Drop-in Frost Tops

Drop-in frost tops are cooled trays with depth that are designed to hold pre-cooled and prepped dishes in desired temperatures for quick serving. They are commonly utilized in large cafeterias, hotels, restaurants, open buffets, salad bars, dessert stations, grocery stores, and more. Drop-in frost tops unite storage and display features in one body, allowing customers to browse and collect items without extra staff attention. They quicken the service process in commercial settings and store pre-cooked meals at optimal temperatures for everyone in line.

Drop-in frost tops work through a connection to a compressor and a condenser and similarly achieve cooling to commercial refrigeration units. Condensers of these units are usually bottom-mounted to save space, but there are other types, such as built-in and drop-in.

To make a lasting investment, it is crucial to thoroughly understand the key features of drop-in frost tops, such as thermostatic control, surface temperature range, materials, insulation types, surface finishes, cooling systems, energy-efficiency certifications, and customization options. These features define how much you’ll have to spend on the unit both upfront and long-term, whether it can fit in with your space aesthetically, what kind of products you can store and for how long, and what you should keep an eye on while shopping.

You should have a surface-level knowledge of the technical features of frost tops to buy the most durable and reliable unit and spot issues during the installation phase or throughout operations. Technical aspects of frost tops include but are not limited to types of refrigeration systems, compressor types and performance, refrigerant types, cooling solutions, electrical and ventilation needs, smart controls and automation, and energy conversion features.

You need to consider space and layout considerations, routine cleaning and upkeep needs, and common issues and solutions during the pre-purchase research. The right unit for your business will improve the aesthetic appeal of your self-serve area, offer versatility, maintain optimal temperatures for your products and extend their freshness, offer easy access for customers, and reduce labor and maintenance tasks for the staff.

To benefit from all these advantages, carefully assess your business needs and circumstances, such as the space you have, the volume you need, and your budget. The top brands and models with good reputations and reviews are a great place to start your search. A frost top is utilized in many industries, from catering to hospitality. Once you purchase, observe a boost in your daily workflow and customer satisfaction regardless of your sector.

What is a Frost Top?

A frost top is a refrigerated serving unit designed to hold and display pre-cooked and cooled products at optimum temperatures for the customer’s convenience in a self-service area. Drop-in frost tops have sufficient depth to store products while keeping them visible to the browsers. They have cooling mechanisms attached to their bodies and maintain temperatures between 32°F and 20°F (0°C and -6.667°C) unless set otherwise.

They can be commonly found in open buffets, hotel restaurants, school cafeterias, and similar spaces with self-serve stations. Frost tops are typically designed for indoor use and don’t perform as well outside room temperature, around 86°F (30°C). They are called drop-in frost tops because they are typically dropped into counters.

How Do Drop-In Frost Tops Work?

Drop-in frost tops utilize a refrigeration cycle to maintain low surface temperatures, ideal for keeping perishable items cool in food displays. The cooling cycle is almost the same as any refrigerated unit, with the key difference being focused and unified surface cooling. The refrigerant absorbs heat as it evaporates in the evaporator coil. The coils are tightly placed right underneath the surface to keep it cold. The refrigerant is then compressed, releasing heat in the condenser coils before re-entering the evaporator after passing through an expansion valve.

In addition to the cooling cycle, a good insulation layer, a sound thermostat, and high-quality build material are integral to the functioning of a drop-in frost top. A thermostat controls the temperature, ensuring consistency and reliability, while insulation and materials with high R-value and durability, like stainless steel with polyethylene foam insulation, aid in maintaining the desired temperatures.  

What are The Types of Drop-in Frost Tops Cooling Systems?

Drop-in Frost Tops types change according to the cooling system and installation style.

According to the cooling systems, static cooling, forced air cooling, and water cooling are 3 types of drop-in frost top cooling systems available on the market.

• Static Cooling: Static cooling relies on the refrigerant’s natural movement through the coils and does not utilize fans to push it around. The lack of fans and pressuring creates a far simpler mechanical design, which is ideal if you don’t have quick and easy access to professional maintenance.
  
