How to know if your commercial fridge is overloaded?
This guide walks through what really happens when your commercial fridge gets overloaded.
21 August 2025
Overloading a commercial fridge is like running your van on flat tyres. It’ll get you there, but at what cost?
Yet across the UK, businesses often expect their fridges to support more than they’re designed for.
Overpacked commercial fridges work harder than they’re designed to do, and it’s hurting businesses more than they realise. This guide walks through what really happens when your commercial fridge gets overloaded.
When your fridge fights back: early warning signs of overloading
A commercial fridge looks solid. Stainless steel, thick doors, strong shelves. But pack it beyond its limits, and even the toughest unit will start to protest. The warning signs show up long before anything breaks.
The first sign is temperature. If you notice temperatures regularly exceeding 5°C, there could be all sorts of reasons. However, one reason is that the internal airflow may be blocked. Many commercial units use fan-assisted cooling to maintain a consistent interior temperature and humidity. When products block vents or cramp the fan’s space, that cold air can’t circulate. Warm pockets form, which means food spoils faster. HACCP temperature logs begin to show irregular readings, making it harder to prove food safety. And that’s a problem.
The next sign? Frost and ice. A thin build-up on the back wall or around the evaporator isn’t unusual. But thick ice in these areas signals a deeper issue, and airflow could be the culprit. When airflow is restricted, the evaporator coils get too cold. Moisture from the fridge air freezes on contact and, over time, this can damage the coils or force the fridge into a defrost cycle too frequently.
Then there’s the door. Items pushing against the door lining can prevent full closure, which can damage its seals and allow warm air in.
And finally, listen to your fridge. A well-running fridge hums now and then and stays silent the rest of the time. But an overloaded unit requires more cooling. This forces the compressor to run longer and harder. If the fridge cycles frequently or even constantly, or makes clicking or buzzing sounds, the compressor may be struggling. And internal airflow could be the reason.
The hidden costs of stuffing too much in
Overloading your commercial fridge might feel efficient in the moment. One more crate squeezed in. But the long-term costs can tell a very different story.
An overloaded fridge can use up to 30% more energy, depending on how badly the airflow is restricted. It might not seem like much right now, but consider that your refrigerator operates 24/7, 365 days per year. That’s a lot of money you don’t need to be spending.
What else is there to mention? Compressor strain leads to component failure and coolant leaks. Evaporator fans overheat. Sensors wear out early. Condenser coils get dirtier due to longer run times. Your unit might get more humid. And so on.
As a result, HACCP compliance becomes harder. If your logs indicate unstable temperatures or if probe readings vary across shelves, these are red flags for an auditor. Even if your food remains safe, inconsistent records raise concerns and can erode customer trust, something no business in the hospitality industry wants. It’s difficult to measure precisely, but a hit to your brand reputation is one of the costliest mistakes you can make.
And finally, breakdowns. If a fridge fails, urgent action is required. You’ll need to immediately move everything into a different fridge or, if it’s too late, throw everything away. Your staff might not be able to work that day. You might not even be able to open. You’ll need to make an emergency call to an engineer (more money) who might need to make an emergency repair (even more money).
Prevention in this case is far better than a cure.
What to do to avoid fridge overcrowding costs
On the plus side, planning helps avoid these situations. Here are a few things to implement to avoid those costs and keep your fridge operating at peak efficiency:
- Use load diagrams that show ideal shelf positions.
- Set daily airflow checks.
- Follow maintenance schedules, even if the fridge seems fine.
- Clean your condenser coils monthly.
- Check your door seals weekly.
- Log your compressor cycle times if possible.
Why airflow matters more than shelf space
The key to fridge efficiency isn’t how much you cram in, but how well cold air flows around the load. A fridge’s interior is basically a miniature climate system. Cold air flows across products, pulling heat out, which is the principle of ‘heat exchange’.
Blocking the evaporator fans prevents efficient circulation. Poor airflow means uneven cooling. Your front rows chill faster. Your back rows warm up. Condensation forms. Bacteria thrive in such conditions, as they’re conducive to growth.
Thankfully, it’s not the end of the world. There are several things you can do to help prevent this. The first thing to look at is proper shelf spacing. Leave at least 5cm between stacked items and avoid pushing containers flat against the back wall, where the cold air enters. Use perforated or wired shelving wherever possible, because that makes vertical airflow much easier.
Product placement also makes a significant difference. Heavier items belong on lower shelves. Lighter or frequently accessed products go higher up. This reduces the need for reshuffling and keeps the airflow channels clear. To help with this, consider labelling your shelves (on the front edges) to help keep your stock organised and avoid double-stacking. And on that note, ensure that all your staff follow a first-in, first-out (FIFO) system. FIFO means products nearing expiry don’t get lost behind newer ones.
If you find yourself rearranging items every time just to make the door close, it’s time to rethink your entire approach. It means you either need less stock or a bigger, more efficient refrigerator. Either approach could work. And if it’s a new unit you’re after, our expert team here at TEFCOLD UK can help.
Source your new commercial fridge from TEFCOLD UK
At TEFCOLD UK, we work with catering, hospitality and retail businesses across the UK, plus more sectors, ranging from cafes and fast-food outlets to convenience stores, pop-ups and luxury restaurants.
So, if your fridge looks full but seems unable to keep pace with your needs, speak to our team. We’ll help you find a commercial fridge that operates at maximum efficiency and minimal cost.
Get in touch with our friendly team today for a commitment-free chat to discuss your needs. We look forward to helping you identify the best commercial fridges for your business.