Presentation on theme: "LLOYD INSULATIONS (INDIA) LIMITED"— Presentation transcript:
1 LLOYD INSULATIONS (INDIA) LIMITED MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY
2 INDIA’S FOOD ECONOMYIndia is one of the largest producers of fruits and vegetables in the world.Inadequate handling infrastructure and methods result in a value-loss of over 30% of all fresh produce.There is no proper Cold Chain for any Agricultural/Horticultural Products
3 THE COLD CHAIN Harvest Cooling (pre-cooling) Cold Storage Transport to marketHandling at DestinationHandling at home or food service
4 MAINTAINING THE COLD CHAIN FOR PERISHABLESHarvestProtect the product from the sunTransport quickly to the packinghouseCoolingMinimize delays before coolingCool the product thoroughly as soon as possibleKeep the product at optimum temperatureShip to market as soon as possibleTemporary Storage
10 MODERN COLD STORES FOR TODAYS COLD CHAIN INDUSTRY Cold Stores Plays an Important Role in the Cold Chain
11 DEFINITION OF A COLD STORE A Cold Store IS A BUILDING OR A GROUP OF BUILDINGS WITH THERMAL INSULATION AND A REFRIGERATION SYSTEM, IN WHICH PERISHABLE FOODSTUFFS CAN BE STORED FOR VARIOUS LENGTHS OF TIMES IN SET CONDITIONS OF TEMPERATURE, HUMIDITY AND APPROPRIATE ENVIRONMENT TO SLOW DOWN DETERIORATION AND SPOILAGE, WHICH WOULD OCCUR IN A NATURAL ENVIRONMENT.
12 DEFINITION OF A COLD STORE A Cold Store may also be defined as a sealed structure the internal volume of which is maintained at a temperature generally below ambient & and other conditions and used for the storage of goods of all types, mainly foods.
13 DESIGN ASPECTS OF A COLD STORE The design of Cold Stores Stores follows what is known as a ‘Cold Store LOGIC’.The starting point is ‘Product to be stored’.Once the ‘Product’ is identified, it defines the ‘Optimum Storage Conditions’ (Temperature, Humidity and Environment).The ‘Packaging of the product’ both as received and as required at delivery (Handling) determines the type of Racking.The ‘Quantum’ to be handled and Held in Storage outlines the size of the store.The Location and its Ambient conditions then ensure the proper selection of the Five Elements of a Cold Storage.
14 ELEMENTS OF A COLD STORAGE The five important elements of a Cold Storage are:Land &Civil BuildingThermal Insulation (of Structure and Piping)RefrigerationMaterial Storage System (Racks)Product Handling TechniquesServices (Electricity, Water )
15 COLD STORE-SPECIFICATIONS THE CONDITIONS OF STORAGE Normal temperatures of storageDifferential of controlsDuration of storage, by product or category of productMethod of handling the loads (hand truck, pallet truck, fork-lift truck, rail)Method of stacking ( height of stacks, size of load units) theproduce which may if necessary, be stored together
16 COLD STORE - SPECIFICATIONS The StoreWhether it is to be set up in an existing building or a new building is to be constructedNumber of Refrigerated rooms and their configurationsLayout of the store and the machine roomMeans of accessCharacteristics of pre-existing equipmentConstraints if anyExtensions and future expansions
17 COLD STORE - SPECIFICATIONS The EnvironmentClimate:External temperatures during 6 hour period ( from 9.00 to 15.00)MaximumMinimumAnnual meanRelative humidity :Extreme valuesRainfall :Frequency,Degree of precipitation
18 COLD STORE - SPECIFICATIONS The Resources AvailableEnergy resources:nature, power, method of supplyWater resources:origin ( river, well, sea )temperature and flowchemical compositionpresence or absence of mud or sandLabor resources:local availability of labortechnical operating and control personnelhandling and general maintenancepersonnel
19 COLD STORE - SPECIFICATIONS Other Specifications:Maximum allowable heat ingress via the walls(5 to 6 W/m2 in frozen and 8 to 10 W/m2 in chill storage as per IIR guidelines)Special requirements of construction(e.g. resistance of the insulation to fire and insects, toxicity of the refrigerant fluid etc.)
20 NEED FOR EFFECTIVE LOW TEMPERATURE COLD STORAGE IN INDIA. India is a large producer of all kinds of Foods, of both Plant (living) and Animal Origin.India is also classified as having a Warm Tropical type climate for most of the year.With high ambient Temperatures (+35°C) and high humidity conditions, preservation techniques involving low temperature storage are mandatory for slower aging, for extending the Shelf Life and less loss of weight, inhibiting the growth of spoilage organisms, and restricting the development of Toxins.
21 NEED FOR LOW TEMPERATURE STORAGE (CONTD.) Fresh fruits and vegetables, being ‘living items’, are affected by the conditions under which they are stored and handled.They continuously influence their storage environment by heat of respiration, by gases exchanged (O2, CO2, C2H2), and the effect of Humidity.Correctly Designed and Operated Refrigerated Storage and proper handling Techniques as envisaged in a Cold Chain have a direct influence on quality at point of Sale and therefore the returns from the produce.
