Development of a New Door System with High Thermal Resistance and Improved Sealing Performance for Refrigerated Display Cabinets

In this study, a new door system design was developed for the door-to-door and door-to-frame junctions of the Refrigerated Display Cabinet (RDC), where energy savings are concentrated. The aim is to improve sealing performance by reducing thermal bridges, thereby reducing the system's overall energy consumption. As part of the design, the silicone filling volume in the door bottom mold was increased, a magnetic seal element was integrated, and a new door gasket was developed. Test studies were conducted in accordance with ISO 23953-2:2023, and comparative analyses were performed using the current system. Experimental results showed that the new design improved heat transfer efficiency by increasing the temperature difference between the evaporator inlet and outlet. Additionally, the average product temperature in the cabinet was improved by up to 5%. According to energy consumption analyses, annual energy consumption decreased from 13,231 kWh to 6,906 kWh, resulting in approximately 47.8% energy savings. Carbon emissions calculations over a ten-year lifespan showed a decrease from 82,033 kg of CO₂ to 42,816 kg of CO₂. As a result, the new door system was evaluated as a long-lasting solution that increases energy efficiency, contributes to environmental sustainability, and provides a more sustainable solution.