1. Capacité
Définit le takt time et l’automatisation
- Unités/jour et équipes/jour
- Mix îlot et porte vitrée
- Lot d’appel d’offres et pic de demande
- Takt time et OEE prévus
Solutions pour
Lignes de congélateurs commerciaux pour chaînes de retail et proximité
Production haut volume de congélateurs commerciaux : congélateurs îlots pour supermarchés, portes vitrées pour la proximité, vitrines surgelés pour hypermarchés. Moussage PU haute pression, moules à double porte et lignes 500 – 5 000 unités/jour.
In one line
Optimisé pour le format retail libre-service — moules de congélateur îlot à faible hauteur et matériel anti-buée spécifiquement réglé pour supermarché et proximité.
Real Pains We Hear from Buyers — and What We Ship to Solve Each One
Four pains commercial-freezer factories hit when scaling for retail-chain tenders. Our line clears each one.
Pain 1
Glass-door anti-fog hardware fails in tropical humid stores — store complaints + warranty replacements eating margin
How we solve it
Anti-fog is heated-perimeter wattage + door seal geometry working together. Our UDM-COMBO door mould sets the seal channel geometry for proper Schott / Saint-Gobain dual-pane door fit; we ship the heated perimeter strip with calibrated 4 W/m wattage zoned by climate (tropical / temperate / cold). Field anti-fog failure rate drops from 6% to <0.5% over 24 months.
Pain 2
Retail-chain tender requires ENERGY STAR + EU Ecodesign — my last cabinet failed both pull-down tests
How we solve it
Pull-down tests fail when foam thermal performance + cabinet airflow + compressor sizing don't align. We ship the line with a pull-down to -40°C test rig built in, with sensors at 12 points inside the cabinet. Run trial cabinets through it before submitting to ENERGY STAR / Ecodesign labs — first-submission pass rate goes from 50% to 90%+.
Pain 3
Convenience-store buyer wants both island freezer and glass-door merchandiser — buying 2 separate lines is impossible
How we solve it
One line, quick-change moulds covering both formats. The PU foaming machine, mould fixture and assembly conveyor are shared; only the cabinet mould + door mould change between island and merchandiser. Changeover 60–90 min. Throughput hit is 25–30%, but capex saved is ~USD 1.5M vs two dedicated lines. Sweet spot: combined volume 500–3,000 units/day.
Pain 4
24/7 duty cycle — first-year warranty replacement rate is 3–4%, killing my channel margins
How we solve it
Commercial freezer warranty failures cluster in 3 places: door hinge fatigue (200K+ open cycles), gasket frost-line failure, glass-pane seal leak. Our line addresses each: high-cycle-rated hinges (Sugatsune / Hettich brands), heated-gasket perimeter, dual-pane sealed glass with leak-test on every unit. Year-1 warranty rate target: <0.8%.
Ce dont vous avez besoin
Lignes de production
26-Station Ground-Rail PU Foaming Line for Refrigerator Doors — Closed-Loop Track Layout
Closed-loop ground-rail PU foaming line dedicated to refrigerator and cabinet DOOR foaming. 26 single-cavity fixture stations on a continuous steel track, 20-sec takt, ~1,200 doors per 8-hour shift (~2,450/day on two shifts) at 85% line efficiency. 2,000 × 900 mm fixture × 200 mm closing height — sized for door panels. Cyclopentane + ATEX Zone 1, steam or oil heating.
En savoir plus
Quincaillerie et accessoires
Ferronnerie & accessoires
Charnières, joints, poignées, LED, évaporateurs & condenseurs
En savoir plus
Machines de moussage PU
Machine PU haute pression
100–1 500 g/s, 2–4 composants, Siemens PLC
En savoir plus
Moules pour équipements de réfrigération
Mold for Upright Glass-Door Display Cabinet
Refrigerator mould (mold) for display cabinets — cast aluminium PU foaming mould for single / double / triple glass-door beverage display cabinets and supermarket display refrigerators. Up to 1,900 × 700 × 1,300 mm, ~30 s/shot.
En savoir plus
Moules pour équipements de réfrigération
Mold for Supermarket Island Freezer
Refrigerator / freezer mould (mold) for supermarket island freezers — long-cavity cast aluminium mould for 2–3 m island freezer cabinets. Single-gun-head one-end horizontal filling for low-defect long-cabinet foaming. Up to 2,600 × 1,100 × 1,100 mm.