22 CONVENTIONAL COLD STORE The basic rules for insulation system are :Using good insulating material having a high insulating value, characterized by a low thermal conductivityProtection to the insulant against vapour ingress, by providing a Vapour Retarder applied directly to the wall to restrict migration of ambient atmospheric moisture into the cold room interior.Brick wallThermal insulationFinal finishBitumencement plasterVapor barrierMetal meshUse an interior lining on insulation essentially to prevent mechanical damagePlaster+Brick+Plaster+VB+Insulation+FinishApprox. 360mm wallLLOYD INSULATIONS INDIA LIMITED
23 CONVENTIONAL COLD STORES EXISTING SITUATIONInsulation Material – Expanded Polystyrene, PUF in 100 – 150mm on walls, fixed between wooden framework, Polythene sheet vapour barrier.Floor Insulation with EPS /PUFslabs – mm.LLOYD INSULATIONS INDIA LIMITED
24 EXISTING COLD STORE - PROBLEMS Moisture ingress thru porous plaster into insulation resulting into cold spots, Algae formationIneffective insulationImproper StorageProduct decayUnhygienic conditionsMore energy consumption due to more compressor running timeLLOYD INSULATIONS INDIA LIMITED
25 EXISTING COLD STORE – PROBLEMS, CONVENTIONAL PRACTICE Sequential application of vapor barrier, insulation & plaster finishWhat about moisture ingress from inside & life of plaster finishBasic Thermal & Civil Engg. Design problemBrick wall?Thermal insulationcement plasterFinal finishBitumenVapor barrierMetal meshLLOYD INSULATIONS INDIA LIMITED
26 EXISTING COLD STORE – PROBLEMS CAUSES OF THERMAL INSULATION SYSTEM FAILUREContinuous moisture ingress through plasterInsulation becoming wet & resistivity decreasesPlaster chipping offVapour barrier becomes weakFormation of cold spotsDeterioration & failure of Thermal Insulation System1 % OF MOISTURE INGRESS = 5 % REDUCTION IN ‘R’ VALUEDOUBLE MOISTURE ATTACKLLOYD INSULATIONS INDIA LIMITED
27 INSULATION LIFE Insulation needs to be properly fixed to surface Insulation needs to be covered & protectedCold Insulation needs vapour barrier on warm sideCold storage Insulation needs vapour barrier on both sides to counter moisture attack on both sides.LLOYD INSULATIONS INDIA LIMITED
28 ELEMENTS OF A MODERN COLD STORE The MODULAR Cold Stores requires the following:a) Pre-fabricated Steel Building (Single/Multi Level of storage)b) Pre insulated factory finished sandwich panelsc) Energy Efficient Refrigeration systemsd) Insulated Doors,e) Loading docksf) Racking systemg) Energy Efficient Lighting and Controlsh) Forklift Trucks
39 SALIENT FEATURES OF PUF/POLYISO PANELS High Strength to weight Ratio with Significant saving in Steel works and Load Bearing Foundation resulting in Large SpansHigh Thermal Efficiency ensures low Heat Transmission and Low Refrigeration CostNo Deterioration in Thermal Efficiency with TimeVertually Maintenance FreeDimensionally Very Stable12 m length Panels ensure less no of Joints and Fast Construction
40 LLOYD PRE-FAB PANELSLLOYD PRE-FAB PolyIso Panels Have been Tested at FM Approvals Lab at Rhode Island USA and are awarded FM Approvals Class I Certification.This is an Unique Achievement for an Indian Manufacturer
41 LLOYD PANEL SYSTEM- FOAM PROPERTIES - THERMAL Temperature Range C CWater vapor permeability ng/pasmThermal +10 C W/mK or Kcal/hr m deg C
43 LLOYD PANEL SYSTEM - FACINGS AVAILABLE SS 304 with /0.6 mm thickness with Strippable Plastic FilmSTELVATITE special Foodsafe coating of British Steel UK mm , 275 GMS/m2 , 15 0 microns filmPLASTISOL COATING HP 200 PVC coated steel 0.6 mm hot dip zinc coated steel to BS EN : 1991 in Fe PO2 G (Galvatite) with 275 GMS/m2 Galvanizing,SMP Coated 175 GMS/m2 Galvanized, 240 MPA steel
44 LLOYD PANEL SYSTEM- FOAM PROPERTIES - FIRE RESISTANCEHorizontal Extent of burn as per BS < 125 mm (PUF)< 25 mm (PIR)Fire retarded Foam giving a self- extinguishing Character on removal of ignition source
45 LLOYD PANEL SYSTEM- PANEL DETAILS DIMENSIONSLength : upto 12 m long (no joint)Width : mmThickness : 40/50 60/80/100/120/150/200 mmJOININGa)Tongue & Grooveb) Labyrinth Joint from a continuous line
46 LLOYD PANEL SYSTEM- DOOR DETAILS FREEZER & CHILL DOORS HINGEDDimensions : mm x 1800 mm1200 mm x 2000 mmSLIDINGDimensions : mm x 2500 mm2000 mm x 2500 mmDoors from BG Doors Holland,Metaflex India