Presentation on theme: "LLOYD INSULATIONS (INDIA) LIMITED MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY."— Presentation transcript:
LLOYD INSULATIONS (INDIA) LIMITED MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY
INDIAS FOOD ECONOMY India 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
THE COLD CHAIN Harvest Cooling (pre-cooling) Cold Storage Transport to market Handling at Destination Handling at home or food service
Harvest Cooling Protect the product from the sun Transport quickly to the packinghouse Minimize delays before cooling Cool the product thoroughly as soon as possible Keep the product at optimum temperature Ship to market as soon as possible Temporary Storage MAINTAINING THE COLD CHAIN FOR PERISHABLES
SHADING TO PROTECT PRODUCE FROM SUN
COLD STORAGE FACILITIES
MODERN COLD STORES FOR TODAYS COLD CHAIN INDUSTRY Cold Stores Plays an Important Role in the Cold Chain
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.
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.
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 theOptimum 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.
The five important elements of a Cold Storage are: Land &Civil Building Thermal Insulation (of Structure and Piping) Refrigeration Material Storage System (Racks) Product Handling Techniques Services (Electricity, Water ) ELEMENTS OF A COLD STORAGE
Normal temperatures of storage Differential of controls Duration of storage, by product or category of product Method of handling the loads (hand truck, pallet truck, fork-lift truck, rail) Method of stacking ( height of stacks, size of load units) the produce which may if necessary, be stored together COLD STORE-SPECIFICATIONS THE CONDITIONS OF STORAGE THE CONDITIONS OF STORAGE
The Store Whether it is to be set up in an existing building or a new building is to be constructed Number of Refrigerated rooms and their configurations Layout of the store and the machine room Means of access Characteristics of pre-existing equipment Constraints if any Extensions and future expansions COLD STORE - SPECIFICATIONS
The Environment Climate: External temperatures during 6 hour period ( from 9.00 to 15.00) Maximum Minimum Annual mean Relative humidity : Extreme values Rainfall : Frequency, Degree of precipitation COLD STORE - SPECIFICATIONS
The Resources Available Energy resources: nature, power, method of supply Water resources: origin ( river, well, sea ) temperature and flow chemical composition presence or absence of mud or sand Labor resources: local availability of labor technical operating and control personnel handling and general maintenance personnel 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.) COLD STORE - SPECIFICATIONS
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.
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.
INSULATIONS INDIA LIMITED22 The basic rules for insulation system are : Using good insulating material having a high insulating value, characterized by a low thermal conductivity Protection 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. Plaster+Brick+Plaster+VB+Insulation+Finish Approx. 360mm wall Use an interior lining on insulation essentially to prevent mechanical damage Brick wall Vapor barrier Thermal insulation Bitumen Metal mesh cement plaster Final finish CONVENTIONAL COLD STORE
INSULATIONS INDIA LIMITED23 CONVENTIONAL COLD STORES EXISTING SITUATION Insulation Material – Expanded Polystyrene, PUF in 100 – 150mm on walls, fixed between wooden framework, Polythene sheet vapour barrier. Floor Insulation with EPS /PUFslabs – mm.
INSULATIONS INDIA LIMITED24 EXISTING COLD STORE - PROBLEMS Moisture ingress thru porous plaster into insulation resulting into cold spots, Algae formation Ineffective insulation Improper Storage Product decay Unhygienic conditions More energy consumption due to more compressor running time
INSULATIONS INDIA LIMITED25 EXISTING COLD STORE – PROBLEMS, CONVENTIONAL PRACTICE Brick wall Vapor barrier Thermal insulation Bitumen Metal mesh cement plaster Final finish Sequential application of vapor barrier, insulation & plaster finish What about moisture ingress from inside & life of plaster finish Basic Thermal & Civil Engg. Design problem
INSULATIONS INDIA LIMITED26 EXISTING COLD STORE – PROBLEMS CAUSES OF THERMAL INSULATION SYSTEM FAILURE Continuous moisture ingress through plaster Insulation becoming wet & resistivity decreases Plaster chipping off Vapour barrier becomes weak Formation of cold spots Deterioration & failure of Thermal Insulation System 1 % OF MOISTURE INGRESS = 5 % REDUCTION IN R VALUE DOUBLE MOISTURE ATTACK
INSULATIONS INDIA LIMITED27 INSULATION LIFE Insulation needs to be properly fixed to surface Insulation needs to be covered & protected Cold Insulation needs vapour barrier on warm side Cold storage Insulation needs vapour barrier on both sides to counter moisture attack on both sides.
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 panels c) Energy Efficient Refrigeration systems d) Insulated Doors, e) Loading docks f) Racking system g) Energy Efficient Lighting and Controls h) Forklift Trucks
PRE - ENGINEERED BUILDINGS
PRE-ENGINEERED BUILDING Pre-Engineered Building is a systematic arrangement of manufactured Engineered components at site.
ADVANTAGES OF PEB Low construction time Reduced cost Large clear spans Low maintenance cost Ease of future expansion
COMPONENTS OF PEB
TYPICAL PEB FRAME
TYPES OF FRAMES
GREEN FOOD PARK LTD., BHAGALKOT
M/s. EASTERN CONDIMENTS, THENI
PRE-FAB PUF/POLYISO PANELS
SALIENT FEATURES OF PUF/POLYISO PANELS High Strength to weight Ratio with Significant saving in Steel works and Load Bearing Foundation resulting in Large Spans High Thermal Efficiency ensures low Heat Transmission and Low Refrigeration Cost No Deterioration in Thermal Efficiency with Time Vertually Maintenance Free Dimensionally Very Stable 12 m length Panels ensure less no of Joints and Fast Construction
LLOYD PRE-FAB PANELS LLOYD PRE-FAB PolyIso Panels Have been Tested at FM Approvals Lab at Rhode Island USA and are awarded FM Approvals 4880 Class I Certification. This is an Unique Achievement for an Indian Manufacturer
LLOYD PANEL SYSTEM- FOAM PROPERTIES - THERMAL Thermal +10 C W/mK or Kcal/hr m deg C Temperature Range C C Water vapor permeability ng/pasm
LLOYD PANEL SYSTEM- FOAM PROPERTIES - MECHANICAL CFC/HCFC FREE material - blowing agent Pentane DENSITY /- 2 Kg/m3 PIR -45+/-2 Kg/m3 Compressive 10% deformation- 2.1 kgf/cm2 Tensile Strength- 2.5Kg/cm2 Bending Strength kgf/cm2 Dimensional Stability (48 hours)- -25 C - 2.0% +70 C - 2%
LLOYD PANEL SYSTEM - FACINGS AVAILABLE SS 304 with /0.6 mm thickness with Strippable Plastic Film STELVATITE special Foodsafe coating of British Steel UK mm, 275 GMS/m2, 15 0 microns film PLASTISOL 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
LLOYD PANEL SYSTEM Horizontal 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 - FOAM PROPERTIES - FIRE RESISTANCE
LLOYD PANEL SYSTEM- PANEL DETAILS DIMENSIONS Length: upto 12 m long (no joint) Width : 1000 mm Thickness : 40/50 60/80/100/120/150/200 mm JOINING a)Tongue & Groove b) Labyrinth Joint from a continuous line
LLOYD PANEL SYSTEM- DOOR DETAILS FREEZER & CHILL DOORS HINGED Dimensions : 900 mm x 1800 mm 1200 mm x 2000 mm SLIDING Dimensions : 1500 mm x 2500 mm 2000 mm x 2500 mm Doors from BG Doors Holland, Metaflex India