Specifying thermal workwear for a cold storage operation is not as straightforward as it might seem. A freezer jacket that works for a forklift driver sitting relatively still in a blast freezer is not the same garment that suits a picker moving between ambient and chilled zones throughout a shift. The exposure profile, the activity level and the temperature range all affect what a garment needs to do.
Getting that wrong has real consequences. Workers who are under-insulated for their environment are at risk of cold stress. Workers who are over-insulated for their activity level overheat during physical tasks, which creates its own set of problems. Sweat build-up against the skin accelerates heat loss when activity drops, often at exactly the point when a worker enters a colder zone.
The ThermaZone Insulation System is Badger’s way of making this simpler to get right.
How the system works
ThermaZone is a colour-coded badging system that matches garments to the environment and activity level. Rather than leaving procurement teams to compare thermal ratings across a catalogue and work out what fits their conditions, the system does that matching for them.
It is built around four ranges:
Winta (Blue) — Maximum insulation for outdoor environments. Designed for workers exposed to cold outdoor temperatures, or those needing added warmth while wearing PPE. Rated from -5°C upward at low to moderate activity levels.
Winta (Blue) — Maximum insulation for outdoor environments. Designed for workers exposed to cold outdoor temperatures, or those needing added warmth while wearing PPE. Rated from -5°C upward at low to moderate activity levels.- Chilla (Red) — Light insulation for active users in cold conditions. Well suited to pickers in chillers, moderate freezer environments, or forklift drivers completing low-level activity in cold zones. Rated down to -15°C.
- Freeza (Orange) — Mid-level warmth for more demanding cold environments. The primary choice for pickers in freezers or forklift drivers in chillers. Rated down to -40°C.
- Xtreme (Green) — Maximum protection for the most demanding conditions. Suited to forklift drivers in freezers, pickers in blast freezers, or workers with poor blood circulation operating in sub-zero or static environments. Rated down to -50°C.
The colour coding is not just a visual aid. It is the mechanism that makes the system work at scale. When an operations manager or procurement team needs to spec workwear across multiple roles and temperature zones, having a consistent and visible system reduces the chance of the wrong garment ending up in the wrong environment.
What EN342 certification means in practice
Badger’s range of Chilla, Freeza and Xtreme garments in the ThermaZone range are certified to the EN342 standard. EN342 is the European standard for protective clothing against cold. It covers insulation performance, wind resistance and the conditions under which a garment provides adequate protection.
For safety managers, that certification means the thermal rating on the garment label reflects independently verified performance, not a manufacturer’s claim. It provides a defensible basis for workwear selection when cold hazard assessments are part of the site’s WHS obligations.
Matching ThermaZone to your site
A few practical considerations when applying the system to a cold storage or logistics operation:
- Workers moving between temperature zones in a single shift may need layering options rather than a single outer garment. ThermaZone ranges are designed to work as part of a layering system, not just as standalone products.
- Activity level matters as much as temperature. A Freeza-rated jacket on a worker doing high-exertion picking in a freezer may result in overheating. Consider whether a Chilla mid-layer with a Freeza outer gives more flexibility across varying workloads.
- Compliance requirements for cold storage environments often include hi-vis. ThermaZone includes hi-vis options across the range so thermal protection and visibility compliance can be addressed together.
- Workers with poor circulation or existing cardiovascular conditions may require a higher-rated garment than the standard site specification. Xtreme exists for exactly this reason.
If you are reviewing workwear specifications for a cold storage or logistics operation, the ThermaZone system is a practical starting point. The Badger team can help match the right range to your specific site conditions, temperature zones and workforce profile.
View the ThermaZone range of products: https://www.badgeraustralia.com.au/product-category/cold-storage-workwear-ppe/chiller-freezer-wear/