En savoir plus
Matières premières PU
Système de matières premières PU
Polyol + isocyanate + agent gonflant, k-factor jusqu'à 0,018
En savoir plusCabinet models you can produce on this line
Every row below is a real cabinet SKU that customers already produce using the moulds in this line — temperature class, capacity, compressor, refrigerant and overall dimensions are field-tested. Use the matrix to match your target cabinet to the right mould configuration.
| Cabinet model | Variant | Temperature (°C) | Volume (L) | Power (W) | Weight (kg) | Compressor | Refrigerant | Size (mm) | Source mould |
|---|---|---|---|---|---|---|---|---|---|
| SD/SC-2000K | — | ≤-18 | 748 | 480 | 95 | DONPER / WANBAO | R290 | 2000 × 1035 × 880 | Mold for Supermarket → |
| SD/SC-2200K | — | ≤-18 | 868 | 480 | 110 | DONPER / WANBAO | R290 | 2200 × 1035 × 880 | Mold for Supermarket → |
| SD/SC-2600K | — | ≤-18 | 998 | 645 | 135 | DONPER / WANBAO | R290 | 2600 × 1035 × 880 | Mold for Supermarket → |
| SD/SC-3600K | Extra-wide deep-bottom | ≤-22 | 2016 | 1560 | 195 | DONPER / WANBAO | R290 | 3605 × 1569 × 930 | Mold for Supermarket → |
| LC-620FX | Single-door refrigeration | -2–8 | 620 | 262 | 75 | DONPER / WANBAO | R290 | 620 × 725 × 2065 | Mold for Upright → |
| LC-1260FX | Double-door refrigeration | -2–8 | 1113 | 374 | 145 | DONPER / WANBAO | R290 | 1260 × 725 × 2065 | Mold for Upright → |
| LD-1260FX | Double-door freezing | ≤-18 | 1066 | 911 | 200 | DONPER / WANBAO | R290 | 1260 × 725 × 2065 | Mold for Upright → |
| LC-1860FX | Triple-door refrigeration | -2–8 | 1685 | 583 | 200 | DONPER / WANBAO | R290 | 1860 × 725 × 2065 | Mold for Upright → |
| LD-1860FX | Triple-door freezing | ≤-18 | 1670 | 1395 | 260 | DONPER / WANBAO | R290 | 1860 × 725 × 2065 | Mold for Upright → |
Source: UREXCEED catalog §07 OEM/ODM cabinet series, cross-referenced to the mould that produces each SKU. Custom cabinet sizes outside this range supported — send us your cabinet drawing for a 7-day quote.
From inquiry to first commercial unit — the 6-step delivery flow
From inquiry to first commercial freezer rolling off your line. ~12 months for a standard 2,000 units/day commercial freezer / merchandiser line.
- 1
Inquiry & Format Mix Scoping
Week 1–2Share target capacity, format mix (island freezer / glass-door merchandiser / convenience-store cabinet), target retail-chain customers (Walmart / 7-Eleven / Carrefour spec required). We send a 1-page proposal with line layout and price range.
- 2
Detailed Proposal & Tender-Compliance Roadmap
Week 2–4If you're bidding for a specific retail-chain tender (ENERGY STAR / Ecodesign / Carrefour spec), share the tender doc — we map our equipment to each compliance requirement. Mould variants picked, PU machine sized, glass-door + anti-fog hardware specced. Quote with 24-line BOM in 14 days.
- 3
Contract & Cabinet + Door Design Freeze
Week 4–830% down. Cabinet CAD + door CAD review with extra attention to glass-pane geometry and hinge mounting (Sugatsune / Hettich specifications). Mould CAD frozen before CNC starts.
- 4
Mould + Glass-Door Station Build
Month 3–7Cabinet moulds + door moulds: 60–90 days. PU machine: 45–60 days. Glass-door alignment + anti-fog hardware assembly stations: 45 days. Pre-shipment FAT — we run trial merchandisers in our shop and ship the pull-down test report.
- 5
Sea Freight & On-Site Installation
Month 7–105–7 × 40' containers from Shanghai/Ningbo. On-site installation by 5–7-person engineer team, 3–4 weeks. Reinforced foundation for foaming station, dedicated electrical for glass-door heated-gasket circuits.
- 6
Commissioning, Pre-Certification Testing & Acceptance
Month 10–12First 100 trial merchandisers built and tested through pull-down rig. ENERGY STAR / Ecodesign pre-submission test pack prepared on first 5 units. Operator training. Acceptance signed when 50 consecutive units pass pull-down + leak-test + electrical-safety spec. 60% payment due here, 10% after 6-month warranty-rate verification.
Heavy-duty retail refrigeration
Retail Merchandiser Configuration
Retail-chain tenders spec cabinets to the millimeter. 4 axes you can choose per tender without re-tooling.
Format
Island freezer (low-profile 600–900 mm) / glass-door merchandiser / convenience-store cabinet. Quick-change moulds 60–90 min.
Glass-door & anti-fog
Dual-pane sealed glass (Schott / Saint-Gobain), heated perimeter strip wattage zoned by climate (tropical 4–6 W/m).
Compliance target
ENERGY STAR / EU Ecodesign / Carrefour / Walmart spec. Pull-down to -40°C test rig built in. NSF Standard 7 optional.
Hinge & gasket
Sugatsune / Hettich 200K-cycle-rated hinges, heated perimeter gasket for frost-line resistance. Premium hardware locked per tender.
Shared engineering reference
PU foam quality, testing and acceptance
Closed-cell ratio, density uniformity and thermal testing are documented once in our quality center.
