interior for storage.

Quick and cost-saving installation

The top-mount self-contained refrigeration package significantly reduces refrigeration labor 

costs. Installation is quick and easy and can be completed without the services of a plumber 

or refrigeration technician. Plumbing is not required. The standard automatic 

condensate evaporator eliminates the need for a drain line on indoor units.

Plug and play design.

Polar-Pak®can easily be installed 

in practically no time at all without 

the services of a refrigeration 

technician or plumber.

Available in both top-mount and 

side-mount models.

Kolpak Polar-Pak

Walk-in to convenience

Design flexibility

Available in cooler, freezer, or combination cooler/freezer. You can 

choose from top or side-mount refrigeration. Floor or floorless 

application, indoor or outdoor, two ceiling heights (6’6” or 7’6”) 

and standard panels allow for various layouts.

D

-
Unsurpassed quality - Host of standard features

Polar-Pak coolers and freezers are made with the same rugged, high performance construction 

that has made Kolpak the leader in walk-in refrigeration. The Polar-Pak modular panels of 4” 100% 

foamed in place non-CFC urethane foam offer superior insulating capabilities. The exterior and 

interior of top-quality galvanized metal offer an attractive and rugged finish. Polar-Pak also offers 

superior air circulation around the coils making it both economical and efficient to run.

• Top-mount refrigeration is flush to the interior

• Hot gas condensate evaporator

• Superior door construction to seal in cold, prevent condensation

• Posi-Loc panel fasteners for a perfect airtight fit

• Adjustable hinges and durable handle

• Interior safety release to prevent accidental entrapment

• Coved corners on floor panels for easier cleaning, greater sanitation

• Heated air-vents on freezers to eliminate vacuum and pressure build-up

No other manufacturer offers you greater flexibility

Polar-Pak is flexible enough to be used in virtually any configuration. There is no need for 

numbered panels. Some standard 7’6” high units are part of our Polar-Pak program, and will ship 

within 7 working days after your order has been received. Orders specifying options will require 

standard lead times.

100% usable storage space

Flush fit ceiling coil design allows full use of walk-in interior for storage.

Quick and cost-saving installation

The top-mount self-contained refrigeration package significantly reduces refrigeration labor 

costs. Installation is quick and easy and can be completed without the services of a plumber 

or refrigeration technician. Plumbing is not required. The standard automatic 

condensate evaporator eliminates the need for a drain line on indoor units.

Plug and play design.

High-quality with fast shipping and easy installation

Kolpak Pre-Engineered uses the same components that have made Kolpak Walk-ins famous for 

quality, flexibility, durability and energy efficiency. Because these units are already engineered 

and utilize standard components, shipping and installation time are greatly reduced.

Built-in efficiency

When you choose Kolpak Pre-Engineered you can rest assured that we have not cut any 

corners when it comes to the performance of your walk-in. 

• Panels are the same high-quality 4” panels that exceed 2009 Panel

Standards. Available in 7’6” or 8’6” heights

• Cam locks ensure panels lock to a rigid air-tight seal

• Corner pieces are 1” x 1” for greater stability and durability

• Door hinges are adjustable to ensure a square air-tight seal for greater energy efficiency

• Lights are energy-saving and long lasting

• Doors feature a standard kick plate for greater durability

• Digital Thermometer is standard on all units

• Single and 3-phase Pre-Charged Remote Condensor, R-22 Coolers, R404A Freezers 

Built-in Flexibility

• Nominal panel sizes are available in 1’, 2’ and 4’ widths, each in either 7’6” or 8’6” heights

• 6’ x 6’ to 10’ x 24’ compartment sizes available

• Single and dual compartment 

solutions available

• 30” and 36” door sizes available to 

best suit your needs

Polar-Pak®can easily be installed 

in practically no time at all without 

the services of a refrigeration 

technician or plumber.

Available in both top-mount and 

side-mount models.

Kolpak Polar-Pak Kolpak Pre-Engineered 

Walk-in to convenience Walk-in to flexibility 

Design flexibility

Available in cooler, freezer, or combination cooler/freezer. You can 

choose from top or side-mount refrigeration. Floor or floorless 

application, indoor or outdoor, two ceiling heights (6’6” or 7’6”) 

and standard panels allow for various layouts.

Kolpak Pre-Engineered 

can be fully assembled 

in under one hour.