  
• Forced Air Cooling: The forced air-cooling mechanism utilizes fans to move the air across the unit. While the structure of these units tends to be slightly more complicated, the fans help lighten the temperatures across the frost top.
  
  
• Water Cooling: Water-cooled units utilize chilled water to create and maintain desired temperatures. This method is energy-efficient and frequently used in regions with higher ambient temperatures.

According to the installation types: built-in, drop-in, and undermount. Each option offers unique benefits depending on your space and operational needs. Below, we explore these installation types to help you decide which is best suited for your business.

• Built-in: Built-in frost tops are designed to be seamlessly integrated into countertops or workstations, creating a sleek and professional look. These units are typically permanently installed and ideal for businesses requiring a long-term, fixed solution for displaying or serving chilled items.

• Drop-in: Drop-in frost tops are designed to fit directly into a pre-cut countertop space, making them versatile and easy to install. This type allows for flexibility in layout, enabling businesses to integrate the unit where needed without requiring permanent modification.

• Undermount: Undermount frost tops are installed beneath the countertop, creating a smooth, flush surface that enhances aesthetics and functionality. This installation type allows easy cleaning and a streamlined design, often used in modern or upscale foodservice settings.

What are The Key Features of Drop-In Frost Tops?

Thermostatic control, surface temperature range, material, insulation, surface finishes, customization options, efficient cooling systems, and Energy Star compliance are the 8 key features of drop-in frost tops.

Thermostatic Control

Thermostatic controls on a drop-in frost top allow for precise setting and monitoring of temperatures. An advanced thermostat allows you to keep tabs on fluctuations and correct deviations.

Surface Temperature Range

The surface temperature range of a drop-in frost top unit is typically from 32°F to 20°F (0°C to -6.667°C), and the factory default set point is always 32°F (0°C). You can adjust the temperature based on the products you are storing.

Material

4 main material options for drop-in frost tops are aluminum, granite, stainless steel, and swanstone. You can decide based on your countertop’s material to match the drop-in’s color and texture. Other than that, each option has its pros and cons. Aluminum is a cheap and lightweight material. It is resistant to rusting and has a shiny sheen to it. However, aluminum units won’t be as durable and more susceptible to denting.

Stainless steel is the most common option for commercial equipment thanks to its reliability, durability, and resistance to corrosion and denting. It is heavier than aluminum but can withstand more weight than aluminum.

Granite is never used to make a full frost top, but it is a material used alongside stainless steel for the top surface. As a natural stone, it has an unmatched aesthetic appeal, and granite’s weaknesses, such as being porous and susceptible to cracking, are usually compensated for using stainless steel. However, these models could be slightly more expensive and have a few extra benefits.

Swanstone is a man-made compression molded acrylic and mineral blend referred to as a solid surface. Swanstone is cheaper than granite and surpasses most materials in durability and resilience.  It requires little to no maintenance, a huge advantage for frequently used commercial equipment.

Insulation

Insulation is key to the efficiency of any refrigerated piece of equipment. Drop-in frost tops aren’t meant for long-term storage, so their cooling cycle won’t be as efficient as a full cooler’s cycle. A thick, high-quality insulation layer can maximize the storage time you can get out of a frost top. Aim for an R-value of 20 to 30 in your frost top. You can opt for one of the popular insulation materials for the best results: polyurethane foam, XPS foam, or polyethylene.

Surface Finishes

Drop-in frost tops’ surface finishes vary to suit different aesthetic and functional requirements. For instance, brushed stainless steel provides a sleek, modern look that is easy to clean and maintain, making it ideal for front-of-house applications. Other finishes might include custom colors or textures to match the decor of a specific establishment. You can even emboss the surface with your logo to customize your unit further. Your choice of surface finish will impact the unit’s resistance to scratches and casual wear and tear, an important consideration in high-traffic areas such as self-service stations. Stainless steel is a safe choice in any case.