Livraisons récentes dans cette catégorie
2024 · MENA
Arabie saoudite — Vitrines boulangerie
Bakery display cabinet project, 500 units/day
2025 · LATAM
Brésil — Extension ligne de congélateurs coffres
Chest freezer line expansion, 2,000 units/day
Les questions que nous posent les propriétaires d'usine
En quoi une ligne congélateur commercial diffère-t-elle d'une ligne domestique ?
Les commerciaux sont plus grands (300–2 000 L), à service 24/7 (vs 40% domestique), avec caisse renforcée, portes haut-cycle (200 000+ ouvertures/an) et souvent en configuration merchandiser vitré. Moules et postes portes diffèrent ; le cœur de moussage PU et le convoyeur sont partagés entre configurations domestique et commerciale.
Qu'ajoute une ligne merchandiser vitré à une ligne porte pleine ?
Trois postes additionnels : (1) moule d'alignement du panneau verre, (2) ruban chauffant périphérique + câblage, (3) poste test fuite et visibilité. Investissement additionnel : USD 350K – 550K pour une ligne 2 000 unités/jour.
Une ligne peut-elle produire îlot et merchandiser vertical vitré ?
Oui avec moules à changement rapide, mais le débit chute de 25–30% à cause du temps de changement. Lignes dédiées plus économiques au-dessus de 3 000 unités/jour combinées. Lignes SKU mixtes bien adaptées aux OEM chaîne retail produisant 500–3 000 unités/jour entre configurations.
Investissement typique pour 2 000 unités/jour commercial ?
USD 2,5M – 4,0M, plus haut qu'une ligne domestique à cause des moules plus grands et postes d'assemblage verre. Lignes merchandiser dédiées vers le haut de la fourchette ; lignes mixtes domestique-commercial au milieu.
Livrez-vous les certifications chaîne retail (ENERGY STAR, EuroSpec) ?
Nous livrons tout l'équipement de test nécessaire pour ces programmes de conformité — pull-down à -40 °C, sécurité électrique, bruit et fuite d'air. Les certifications elles-mêmes (ENERGY STAR, EU Ecodesign, CB, ETL) sont obtenues par votre usine sur les merchandisers finis, pas par le fournisseur d'équipement.
ROI · Cost Analysis
Investment Range & Payback
Indicative range based on 1,800+ delivered lines. Final pricing depends on automation level + add-ons + local labor cost. Request a quote for your spec.
Investment
USD 700K – 2.0M
Payback
20–32 months
Annual Throughput
5K–25K units/year
Configuration note: Heavy-duty commercial use: high-pressure cyclopentane + reinforced cabinet structure + drop-in evaporators. Lower volume but higher average selling price, so ROI is longer.
Service & Support
Garantie & Service
Intervention sur site disponible dans chaque région où nous avons livré des projets.
On-Site Installation
Our engineers fly to your factory to supervise installation, layout verification, and first-run production.
Commissioning + Tuning
Trial run + parameter tuning to your local raw material, climate, and target product spec — until throughput meets contract.
Operator Training
5-10 day on-site training for production team, QC, and maintenance — bilingual manuals + video tutorials provided.
3-Year Warranty + Spares
Core equipment 3-year warranty, electrical 2-year. Spare parts in stock with global express shipment 24h dispatch.
Cross-Sell · One-Partner Synergy
Pair this line with the rest of the factory
The product groups our refrigerator-factory customers buy alongside this line — for full-line synergy and one-partner accountability.
Foaming
High-Pressure PU Foaming Machines
Cyclopentane / 2-component / 3-component models. Cyclopentane is the refrigerator industry standard.
Learn more
Moulds
Refrigerator-grade Moulds
Vacuum-forming moulds for inner liners + foaming moulds for cabinet/door. 30-year mould-cluster network.
Learn more
Materials
PU Raw Materials System
BASF / Covestro / Wanhua MDI + Polyol — calibrated to your climate, foam density, and cycle time.
Learn moreDonnées de dimensionnement de la ligne
Envoyez ces 3 groupes de données pour une proposition techniquement adaptée
Une proposition utile part de votre capacité réelle, des pièces d’armoire et du plan d’outillage. Des plans préliminaires suffisent pour la première analyse ; nos ingénieurs signaleront les cotes manquantes avant chiffrage.
2. Pièce
Définit l’enveloppe du moule et la recette
- L × l × H et ouverture vitrée
- Matériau, épaisseur des peaux et PU
- Température de descente/stockage cible
- Interfaces chauffage, joint et évaporateur
3. Outillage
Définit l’encours de polymérisation et le changement
- Outillages armoire/porte par modèle
- Support anti-déformation des armoires longues
- Polymérisation et démoulage
- Changement de modèle et surface disponible
Formats acceptés : PDF, STEP, DXF, DWG, photos cotées ou fiche du produit actuel. Sans plan, envoyez d’abord L × l × H et l’épaisseur de paroi.
Envoyer les 3 données sur WhatsAppObtenez une réponse rapide d'un ingénieur
Deux façons de nous contacter — envoyez le formulaire de 5 champs ci-dessous ou écrivez directement à un ingénieur projet sur WhatsApp.