It’s an amazing time of the year. With the holiday season upon us, one overlooked factor is the incredible task that must be accomplished at the North Pole’s toy factory. As you can imagine, the cold harsh environment is not the ideal location to put a factory of this magnitude. Recently, the CEO of the vast toy manufacturing empire explained how one product helped immensely. Mr. Claus was very excited about how rapid speed insulated roll up doors changed his product delivery and increased elf productivity.
The weather conditions can change rapidly at the North Pole. Year round, masses of very dense cold air hover above the North Pole due to the low angle of the sun’s rays. This results in that geographic area losing more heat than other areas – making for a very cold factory. The elves started to complain. Mr. Claus decided to install insulated roll up doors on all exterior door openings. But just having insulated overhead doors was just a first step. The team at Santa, Inc. wanted a way to stop the arctic air from leaking in when the coiling doors were closed, too. Luckily they were able to find insulated rolling doors with an advanced overhead door perimeter seal system that decreased the air leakage 94% to less than 0.3cfm/ft2. The thermal qualities of these insulated roll up doors lead to a happier workforce and a huge savings in heating costs. With the cold, icy winter lasting 9 months, Mr. Claus expects significant savings.
During the peak season of 31 hours between December 24th and December 25th, Santa, Inc.’s manufacturing output increases by 132,000,000%, a unique and challenging issue. Due to the fact that Mr. Claus’s corporation does its own deliveries, the extreme cold and winter weather makes heating and outside environmental issues a major concern. With an average delivery schedule of 1,178 units per second, reload times were a big concern. Mr. Claus wanted to make sure that any insulated roll up doors installed were not only the most energy efficient, but had fast open and close cycles. The delivery vehicle travels at approximately 650 miles per second, making every second count. With standard overhead coiling doors opening at the rate of 8 seconds per inch, installing insulated high performance overhead doors increased reload and delivery times by 3x!
After considering the energy efficiency and rapid open and close rates for insulated roll up doors, Mr. Claus said that reliability was another top concern. With one of the tightest delivery schedules in the business, Santa, Inc.’s reputation has been stellar for years. One mechanical mishap with any rolling garage door could be catastrophic to its business reputation. When Mr. Claus chose the new insulated roll up doors, he insisted on door solutions that would open and close for a minimum of 300,000 maintenance free cycles. However, he decided to up the requirement to a 1,000,000 cycle door in some key areas. He didn’t want to worry that any of the insulated overhead doors would cause even the slightest delays in deliveries during peak delivery times.
While the team at Santa, Inc. was excited that the proposed insulated roll up doors offered a thermal perimeter seal for ultimate energy savings, fast open and close rates and peace of mind with long maintenance free cycles, there were still some other features that excited the company. Safety had been a concern in the past. Many factory workers were of below average height, and, while their unique stature is great for assembling small items, standard eye beams associated with other overhead rolling doors could miss the varied height of the workers native to this area. The solution was to make sure all the installed insulated doors also had advanced SafetyGard Light Curtain technology. This advanced system creates an optical light curtain approximately six feet high from the finished floor. If any object breaks the plane of the light curtain, the door will automatically reverse to the open position. The labor union was pleased with this additional safety measure.
After searching and researching, Mr. Claus chose to go with insulated Extreme® High Performance rolling door products from Cookson. Its variety of overhead door products and combination of doors that can offer extremely energy efficient insulation, long lasting, no-maintenance cycles, higher speeds and advanced technology made it the easy choice. The combination of these factors make Extreme products a low lifetime cost, high return on investment solution for Santa, Inc.Happy Holidays!