NEW

D
Kolpak: Specified Number 1 in Walk-ins

As the leader in walk-in cooler and walk-in freezer manufacturing, the customer expects 

things like help on correctly sizing walk-in coolers, a competitive walk-in refrigerator cost 

and the product breadth that allows them flexibility in determining the walk-in solution 

that’s right for them. Kolpak’s commercial freezer, commercial cooler and industrial 

refrigeration system designs are unsurpassed in the industry because they are quality 

controlled and manufactured in house.

Our constant improvement and continuous concern for the customer keeps us at the 

forefront. For the past 8 years running, Foodservice Equipment & Supplies magazine has 

awarded Kolpak with its’ overall Best in Class accolade.

Kolpak continues to lead with a wide range of energy-saving and environmentally-friendly 

products, features and manufacturing processes. Our units offer maximum cold holding 

performance with minimum environmental impact, all while saving the operator money on 

energy, operating, food and ownership costs.

Kolpak walk-ins are now available three ways for added flexibility

Polar-Pak

Kolpak Polar-Pak is Kolpak’s high quality self contained refrigeration units. Featuring the 

industry’s simplest installation there’s no need for a refrigeration technician or a plumber. 

Best for standard size applications, Polar-Pak is built with the same quality, craftsmanship, 

attention to detail and energy savings built into every Kolpak product. 

Kolpak Pre-Engineered (New)

When you require a walk-in for a larger size installation with greater flexibility, Kolpak 

Pre-Engineered is the solution. Made from the same quality panels and components Kolpak 

is renowned for, the Kolpak Pre-Engineered solution features ready made components that 

are ready to assemble. Compartment sizes available 6’ x 6’ to 10’ x 24’ in 1’ increments.

7’6” or 8’6” panel heights and single or two compartment options are available. This results

in faster ship times and a potentially more cost effective solution depending on your

exact requirements.

Kolpak Engineered to Order

Recognized as the standard for quality, efficiency, durability and as the innovation leader. 

Kolpak ETO is a fully customized walk-in solution featuring the industry’s best materials, 

craftsmanship and overall quality. Designed to precise specifications in a wide variety of 

configurations from large to small with many available options.

Walk-in to a better system

Kolpak walk-ins maximize energy saving performance with standard features 

and options. Now available in three convenient high-quality systems.
Kolpak

Parsons, Tennessee Phone (731) 847-5620 Fax (731) 847-5387

Standard Features — save more money

• Kolpak walk-ins exceed 2009 Panel Standards using their standard 4” panel

• Low and medium temp refrigeration systems are designed for use with R404A refrigerant

• Energy saving fluorescent lighting

• PSC motors are 60% more efficient than other types of motors used in refrigeration systems

• Scroll type compressors, optimized for medium temp applications, improve annual energy

and performance efficiencies

Optional Features — save even more energy

• 5” panels are available for even greater energy savings

• Adding an air current, air shield, or swing door options, exceed the 2009 Energy Requirements; 

resulting in additional energy savings

• Ultra high-efficient T-5 fluorescent lighting offers even greater energy savings - 618% more 

efficient than incandescent bulbs

• Electronically commutated motors (ECM) on evaporators (standard in January 2009) regulate 

energy usage to maximize efficiency standard on walk-in refrigeration condensing

AlarmPakTM offers energy savings, food safety, and 

alarms in one convenient package

AlarmPakTM displays, monitors, and alerts for unsafe temperature conditions with visual and audible 

warnings. It also features a door open alarm and an auto on/off feature for lights, solving the two 

bigger operating energy wasters — leaving the lights on and the door open!

Kolpak exceeds government requirements

Kolpak units are available today with standard and optional features which meet or exceed the 2009 Federal Standards. 

• Kolpaks’ 4” panels exceed the 2009 standards with an rating of R-29, exceeding the R-25 standard for coolers. Our panels also exceed the 

2009 freezer standard of R32 with a rating of R-32.1. With Kolpak, there is no need to specify a 5” panel to meet the 2009 

standards — a major cost savings!

• Kolpak freezer floor panels exceed the R-28 insulation standard with a rating of R-29.

Solutions

Kolpak provides many of the operational solutions from Manitowoc Foodservice, a global company dedicated to bringing 

value to foodservice operators by equipping them with highly individualized real-world answers that enhance menus, 

service, profits and efficiency. 

©2009 Manitowoc Foodservice Inc. except where explicitly stated otherwise. All rights reserved.

