What to wear in a refrigerated warehouse

The global frozen food industry is booming! The Markets and Markets report estimates this sector grows by an average of 5.14% per year, and the global market will reach an annual volume of $312 billion in revenue by 2023. This rapid growth translates into more facilities dedicated to cold storage and employee conditions needing to be addressed, of which the most obvious one is providing well-adapted clothing for working in a freezer warehouse. 

Clothing for cold storage warehouses is not the most glamorous topic, but it is an important subject. If you are running a cold storage warehouse, it's crucial that your staff protect themselves with the right clothing tailored for cold and freezing conditions. In this blog post, we will explore some of the best clothing options for keeping your workers warm in a cold storage environment. 

What is a cold storage warehouse?

Cold storage facilities are temperature-controlled warehouses where companies in the food industry store products at low temperatures to avoid spoilage. These cold dedicated facilities are equipped with freezing systems, ventilation equipment, and other important components that keep the temperature consistent at all times.

Two types of cold storage

In the cold storage industry, there are two possibilities:

1. Refrigerated facility: These are warehouses where temperatures vary between 0 and 10°C, essentially acting as massive fridges. Their primary use is for storing foods such as dairy products, delicatessen, meats, vegetables, and certain fruit, but they're also popular in the pharmaceutical industry.
2. Sub-freezing facility: These are cold rooms that maintain a controlled temperature that can range from -30°C to 0°C. They are particularly common in the frozen food industry.

Of course, these two types of cold storage spaces can coexist within the same warehouse, but the difference in temperature could affect the clothing requirements.

How the cold affects the human body

Working in a cold environment can be dangerous to your health, even fatal in certain – but rare – circumstances. In a recent report by the US Labor Bureau of Statistics, workplace deaths due to the cold as a primary or secondary cause reached 78 in 2019.

Common cold exposure risks include

• Higher incidence of colds and flu;
• Loss of body heat leading to general discomfort, thus productivity;
• Fatigue: cold is known to be energy-taxing on the body.

Serious health issues from exposure to freezing temperatures:

• Pain: exposure to cold can cause pain of varying intensity;
• Vasomotor disorders: the sensation of numb fingers and toes.  

These symptoms are grouped under the term vascular acro syndromes. They include Raynaud's syndrome, which affects approximately 10% of the population. In extreme cases, the person can develop frostbite, which may require surgery and even amputation.

Cold storage clothing: the first line of defense in a refrigerated warehouse

Clothing for cold storage must meet certain criteria in order to protect the body from cold-related injuries. Clothing should be loose-fitting and made of materials that will not absorb sweat or water. Wool, down, and synthetic fabrics are all good choices.

Breaking things down according to body structure

When considering cold protection, every part of the human body requires a specific garment.

There are 4 areas that need attention:

1. The body: upper and lower body
2. Head and face
3. Hands
4. Feet 

The 4 body sections need different and specific strategies to counter the effects of cold warehouse conditions, just like any person would need to tailor their clothing according to their needs for a day skiing or trekking in a frigid region of the world. Below, we explore the requirements for each body area to provide great cold protection while ensuring ease of movement to carry out physical tasks. 

Body

The body needs a robust but light industrial quality garment equipped with zippers or Velcro and openings to evacuate humidity. As much of warehouse work is physical, staff tend to sweat a lot, a condition that can exacerbate the cold. This piece of clothing can be 3 single pieces (top and bottom) or full body. Top-quality clothing specially developed for heavy usage in industrial settings is designed with movement and safety in mind. An industrial-grade undergarment with thermal properties is ideal for wearing under the warehouse uniform.

Head and face

Most warehouse environments require workers to wear a hard hat, but a thermal tuque should be worn underneath in cold weather, as heat escapes easily from the head. Workers dedicated to freezing conditions, such as the ones working in a freezer warehouse, will greatly reduce the risk of discomfort by also wearing a facemask. 

Hands

Many warehouse positions require a dual approach to hand cold protection:

• One pair of large pair of thermal gloves or mittens for general work
• One pair of smaller and finer gloves for minute tasks

Footwear

You'd be surprised how quickly freezing floors are felt through poorly insulated footwear, and for this reason, cold warehouse workers need to wear industrial-grade boots. Although keeping your feet warm is top priority, protection against common industrial injuries must be provided, and winter boots equipped with steel toe caps are necessary. Although your staff will be working indoors most of the time – thus diminishing the requirement for heavy-duty snow boots – you will have to anticipate some exposure to snowy conditions, especially if someone is tasked with snow removal. Finally, we recommend polypropylene socks; not only do they provide long-lasting cold protection, but are also very durable and easy to wash and dry.

Here are some of the better-known workplace work boot brands:

• CAT
• CATERPILLAR
• TIMBERLAND 

Strategies for working in a refrigerated warehouse

Although clothing is the first step to ensure a comfortable workday in a freezing storage facility, companies can follow a few more pieces of advice to enhance their staff experience and lessen the hardships common with cold conditions.

Provide a warm room for breaks

A properly heated room will go a long way in providing a restful space where employees can take breaks, drink coffee and have lunch.

Provide time to take warm breaks

The body struggles when exposed to freezing temperatures for long periods of time. Warehouse employees working in freezing environments may require a 10-minute break every hour.=

Encourage staff to eat a healthy and balanced diet rich in carbs

The body going through physical work in cold conditions consumes vast amounts of energy, and eating a well-balanced diet is a must. Foods rich in complex carbs such as rice and potatoes make great winter fuels, as the body uses them most efficiently. Other than lunch, encourage your employees to enjoy a healthy snack during breaks.