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Working in cold storage environments presents unique challenges for workers, particularly when it comes to layering for freezer work. When faced with temperatures that can plummet to -30°C or below, how many layers is enough?
Addressing such questions is vital as the correct choice of clothing is essential, not just for comfort but for safety and productivity.
In this article, we explore the critical concept of layering for freezer work, highlighting how to achieve both maximum warmth and mobility.
When working in extremely cold environments like freezers, there are three main risk categories to be aware of:
In the face of such risks, it is important to remember that wearing one thick layer of clothing is not enough. The secret to staying warm while maintaining mobility lies in layering, which allows you to trap heat efficiently, regulate body temperature, and adapt to changing conditions throughout the workday.
Each layer of clothing serves a specific function:
This multi-layered system ensures that workers stay warm without feeling restricted, allowing for freedom of movement during physically demanding tasks. Let’s delve deeper into the individual function of each vital layer.
The base layer is the foundation of any effective layering system. When you’re working hard in a freezer environment, it’s not uncommon to sweat. Sweat, if not managed properly, can quickly cool down and lower your body temperature, leading to a dangerous situation.
Choosing the right material for the base layer is crucial. It should be designed to move moisture away from the body, keeping you dry and warm.
Here at Ark Safety, we offer a range of thermal base layers made from advanced materials such as merino wool blends or synthetic fabrics like polyester. These materials excel at pulling moisture away from the skin, allowing it to evaporate instead of clinging to your body and making you cold.
Avoid cotton for this layer, as it tends to absorb moisture and hold it, creating a cold, clammy feeling that can contribute to hypothermia in extremely cold conditions.
The job of the mid-layer is to trap warm air close to the body, providing a buffer between your body heat and the cold environment. Effective insulation is all about the material’s ability to trap air, creating pockets of warmth.
Insulating materials like fleece, down or advanced synthetic fibres are highly effective at maintaining warmth without adding unnecessary bulk. Down is a popular choice for its superior warmth-to-weight ratio, but it can lose its insulating properties if it gets wet. That’s why many freezer workers opt for synthetic alternatives, which perform well even in damp conditions.
It’s also important to consider flexibility when choosing a mid-layer. Insulating garments should be thick enough to keep you warm, but not so bulky that they hinder movement. Choose a workwear provider that prioritises ergonomically designed clothing, allowing for a snug but flexible fit, ensuring you can move freely and easily handle your tasks.
The outer layer is your first line of defence against external elements. While most freezer environments are sheltered from rain, wind and humidity can still pose a risk to workers. A good outer layer needs to be windproof and water-resistant to protect the inner layers from exposure, while still allowing moisture from sweat to escape.
Our freezer work jackets and overalls are designed to provide maximum protection against cold, wind and moisture. These garments have features like sealed seams, high collars, adjustable cuffs and durable zippers to ensure no cold air can penetrate.
One thing to remember when considering the outer layer is striking a balance between warmth and mobility. While a thick, heavy-duty outer jacket may seem like the obvious choice for a freezing environment, too much bulk can restrict your movement. Choose something lightweight that won’t weigh you down, ideally with reflective strips for enhanced visibility in low-light conditions.
No layering system is complete without the right accessories. Extremities like hands, feet and the head are particularly vulnerable to harsh temperatures, and failing to protect them can result in workers suffering from cold-related illnesses like frostbite or hypothermia.
Insulated gloves with a waterproof outer layer and fleece or synthetic liners are essential for handling materials in the cold without losing dexterity. Similarly, thermal socks made from wool or synthetic blends paired with insulated, slip-resistant boots will keep your feet warm and dry throughout the workday.
While layering is crucial for warmth, it is equally important not to over-layer. As we already touched on, too many bulky layers can restrict movement, which could lead to reduced productivity and even injury. Here are some tips to help maintain the balance between warmth and mobility:
Each layer should fit snugly but not tightly. This ensures good insulation without cutting off circulation or restricting movement.
Modern insulation materials are designed to provide maximum warmth with minimal bulk, so opt for lightweight layers that still offer the necessary protection.
Wet layers will cool your body rapidly, so ensure your outer layer is windproof and water-resistant, and your base layer wicks moisture effectively.
Be prepared to adjust your layering system as the day progresses. If you feel overheated, it may be necessary to remove a mid-layer to avoid sweating excessively.
Working in freezer environments requires careful consideration of how to dress effectively. By adopting a thoughtful layering strategy – starting with a moisture-wicking base layer, followed by insulating mid layers, and topped with a protective outer shell – workers can maintain optimal warmth and mobility, empowering them to handle the demands of freezer work.
The high-quality PPE and workwear solutions we offer at Ark Safety are designed specifically for cold environments, helping workers to stay warm, safe and comfortable without sacrificing mobility. Our comprehensive range of freezer wear ensures that workers across Ireland, Europe and the UK are protected, comfortable and mobile, no matter how cold their working environment may be.
Contact our experienced team of PPE specialists today for help creating the perfect safety wear solution for your needs.