Customization Options

Customization options for drop-in frost tops allow establishments to tailor their units to their specific functional and aesthetic needs. This might include custom dimensions and shapes to fit a unique space and additional features such as integrated lighting or sneeze guards, branding on the surface, added lids, etc. You can contact your local dealer to learn about their services if you need one or a few customizations.

Investing in a custom unit will decrease the resale value of the unit. Still, it will ensure that the frost top fits seamlessly into the existing setup and enhances your food service area’s overall functionality and aesthetic. This flexibility is valuable in creating a cohesive and efficient food display in self-serve stations with minimal staff attention.

Efficient Cooling Systems

Efficient cooling systems for drop-in frost tops can elongate the shelf life of your products. You can invest in one of the three main cooling systems for different benefits. Static cooling will work quieter and require a simpler maintenance run. Forced air cooling will ensure the cool air is evenly distributed across the unit but will be slightly noisier due to the fans, which might not be great for your staff. Hydronic cooling will work great in heightened ambient temperatures and prove efficient, but it might require slightly more frequent check-ups and a connection to drainage.

Energy Star Compliance

Energy STAR compliance of a drop-in frost top certifies the unit’s energy efficiency. With such a small step, you can significantly reduce your carbon footprint and utility bills. Keep in mind that ENERGY STAR is a US-based certification, and in Europe, energy certifications use A+ to signify a unit’s efficiency.

What are the Technical Aspects of Drop-in Frost Tops?

You should know about 10 technical aspects of drop-in frost tops before investing:

• Available types of refrigeration systems
• Compressor types and performance
• Space and layout considerations
• Smart controls and automation
• Cooling solutions
• Eco-friendly refrigerants
• Energy conservation technologies
• Electrical and ventilation needs
• Routine cleaning and upkeep
• Common issues and solutions.

Having a keen grasp on these subjects helps you search for the best drop-in frost top for your establishment.

1. Types of Refrigeration Systems

Types of refrigeration systems used in drop-in frost tops include self-contained and remote systems. Self-contained systems have all components integrated within the unit in one place, making them easy to install and maintain. However, having the compressor with your unit can generate unwanted nuisances such as heat and noise. In remote systems, the compressor and condenser are located away from the display area to help reduce noise and heat in the service area. This refrigeration system requires more complex installation and maintenance but could be worth it for your customers’ convenience.

Compressor Types and Performance

Compressor types and performance are directly related. There are two main types of compressors: reciprocating compressors and scroll compressors. Reciprocating compressors are commonly used for their reliability and efficiency for small to medium-sized applications. Scroll compressors are mostly known for their quieter operation and higher efficiency and are preferred for larger units and continuous operation settings.

The compressor’s capacity is measured in BTUs (British Thermal Units), and it should match the cooling requirements of the frost top to ensure optimal performance and energy efficiency. High-performance compressors help maintain consistent temperatures even under heavy usage.

Space and Layout Considerations

Space and layout considerations are key for installing and operating drop-in frost tops. The unit must fit within the designated counter or display area with adequate clearance for ventilation and maintenance. You should leave a 3 inch (7.62 cm) allowance on all sides and keep the unit away from combustible materials.

The layout should allow easy access to power sources and drainage if necessary. Consideration of traffic flow around the unit is important to ensure that it does not obstruct service or customer access since these units aim to satisfy self-serve needs.

The surrounding environment’s temperature and humidity levels can affect the unit’s performance, so proper placement is crucial. An ambient temperature exceeding 86°F (30°C) will negatively impact the unit’s performance. Try to keep it indoors and away from direct sunlight.

Smart Controls and Automation

Smart controls and automation features on drop-in frost tops aim to improve their functionality and ease of use even more. Most common features include digital thermostats, monitoring and alarm gadgets, remote controls, data logging, and more.