To learn how Manitowoc Foodservice and its leading brands can equip you, visit our global web site at 

www.manitowocfsg.com then find the regional or local resources available to you.

4498 3/09

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Architectural Specifications

General 

Walk-in coolers or freezers provided under this portion of the specifications shall be prefabricated, of modular 

design and construction. They shall be designed to allow convenient and accurate field assembly and future 

enlargement by the addition of panels. 

Panel Fabrication 

Standard wall, ceiling and floor panels shall be nominal 2' and 4' in width and shall be interchangeable with like 

panels. Standard heights of walk-ins shall be. Corner panels shall be 90-1/4 angles with actual 12' exterior 

horizontal measurements. Nominal 1' and 3' panels shall be used if required to meet job site conditions. Available 

heights with floor or 4" vinyl screeds: 7' 6" 8' 6", 9' 6", 10' 6", 11' 6", 12' 6". Available heights without floor, with 1 

1/2" vinyl screeds: 7' 4", 8' 4", 9' 4", 10' 4", 11' 4", 12' 4". Panels shall consist of foamed - in - place urethane 

insulation, sandwiched between interior and exterior metal "skin" which has been die-formed and gauged for 

uniformity in size. Edges of panels shall be foamed - in - place tongue and groove with locking facilities foamed - in 

- place at time of fabrications. 

Floor Construction (select one) 

• Floor Panels: Panels shall be fabricated similar to other panels, designed to readily withstand uniformly 

distributed loads of 700 lbs. per square foot. Floor (will/will not) be recessed. Floor (will/will not) be covered 

by the tile and grout, or concrete wearing floor. 

• Floorless: Provide 1-1/2" high or 4" high Temp-Guard vinyl screeds. Screeds must be coved on both sides 

and sit flat on the floor. Screeds shall be nailed or lag fasteners shall be allowed. Wall panels lock to 

screeds on 2'0" centers. 

Insulation 

Each panel shall be filled with rigid "Foamed-In-Place" urethane having a thermal conductivity (K factor) of .133 

BTU/hr./ft squared per degrees Fahrenheit/inch and an overall coefficient of heat transfer (U factor) of not more 

than .03. "R" factor shall be 31 or greater. Insulation shall have a 97% closed cell structure. Overall thickness shall 

be 4". 

Metal Finishes 

Panel skins, standard models, standard and optional metal finishes are as follows (Specify one or a combination of 

the following): 

• Exterior and Interior walls shall be one of the following: 

1. .26 gauge stucco-embossed Galvalume steel. 

2. 032 stucco-embossed aluminum. 

3. 22 gauge Type 304 stainless steel, #3 finish. 

4. 20 gauge Type 304 stainless steel, #3 finish. 

5. 26 gauge stucco-embossed Galvalume pre-painted white. 

6. Other metal finishes and paint colors available. Consult factory. 

• Exterior floor and ceiling shall be 26 gauge Galvalume steel on all walk-ins, unless otherwise called for. 

• Interior floor shall be one of the following: 

1. .100"smooth aluminum 

2. 16 gauge stainless steel 

3. .100 tread plate aluminum 

4. 16 gauge galvanized steel (tile and grout applications) 

Panel locking assemblies 

Assembly of walk-in shall be accomplished by Posi-Locs. Posi-Locs shall be foamed-in-place and activated by a 

hex wrench provided by the manufacturer. Access ports to locking devices shall be covered by snap caps. Access 

ports shall be on interior to allow assembly of walk-in from the inside. 

Section gaskets 

NSF listen gaskets shall be foamed-in-place to the male side of all panels, on both interior and exterior. Gaskets 

shall be impervious to stains, greases, oils, mildew, etc. 

°Kolpak"
Entrance door and door panel 

Each walk-in shall be fitted with one standard 34" x 78" swing-type entrance door. The door shall be flush type, 

finished in and out to match the wall in which located. Doors and door section shall be listed by Underwriters 

Laboratories and equipped with the following: 

• Door shall be equipped with magnetic gasket, Posi-Seal door closure and latch. Hardware has provisions 

for locking and a safety release which prevents entrapment of personnel within the box 

• Door shall be self-closing with two strap-type, cam-lift hinges. 

