Panel thickness is one of the most important — and most frequently misunderstood — cold room specifications. Too thin and you pay for it every month in electricity. Too thick and you’ve spent more than necessary upfront. Here’s how to get it right.
Standard Panel Thicknesses
Polyurethane cold room panels are manufactured in standard thicknesses:
| Panel Thickness | Typical Application |
|---|---|
| 60mm | Display cases, low-volume retail (rarely used for walk-in rooms) |
| 80mm | Chiller rooms in moderate climates, small rooms |
| 100mm | Standard chiller rooms in Kenya’s typical conditions |
| 120mm | Chiller rooms in hot climates or with high ambient exposure |
| 150mm | Freezer rooms (-18°C to -25°C) |
| 200mm | Deep freeze rooms (-25°C and below), blast freezers |
Why Thickness Matters
Insulation works by resisting heat flow. The thicker the PU foam, the higher its thermal resistance (R-value), and the less heat passes through the panel per hour. In practical terms, a 100mm panel passes roughly 20% less heat than an 80mm panel, reducing the refrigeration load and electricity consumption accordingly.
In Kenya, where ambient temperatures are high and electricity costs are significant, investing in thicker panels than the minimum has a real payback period — often two to four years in energy savings.
What to Specify for Kenyan Conditions
Chiller rooms (0°C to +8°C):
- Nairobi and high-altitude regions: 100mm panels are standard
- Mombasa, Kisumu, and hot lowland regions: 120mm panels are recommended
Freezer rooms (-18°C to -25°C):
- All regions: 150mm panels as a minimum
- Very hot regions or outdoor installations: 200mm panels should be considered
Pharmaceutical cold rooms: Follow the equipment manufacturer’s specification and any regulatory guidelines from the Pharmacy and Poisons Board.
Floors and Ceilings
Wall panels and ceiling panels should be the same thickness. Floor panels in freezer rooms should be at least 100–150mm of insulation beneath a wear-resistant surface layer. Do not allow a contractor to specify thinner ceiling panels than walls — the ceiling is often the greatest source of heat gain because hot air rises and accumulates at roof level.
Don’t Accept Undersized Panels
Some budget cold room contractors in Kenya use 80mm panels for freezer rooms to reduce cost. This is false economy — the refrigeration system will run almost continuously, electricity consumption will be high, equipment will wear out faster, and maintaining target temperatures in hot weather may be impossible. Always insist on correct panel thickness for your application.
For most chiller rooms in Kenya, 100mm panels are the practical minimum. For freezer rooms, 150mm is non-negotiable. If your contractor quotes thinner panels without a compelling technical justification, request a revised specification or seek another opinion. The few thousand shillings saved on thinner panels will cost far more over the life of the cold room.