Digital thermostats provide precise temperature control and monitoring, ensuring consistent cooling performance. Some units come equipped with programmable settings that allow operators to set different temperatures for various times of the day, optimizing energy use. Remote monitoring and diagnostics enable technicians to troubleshoot and adjust settings from a distance.

Cooling Solutions

Cooling solutions for drop-in frost tops impact the overall efficiency and performance of the unit. There are three common methods. Static cooling systems rely on natural convection to function quieter and be more energy efficient. However, its distribution of the cool air could be potentially less uniform.

Forced-air cooling systems use fans to circulate cold air, ensuring even cooling across the surface, which is ideal for high-demand environments. Yet, the fans are bound to make noise and warrant extra maintenance. Hydronic cooling systems, which circulate chilled water or glycol, offer precise temperature control and energy efficiency, making them suitable for applications requiring strict temperature maintenance.

Eco-Friendly Refrigerants

Refrigerants are the cooling agent gases used in refrigeration units. As the markets are phasing out the dangerous refrigerants, they are introducing more eco-friendly options. You can opt for variants such as R-32, R-513A, R-600. These options have significantly lower Global Warming Potential (GWP) and are not ozone-depleting.

Energy Conservation Technologies

Energy conservation technologies in drop-in frost tops can significantly improve the unit’s efficiency and lower utility bills. Features such as variable speed compressors, which adjust the cooling capacity based on demand, can significantly reduce energy consumption. Energy-efficient fans and LED lighting contribute to lower power usage. Implementing these technologies reduces operational costs and supports sustainability efforts by minimizing the unit’s carbon footprint.

Electrical and Ventilation Needs

Drop-in frost tops’ electrical and ventilation needs require careful attention before and during installation. The unit requires a dedicated electrical circuit to ensure a stable power supply and prevent overloading. The voltage needed for each unit is specified in the product’s operation manual. Adequate ventilation around the unit, especially for self-contained systems, is necessary to dissipate the heat generated by the compressor and condenser. Poor ventilation can lead to overheating, reduced efficiency, and increased wear on the refrigeration components.

Routine Cleaning and Upkeep

Routine cleaning and upkeep of a drop-in frost top are essential to keep the unit functioning efficiently for as long as possible. You can follow these 3 basic cleaning principles to ensure the longevity of your unit. Firstly, you should clean the surface to remove any food residues, which can affect cooling performance and hygiene daily. Secondly, the condenser coils should be cleaned regularly to ensure efficient heat exchange. Thirdly, checking and replacing worn-out gaskets and seals can prevent cold air leaks, maintaining the unit’s efficiency.

For upkeep, you should establish a routine maintenance schedule. Tasks, such as inspecting the compressor and refrigerant levels, help identify potential issues before they become major problems and ensure reliable operations. You should schedule professional check-ups at least once a year to be on the safe side.

Common Issues and Solutions

Understanding common issues and their solutions can help maintain the reliability of drop-in frost tops and help you resolve issues before they become irreversible. The most common issues include temperature fluctuations and frost build-up. Issues like inconsistent temperature can be traced to thermostat malfunctions or refrigerant leaks. You should monitor the thermostat readings and occasionally compare them to an external one to ensure they are in working condition.

Frost build-up on the surface may indicate poor insulation or frequent door openings. Regular inspection and maintenance can prevent these problems. A troubleshooting guide and a regular maintenance schedule can help quickly resolve common problems and maintain the unit’s performance.

What are The Benefits of Drop-In Frost Tops?

There are 6 main benefits of drop-in frost tops for your business: aesthetic appeal, versatility, maintaining optimal temperatures for cooled products, extended freshness, ease of access and service for the customers, and reduced labor and maintenance needs from the staff. These benefits will make your workflow smoother, reduce the pressure on your staff, create a more welcoming atmosphere, and boost your profits.

Aesthetic Appeal

Drop-in frost tops are display units at their cores, and by holding and showcasing your vibrant products with their shiny finish, they can improve the aesthetic appeal of your space. Open buffets in the hospitality industry can use this benefit to their advantage by making their guests’ self-serve experience feel more luxurious.

