Case Study: Solving Blast Freezer Caster Failures in Food Manufacturing Facilities
In food production and manufacturing environments, mobility is a critical requirement for safety and efficiency, especially in extreme conditions like blast freezers and cold storage. When standard casters fail at sub-zero temperatures, facilities face frozen wheels, safety hazards, compliance risks, equipment damage, and costly downtime. This case study shows how Caster Connection partnered with a U.S.-based ice cream manufacturer to quickly resolve caster failures inside a blast freezer, restoring safe, reliable mobility and confidence in daily operations.
Customer Overview
The customer is a U.S.-based premium ice cream manufacturer operating within a highly regulated food production facility. Their operation depends on mobile carts to transport product through blast freezers, cold storage, and production areas, where temperatures routinely reach -35°F to -40°F.
Like many food manufacturers, the customer required:
- Reliable mobility in extreme cold
- Food-safe, corrosion-resistant materials
- Load-rated caster systems compatible with existing carts
- A solution that could be implemented quickly without disrupting production
The Challenge: Caster Lockup in Extreme Cold Storage
The manufacturer initially purchased 5” x 1-1/4” CC Apex wheels through Caster Connection’s website for use on carts inside a blast freezer.
While suitable for many demanding applications, the wheels were not designed for extended dwell times in extreme sub-zero environments.
Key challenges included:
- Carts remained inside the blast freezer over the weekend
- By the start of the workweek, casters were frozen solid and unable to roll
- Employees were forced to push or drag immobile carts, increasing ergonomic and safety risks
- The issue resulted in an OSHA violation, requiring immediate corrective action
- Total scope: 240 casters
Additional Mounting & Load Issues
In an attempt to make the original casters fit their carts, the customer had been:
- Using custom-fabricated adapters to accommodate threaded stem casters
- Experiencing failures under load, as the stems and fabrications were not designed to handle the full weight of the carts
The facility needed more than a wheel swap—they needed a complete, application-specific mobility solution.
The Caster Connection Approach: Engineering a Purpose-Built Solution
Caster Connection worked directly with the customer to evaluate:
- Temperature exposure and dwell time
- Load capacity and weight distribution
- Cart design and leg dimensions
- Food safety, sanitation, and corrosion resistance requirements
- Urgency driven by OSHA compliance
Rather than offering a generic replacement, Caster Connection designed a cold-rated caster system specifically engineered for blast freezer applications in food manufacturing.
The Solution: A Cold-Rated, Food-Safe Caster System
Solid Nylon Wheels
- Designed to perform reliably in sub-zero temperatures
- Resistant to freezing, cracking, and deformation
- Ideal for blast freezer, cold storage, and frozen food production environments
Stainless Steel Swivel Forks
- Corrosion-resistant for washdown and sanitary conditions
- Suitable for food and dairy manufacturing standards
- Maintains structural integrity in cold environments
Stainless Steel Expanding Adapters
- Eliminated the need for failing custom fabrications
- Provided a secure, load-rated mounting solution inside cart legs
- Improved safety, durability, and long-term performance
Zerk Fittings for Low-Temperature Lubrication
- Allowed maintenance teams to inject low-temperature grease
- Prevented bearing lockup after prolonged freezer exposure
- Extended service life and reduced maintenance disruptions
Validation Through Testing
Understanding the urgency and risk, Caster Connection:
- Supplied sample caster assemblies immediately
- Enabled the customer to test the solution over a full weekend inside the blast freezer
- Confirmed performance before proceeding with the full deployment
The results were immediate:
- Casters remained fully mobile after extended exposure to -40°F
- No freezing, binding, or structural failures occurred
- OSHA concerns were resolved without further production interruption
The Results: Safety, Compliance, and Confidence
- OSHA violation resolved
- Reliable mobility in extreme cold environments
- Improved ergonomics and worker safety
- Elimination of custom mounting failures
- Reduced downtime and maintenance risk
Most importantly, the customer gained confidence knowing their caster system was designed for their environment—not adapted after failure.
Why This Case Study Matters for Food Manufacturing Facilities
Food production environments—especially those involving blast freezing or cold storage—require caster systems that can withstand:
- Prolonged exposure to sub-zero temperatures
- Heavy static and dynamic loads
- Sanitation and corrosion challenges
- Regulatory and safety scrutiny
Caster Connection helps food manufacturers across the U.S.:
- Prevent caster failures before they happen
- Maintain OSHA compliance
- Improve material handling efficiency
- Protect workers and equipment
Experiencing Caster Issues in Cold Storage or Food Production?
If your facility is facing:
- Casters freezing or locking in blast freezers
- OSHA or safety concerns
- Load or mounting failures on carts and racks
Start with a Caster Needs Evaluation and our team will help you implement a solution engineered for your environment.
