Lighting Challenges in Freezers and Cold Stores: What You Need to Know

Lighting cold storage areas like freezers and chillers is far more demanding than illuminating standard rooms or warehouses. These environments impose extreme conditions that require specialised planning and equipment. Whether you’re outfitting a small walk-in unit or a large-scale industrial cold store, understanding the unique lighting challenges is essential for safety, efficiency, and long-term reliability.

Here’s a breakdown of the key challenges and how to tackle them effectively.

1. Extreme Temperatures: A Real Test for Lighting Systems

Freezers and cold stores often operate at temperatures as low as -30 °C or lower. Many standard lighting solutions simply aren’t designed to perform in these conditions - they may flicker, respond slowly, or fail entirely.

What to consider:

• Sub-Zero Rated LEDs: High-quality LED fixtures built for cold environments deliver reliable, instant illumination and greater energy efficiency.
• Check Temperature Ratings: Ensure the internal drivers and components are certified to operate at your facility’s minimum temperature.

2. Moisture, Condensation & Corrosion: Hidden Hazards

Frequent door openings, temperature differentials, and defrost cycles create humid conditions that can lead to condensation. Over time, moisture exposure can damage lighting fixtures unless they’re properly protected.

Choose fixtures that are:

• IP65 Rated or Higher: To guard against water ingress and maintain performance in damp, icy settings.
• Corrosion-Resistant: Materials like stainless steel and polycarbonate are ideal for resisting both moisture and harsh cleaning agents.
• Tightly Sealed: Even a small compromise in the housing can lead to internal moisture buildup and failure.

3. Motion Sensors: Smart, But Not Foolproof

Incorporating motion sensors helps conserve energy by activating lights only when the area is occupied. However, traditional sensors may not perform well in freezing environments.

Keep in mind:

• Use Low-Temperature Rated Sensors: PIR (Passive Infrared) sensors may struggle in the cold. Microwave sensors are often more reliable, as they’re less affected by ambient conditions.
• Consider the Placement: Avoid installing sensors near fans, vents, or doors - these areas can trigger false readings or reduce detection accuracy.

4. Emergency Lighting: A Cold-Weather Challenge

Emergency lighting is vital for safety, especially during power failures. But cold temperatures can reduce battery performance and compromise reliability.

Key solutions include:

• Cold-Resistant Batteries: Lithium batteries designed for low temperatures outperform standard packs, though they may be harder to source and more expensive.
• External Battery Housings: Placing batteries outside the cold zone, connected by insulated conduits, helps maintain capacity and extends battery life.
• Automated Testing: In hard-to-reach areas, such as ceiling-mounted fixtures, self-testing and remote monitoring ensure functionality and compliance without constant manual checks.

Conclusion: Plan Smart for Cold Storage Lighting

Lighting in cold storage environments goes far beyond basic illumination - it’s about ensuring durability, energy efficiency, and operational safety under extreme conditions. From choosing sub-zero rated LEDs to installing moisture-proof, corrosion-resistant fixtures and reliable emergency systems, every element should be selected with care.

The right lighting system not only minimises maintenance headaches but also ensures compliance with safety regulations - protecting both people and product.

Recommended Product: The Drummond 5 Freezer Series by Kellwood Lighting

Kellwood Lighting offers specialised LED solutions designed specifically for freezer applications. The Drummond 5 Freezer and Cold Store Lights stand out with:

• Wide Operating Range (-40 °C to 50 °C): Reliable in both freezer and chilled environments.
• Corrosion-Resistant Coating: Available with a marine-grade finish to withstand harsh, moisture-laden conditions.
• Remote Emergency Battery Back-up (3 Hours): External battery units provide dependable power during outages.
• High IP Rating (IP66): Dustproof and resistant to high-pressure water jets—ideal for washdowns and frost-heavy areas.
• Impact Resistance (IK10): Built to withstand knocks and impacts common in busy freezer settings.

Explore the Drummond 5 Series and see how it can help optimise lighting in your cold storage facility.