Versatility

Drop-in frost tops are a jack of all trades since they unite display and storage features in one body and minimize staff labor by being accessible to customers. They are lightweight and easy to store when not in use. The versatility aspect of frost tops is highly beneficial to mobile businesses such as caterers. You can get 2 functions with one purchase, and you don’t need to spend too much effort or time on it.

Maintaining Optimal Temperatures

Pre-cooked and pre-cooled products require optimal storage temperatures to stay fresh and healthy. Drop-in frost tops can maintain optimal temperatures while storing and displaying the items for the customers’ attention. This feature is great in cafeterias with long lines or grocery stores needing all-day storage and display units. By preserving the products in top condition, you can ensure that every customer, whether at the front or end, can get the same quality out of their purchase. You will extend the shelf life of your food while boosting customer satisfaction!

Extended Freshness

Extended freshness of pre-cooled products is a huge perk of drop-in frost tops. Frost tops are usually used in self-service stations, and the products placed in these sections can go unattended for a long time. The cooling mechanism attached to frost tops ensures that your products are as fresh as possible for browsing customers and require very little attention in terms of preservation from your staff.

Ease of Access and Service

Ease of access and service is the biggest selling point of drop-in Frost Tops since, through this feature, they promote self-service instead of constant staff labor. Minimizing staff attention during the service will boost your profits since you will need a less crowded team and will be able to utilize their abilities more efficiently. Self-service is a popular choice among customers, thanks to the freedom it grants them while they browse.  

Reduced Labor and Maintenance

Drop-in frost tops reduce labor and maintenance needs significantly. The cooling mechanisms attached to their bodies are fairly simple, staff attention is not needed thanks to the self-service compatibility, and the casual use of the frost tops doesn’t warrant too much wear and tear as it is. You can expect a lot of use from a drop-in frost top before it malfunctions.

How to Choose the Right Drop-in Frost Top for Your Business

To buy the right drop-in frost top for your business, you should first assess your needs in terms of volume and usage, consider your space availability and budget, and look into the top brands and models to compare and contrast.

Assessing Business Needs

Assessing business needs is a two-stage process. First, you need to consider your circumstances, and then you can move on to your demands. Since you can’t fit a 15×15 unit in a 5×5 counter, any considerations before considering the space availability are unhelpful. Measure your area and counter carefully and as precisely as possible. Try to note down any additional space that might be utilized later if the current space doesn’t meet the demand.

Then, consider the volume you will need based on the daily demand you expect. While the demand is pretty much fixed for cafeterias and hotels, grocery stores and similar might be better off opting for medium to large frost tops to be safe.

Consider Your Budget

You should budget carefully before investing, both for the initial and long-term costs.

• Initial Investment vs. Long-Term Savings: The upfront cost of a drop-in frost top can range from as low as $2,600 to $14,000. The price depends mostly on the size and material of the unit. While you might gravitate towards the cheapest option, you should consider long-term costs before making that decision.
  
  Having an ENERGY STAR certification, using eco-friendly refrigerants, having a simpler mechanical make, being made of sturdier materials like stainless steel, being the product of a known brand, and more are all factors that could raise the price of a unit. Yet, most of these qualities are worth the buck in the long run.
  
  For instance, energy efficiency will lower your utility costs, being made of sturdy materials will ensure the longevity of your investment, and shopping from a known brand will ensure reliable support in case of a breakdown. These benefits will mitigate the long-term maintenance and operation costs. You should strive to maximize long-term benefits while sticking to your initial budget.
  
  
• Financing Options: If you don’t have thousands lying around, you don’t need to worry since many dealers offer flexible financing options now. Net 30 is a popular perk that lets you postpone the payment for 30 days. Instant rebates, which means getting a discount right on the spot before the purchase, are growing more common to gain customer trust. Financing plans vary from dealer to dealer, but you can expect to pay the cost of the unit in monthly installments that won’t break the bank.