• Door jamb shall be made of Fiberglass Reinforced Plastic. An isolated, low wattage heater strip covered by 

magnetically attracting stainless steel shall be fitted onto this jamb (freezer only). This strip shall provide 

perfect sealing of magnetic gasket and prevent frost and condensation build-up. 

• Each entrance door section shall be provided with an incandescent type vapor-proof light, pilot light switch 

and conduit between switch box and outlet box. Concealed wiring shall be standard on each entrance door 

section. 

• A threshold with non-skid striping shall be provided with each door section. Heater wire shall continue 

beneath the threshold (freezer). 

• A 2" dial thermometer shall be included with each door section to indicate inside temperature. 

Partitions 

Fabrication and finish of partition walls shall be the same as the walk-in walls and shall lock into wall, ceiling, 

and/or floor panels, with Posi-Loc assemblies. Tongue and groove foam fabrication shall provide the thermal break 

between cooler and freezer compartments. Wall "T" panels shall be 23" x 12" symmetrical tee. Heater wires not 

required. 

NSF 

All walk-ins shall be fabricated to comply with National Sanitation Foundation No. 7. The NSF label shall be affixed 

to the interior door pan. All interior corners, including floor shall be coved. 

Air Vent 

A Tri-Action air vent shall be provided to equalize pressure between the interior and exterior, caused by sudden 

temperature changes due to door openings and evaporator defrosting. The vent shall be heated to prevent 

moisture and/or frost accumulation (required for freezers). 

Installation Instructions 

A complete set of installation instructions shall be included with the walk-in. These instructions shall cover the 

erection and assembly of the walk-in, and the installation of refrigeration systems. A floor plan print shall be 

included. 

Refrigeration Equipment 

Condensing units shall be fully hermetic or semi-hermetic type. Refrigerant shall be R-22 or R-404A unless 

otherwise specified. Condenser shall be air-cooled or optional water-cooled. Condensing units shall be factory 

assembled and UL or ETL listed. Evaporators shall be forced air type. Air discharge shall be parallel to the walk-in 

ceiling. Fan motors, guards multi-fin and tube-type coil, shall be housed in heavy gauge aluminum. Unit shall have 

drain pan with suitable drain pipe fitting. Freezer evaporators shall have and automatic electric defrost system 

including heater, time clock, fan delay control, and heated drain pan. Defrost shall be time initiated and 

temperature terminated with built-in fail-safe control. All evaporators shall be UL listed. All systems include pump 

down cycle to provide additional protection against unwanted refrigerant flow. 

These basic components shall be supplied by Kolpak as one of the following systems: 

• "CS" Self-Contained Top Mounted 

• "SS" Self-Contained Side Mounted 

• "PCL" Pre-Charged Lines (Remote) 

• "PR" Pre-assembled Remote See Refrigeration Systems for details on above systems. 

Refrigeration Accessories 

Low Ambient Kit 

For air-cooled condensing units installed outdoors (to -20°F) where sub-zero ambient temperatures prevail for 

sustained periods - include crankcase heater, head pressure control, and rainproof housing. 

For below -20°F ambient temperatures, consult factory. 

°Kolpak"
Drain Lines 

Installing contractor shall provide suitable drain lines from all evaporators. Drains shall be trapped outside the 

walk-in. Freezer drains shall be copper tubing and shall be heated and insulated to prevent freeze-up. All plumbing 

to be in accordance with local codes. Drain line heater kits available from Kolpak in 6', 2' or 18' lengths. 

Condensate Evaporator 

Required if job site does not have a floor drain near the walk-in. An electric condensate evaporator shall be 

provided for wall mounting on exterior of the walk-in. 115-60-1 AC continuous service voltage required. 

Insulated Evaporator 

Top-mounted coil system can be used to provide more useable storage space. Coil is positioned above interior of 

ceiling. 

°Kolpak"
Product 

Details

Key 

Features

Approvals

Product Details

Exclusive patented DURATHANE 100% urethane tongue and groove construction - a major 

advance in walk-in refrigeration.

Four and five inches urethane foamed-in-place zero ozone depleting insulation.

Durable high-density urethane panel perimeter - no pre-installation damage.

No exposed low-density urethane surfaces - no deterioration during pre-installation panel 

storage.

No need for non-insulating internal metal straps or rods.

Lightweight panels with added strength.

Fast, easy assembly - Insta-Lok positive camlock device with exclusive self-centering pinstrike assembly - instant panel alignment.

Easy to relocate or enlarge.

