ISD Solutions exports single envelope know-how for NewCold frozen distribution centre in Melbourne

Largest high-bay cold storage warehouse in Southern Hemisphere

Gloucester 20 March 2017:  ISD Solutions, the UK’s leading specialist subcontractor in the design and construction of composite panel, single envelope coldstore warehouses, has won an A$12m order from Dutch cold chain logistics specialist NewCold, to build the company’s latest super-efficient freezer storage and distribution facility near Melbourne, Australia.

ISD builds a super-efficient freezer storage and distribution facilityThis is ISD Solution’s first Australian cold store construction project and follows the creation of an Australian subsidiary earlier this year with the goal of introducing their acknowledged design and construction expertise with thermally efficient insulated PIR panels, to cold store warehouse and distribution clients across the region. ISD Solutions have previously delivered several ‘’Single Envelope’’ high-bay freezer projects in the UK, in Gloucester, Wisbech, Dublin and Macclesfield .

 The contract involves the design and construction of the external single envelope for a 35m tall high-bay freezer operating at -25 degrees C and a detached 15m tall low-bay section. Together these will have a combined floor area of 19,000m2 and storage capacity for 100,000 Australian standard pallets. ISD expects to use some 60,000m2 of Kingspan CS panels during the build and once completed, mid 2017, the facility will be the largest automated high-bay freezer warehouse in the Southern hemisphere.

The fast expanding frozen and chilled food industry in Australia combined with growing demand for more thermally efficient, sustainable, chilled and frozen storage facilities globally makes single envelope construction and clad rack freezers using PIR insulated panels increasingly attractive. 

Significantly improved thermal performance compared to conventional construction materials and polystyrene based insulation is a key factor for the Australian market. High-bay single envelope solutions are also faster to build with a 20% saving on site time, lower carbon and becoming more viable as land prices increase. The ability to operate with oxygen reduction fire safety technology partly as a result of the airtightness of the structure brings further benefits.

TNew super-efficient freezer storage and distribution facility in Australiahe team are using BIM level 2 processes during the project to ensure seamless collaboration with the design team, structural engineers and lead contractor Hansen Yuncken Pty Ltd. This is particularly important for single envelope structures at this height where high tolerances for the structural steel supporting the composite panel envelope are crucial.

ISD is sharing knowledge and expertise with the structural team and is responsible for load and fixing calculations for the envelope, all independently approved, to ensure long term integrity and thermal performance of the envelope. High wind loadings in the Melbourne area have made this doubly important. The team is also advising on insulation and specific sequencing for the floor construction required for this type of building, as this is fundamental to forming an insulated envelope in its entirety where all interconnecting insulation junctions need to be continuous. Careful attention to detail is required around the dual purpose high density timber blocks used, which act as a supporting foundation for the steel frame as well as an insulant and are integral to the floor design and insulation.

Commenting, Tony Wall, Managing Director for ISD Solutions said: “We are delighted to have been chosen for NewCold’s first venture into the Australian market. With other projects on the horizon, this is a clear sign our decision to target the Australian market is bearing fruit. The design team has worked hard to deliver workable solutions that overcome high temperatures and extreme wind loadings to ensure a resilient structure and it’s been a steep learning curve with very different site working practices and challenging material logistics simply because of the vast transport distances involved.”

Aside from extensive design work for fixing calculations, accommodating high summer temperatures, typically above 40°C, has been a major factor in the composite roof build up. The 200mm composite roof panel, normally suitable in the UK, was enhanced with a further 40mm thick layer before adding the final waterproof finish. This will ensure thermal efficiency between the internal chamber at -25°C and the extreme temperatures of the upper roof surface during high summer.

Bram Hage, Founder of NewCold said: “We’ve found the ISD team to be great partners, bringing with them a successful track record of delivering complex projects to plan.  In Melbourne, they have overcome significant challenges from unprecedented regional floods and high winds and we are confident their flexible, pragmatic professional approach will deliver again.”

In their expansion into Australia, ISD will initially target the design and construction of external single envelope storage and distribution facilities, but also sees opportunities similar to those in the UK market for internal chill-store and cold-store facilities within the grocery and food manufacturing sectors as well as clean rooms, pharmaceutical manufacturing and storage, and other temperature critical sectors.


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Notes to Editors


ISD Solutions is the UK’s leading contractor in composite panel construction and cladding projects from cold stores, food processing facilities & distribution centres to clean rooms & data centres. A pioneer in thermally efficient, single envelope construction, ISD also offers a full range of modular cold store solutions for the grocery, hospitality and pharmaceutical sectors. A diverse customer base of blue chip organisations includes Ocado, Aldi, Partner Logistics, Waitrose and Sainsbury’s.

With offices and manufacturing facilities in Gloucester, ISD’s capabilities include a cold store maintenance division providing planned maintenance or emergency call out for temperature critical storage facilities and a new Industrial Waterproofing division covering roofing projects as well as bridge decks, loading bays and car parks. The company opened its Australian subsidiary in 2016.



NewCold is an integrated service provider in the area of temperature controlled warehousing and transport, rapidly developing a global network of highly automated supply chains. Solutions are designed specifically for food producers and retailers, linked through multimodal transport solutions infrastructure. NewCold is considered to be a technological leader in its industry and provides providing exceptional service to industry leading brands. NewCold distinguishes itself from its competitors by having in-house knowledge on designing, developing, and operating highly automated warehouses: a result of its key management team successfully completing over 20 highly automated warehouses of this type of facilities across different industries in the last 15 years.

Since its incorporation in 2012, NewCold has developed over US$350 million of assets, including new projects and acquisitions throughout Germany, UK, France, and Poland. NewCold currently has in excess of 400,000 pallet spaces under development globally, with over 200,000 pallet spaces being delivered in Melbourne, Australia by mid-2017. Melbourne will also serve as their Asia-Pacific headquarters.


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