Compare Brands and Models

Working with an established brand and buying a highly reviewed model is important to ensure the unit’s reliability and the support system behind the warranty. Here is a breakdown of the 8 most popular brands for drop-in frost tops.

• Atlas Metal: Atlas Metal prides itself on being extremely hands-on and strives to create long-lasting customer relationships. You can count on an Atlas warranty and support network should anything go wrong with your unit since the brand understands how precarious and difficult it is to work in the food industry.
  
  
• Delfield: Delfield is an established name in the industry. It offers standard 90-day labor and a 1-year parts warranty. Delfield N8273P is one of the brand’s top-selling units, and it is widely bought thanks to its UL and NSF certification, convenient installation, and use of eco-friendly R290 refrigerant.
  
  
• Hatco: Hatco is an innovative brand, and it is possible to find programmable controls and patented thermal breaks, which reduce condensation, on their drop-in frost tops. Hatco offers 2-3 different color options for their products.
  
  
• Piper Products: Piper Products have been in the industry since 1960. Since they started their journey as a catering company initially, they now mostly specialize in catering and buffet equipment. Their drop-in frost tops are manufactured with intimate knowledge of customer needs and are highly popular among business owners.
  
  
• Randell: Randell products are Made in the USA, NSF, and are UL certified. They are available in many sizes and dimensions and mostly in self-contained format for easy access and maintenance. Their bases are slightly rotatable, making ventilation, infrastructural connections, and maintenance easier. They use eco-friendly refrigerants.
  
  
• Rotisol USA: Rotisol USA drop-in frost tops tend to be pricier, thanks to their granite tops, which are somewhat of a rarity in the industry. Granite tops offer an extra sleek and aesthetic look that cannot be achieved otherwise, and they are far more durable than aluminum and other similar material options.
  
  
• Vollrath: Vollrath was founded in 1874 and has a big legacy of providing value to businesses with high-quality and innovative products. Sustainability and offering customized solutions are two of their biggest focus as a brand. You can acquire a reliable frost top from Vollrath, and rest assured that you have a titan in the industry behind your product.

Industry-Specific Applications

Drop-in frost tops are versatile pieces of equipment with varied industry-specific applications. They can be found in various settings, such as ice cream shop supplies and hotel restaurant equipment.

• Ice Cream Shops: Ice cream shops can utilize drop-in frost tops to preserve pans of ice cream while keeping them open for customer browsing. Drop-in frost tops can be easily integrated into the counter, benefiting your business.
  
  
• Hospitality and Catering: Hospitality and catering industries serve large masses over short periods, and having self-serving buffets is a lifesaver for those working in these industries. You can put half of your menu, drinks, desserts, and more into a drop-in frost top, and rest assured that each guest will get the same quality product with no attention needed from you.
  
  
• Retail and Supermarket: Retail and supermarkets incorporate frost tops into deli counters and salad bars to enhance product appeal and promote free browsing. The accessibility and ease of use of these units are perfect for grocery stores.
  
  
• School Cafeterias: School cafeterias are similar to hotels in that they serve many people in short periods, and they need to delegate as much as possible to make that happen. Frost tops can hold and display various food items and allow students to pick them up for themselves to quicken the service process.

Conclusion

Drop-in frost tops are invaluable in various commercial environments, from cafeterias to hotel restaurants, by maintaining optimal temperatures for pre-prepared dishes and enhancing the efficiency of self-service operations. A comprehensive understanding of features like thermostatic control, material composition, insulation, and surface finishes is crucial for making a well-informed investment. Additionally, knowledge of the technical aspects such as refrigeration systems, compressor performance, and smart controls is essential for selecting a reliable unit.

Choosing the right frost top boosts the visual appeal of your service area and enhances operational efficiency and customer satisfaction. Considering factors like space, volume needs, and budget, you can find a model that integrates seamlessly into your business. Whether in catering or hospitality, a high-quality drop-in frost top will significantly improve workflow and customer experience regardless of your industry.