Prefabricated panels within 1” increments up to 46” wide and 1’ x 1’ corners. Door, partition 

and height within 1” increments to meet space requirements.

Complete design flexibility - custom sizes and configurations available upon request.

Standard stucco aluminum finish – optional finishes of smooth aluminum, smooth and stucco 

stainless steel or smooth and stucco galvanized.

Floor panels of smooth aluminum – optional 16 gauge stainless steel, treadbrite aluminum, 1/8 

aluminum treadplate – all made to withstand uniformly distributed loads up to 600 lbs. per sq. 

ft., or for additional floor strength THERMO-KOOL’s DURA-FLOOR available to withstand 

stationary floor loads of up to 12,000 lbs. per sq. ft. For floorless applications vinyl u-channel 

and 4-1/4” foam screeds available.

Complete refrigeration systems sized to any requirement.

Choice of remote, remote pre-assembled, top mount quick connect and remote quick connect 

refrigeration systems.

A heavy reinforced steel u-channel frame is foamed-in-place to give extra support and rigidity 

to the frame and to prevent racking, distortion, warping and twisting of the door section.

Three self-centering, self-aligning “Insta-Loks” per every standard panel (number of “InstaLoks” increase accordingly when panel height over 8’6”)

Optional second heater wire and thermostatically controlled thermostat available

Integrated foamed-in-place interior ramps

Walk-ins pre-assembled at factory prior to shipment for Quality Control Inspection to ensure a 

trouble-free installation

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Product 

Details

Key 

Features

Approvals

Key Features

THERMO-KOOL’s panel design allows us to provide non-standard walk-in sizes and designs 

(i.e. column surrounds, angle walls, etc.) when specified with each panel locking in place and 

without the panels being considered special. There is no cut and paste in the field!

THERMO-KOOL walk-in panels consist of 4” or 5” foamed-in-place zero ozone depleting HFC 

134a blown Class I urethane foam classified according to UL 723 (ASTM-E-84) as tested by 

Underwriters Laboratories, Inc. The core material has a flame spread of 25 or less and a 

smoke density of 250.

THERMO-KOOL walk-in panels feature a patented DURATHANE high-density urethane 

patented tongue and groove panel perimeter. We feel that this construction gives our walk-in 

superiority as far as durability and ease of installation are concerned.

THERMO-KOOL partition, door panel and height can be manufactured within 1” increments to 

meet shelving space and building requirements.

THERMO-KOOL has available the DURA-FLOOR, a heavy duty structural support floor which 

has the capability to withstand up to 12,000 lbs. per sq. ft. stationary floor load as tested in 

accordance with the ASTM Standard Designation Specifications.

THERMO-KOOL offers an interior NSF approved foamed-in-place ramp which is an integral 

part of the floor panel.

THERMO-KOOL’s panel design allows a panel span of 16’ indoors with no additional support 

required.

THERMO-KOOL panels which require hurricane tested criteria have Miami-Dade BCCO and 

Florida Building Code acceptance and approval.

THERMO-KOOL’s door construction consists of a heavy reinforced steel u-channel frame 

which gives extra support and rigidity to our door section. Our patented door construction is in 

accordance with UL requirements and is UL listed.

All THERMO-KOOL walk-in panels are manufactured under U.S. Patent #5,424,118 and 

THERMO-KOOL doors are manufactured under U.S. Patent #5,727,349.

THERMO-KOOL panels have three self-aligning, self-centering “Insta-Loks” per every 

standard height panel (number of “Insta-Loks” increase accordingly when panel height is 

above 8’6” high) foamed-in-place into the high density perimeter which does not allow 

movement and eliminates the lock assembly from being pulled out during assembly and/or 

disassembly.

THERMO-KOOL has an armored anti-sweat heater cable running under the threshold which is 

easily accessible for replacement. An additional heater and a heater wire thermostat are also 

available upon request.

THERMO-KOOL offers a foamed-in-place concealed locking bar for additional security with no 

portion of the locking bar exposed on the exterior of the walk-in door.

THERMO-KOOL walk-ins are set up at the factory prior to shipment for a complete quality 

control inspection to ensure a trouble-free installation. Also, THERMO-KOOL provides 

complete installation manuals and drawings which give step-by-step instructions of the 

installation process.

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THERMO-KOOL’s ten-year panel warranty covers any defects in material or workmanship 

under normal use and service.

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