1. COLD CHAIN APPLICATIONS – CHALLENGES AND TECHNOLOGY
HARSHAL SURANGE
ACR PROJECT CONSULTANTS

2. Safe Hygienic & Refrigeration Assisted
COLD CHAIN
From to
FARM CONSUMER
NOT NEW TO INDIA – FAIRLY WELL ESTABLISHED FOR MILK & MILK PRODUCTS
-- TO SOME EXTENT FOR FISH, MEAT AND POULTRY PRODUCTS
- - STILL AT INFANCY FOR FRUITS AND VEGETABLES
Cold Chain
Safe Hygienic & Refrigeration Assisted
Food

4. DIFFERENT COMPONENTS OF THE COLD CHAIN
CONVENTIONAL COLD STORAGE
PACKHOUSES, PRECOOLING & COLD STORAGE
C.A.STORAGE
FROZEN FOODS PLANTS
A.C / VENTILATED STORAGE
DISTRIBUTION CENTERS
SUPER MARKETS / RETAILERS
REFRIGERATED TRANSPORT

5. ROUTE – A -- CONVENTIONAL COLD STORAGE
FARM I
BULK
PACKING
  I
TRANSPORT
CLEANING
SORTING
GRADING
COLD-STORAGE
(DRYING)
DISTRIBUTION
CENTER/ SUPER MARKET / RETAILER
Multipurpose C/S at
Consuming Centre
BULK C/S at Producing Centre
POTATOES / APPLES /
RED CHILLIES / RAISINS
DRY
FRUITS
FRESH F&V
SPICES
PULSES
JAGGERY
BEANS
MILK
PRODUCTS
NEW PRODUCTS GETTING ADDED LIKE
TURMERIC, CARROTS etc

6. TYPICAL CONVENTIONAL MULTI-FLOOR STRUCTURE WITH MANUAL LOADING
Cold Store
FROM TO
TYPICAL CONVENTIONAL MULTI-FLOOR STRUCTURE WITH MANUAL LOADING
MODERN MULTIPRODUCT MULTI FLOOR STRUCTURE WITH MECHANISED LOADING

7. ROUTE – B -- PACK HOUSE WITH PRECOOLING AND COLD STORAGE
FARM
  I
BULK
PACKING
TRANSPORT
CLEANING
(WASHING)
(DRYING)
SORTING
GRADING
PRE-COOLING
COLD-STORAGE
REFRIGERATEDTRANSPORT
DISTRIBUTION
CENTER/ SUPER
MARKET / RETAILER
PRECOOLING IS A PROCESS OF ACCELERATED COOLNG IMMEDIATELY AFTER HARVESTING
THE ITEMS, WHICH, USUALLY, FOLLOW THE PRECOOLING ROUTE, ARE GRAPES, STRAW-BERRIES, POMEGRANATES & ALSO FLOWERS - PRECOOLING WITHIN A SHORT TIME AFTER HARVESTING
NUMBER OF UNITS ESTABLISHED IN MAHARASHTRA, KARNATAKA ANDHRA, U.P, M.P ETC,. OTHER STATES ARE FOLLOWING SUIT.
GRADING & PACKING MANUAL / MECHANISED

8. PROCESSING FACILITIES

10. ROUTE - C - CONTROLLED ATMOSPHERE STORAGE
FARM
  I
BULK
PACKING
TRANSPORT I I 
CLEANING
SORTING
GRADING
 C.A
 SORTING
REFRIGERATED
DISTRIBUTION
CENTER/ SUPER
MARKET / RETAILER
USED TO EXTEND THE STORAGE LIFE OF
SEASONAL PERISHABLES.
INVOLVES DELAYING THE NATURAL
RIPENING PROCESS.
LARGELY USED IN DEVELOPED COUNTRIES ESPECIALLY FOR APPLES AND TO SOME EXTENT FOR PEARS AND PLUMS (APPLES CAN BE STORED UPTO 8 MONTHS)
CA TECHNOLOGY IS AT IT’S INFANCY IN INDIA AND THE ESTIMATED PRESENT CAPACITY IS AROUND MT
IT HAS A GOOD POTENTIAL FOR GROWTH

13. ROUTE – D -- FROZEN FOODS
FARM I 
BULK
PACKING
  I
TRANSPORT
CLEANING
SORTING
GRADING I
SHORT TERM
USAGE
PROCESSING
(PACKING)
FREEZING
BULK PACKING
FROZEN FOOD
STORAGE
REFRIGERATED
DISTRIBUTION
CENTER/ SUPER
MARKET / RETAILER 
FROZEN FOODS
PROCESSING, (PACKING) & FREEZING
STORAGE IN FROZEN STATE
POPULAR ITEMS ARE :
GREEN PEAS,
CORN,
OKRA,
MIXED VEGETABLES,
TOMATO PUREE,
MANGO PULP,
MANGO SLICES
DICES,
PINEAPPLE SLICES ETC
FISH, MEAT, POULTRY PRODUCTS, DAIRY PRODUCTS & COOKED FOOD

14. MODERN MEAT PROCESSING PLANT

16. ROUTE – E – STORAGE OF PRE-FROZEN FOODS
FARM
  I
BULK
PACKING I 
TRANSPORT
I  
  I
PROCESSED
PACKED &
FROZEN
FOOD
REFRIGERATED
FROZEN FOOD STORE I
DISTRIBUTION
CENTER/ SUPER
MARKET / RETAILER
PRE-FROZEN FOODS
UNDERGO PROCESSING AND FREEZING AT THE MAIN PROCESSING PLANTS
ITEMS LIKE ICE CREAMS, BUTTER, CHEESE, FISH, MEAT AND POULTRY PRODUCTS
TRANSPORT THROUGH-OUT IN REEFER VANS/ CONTAINERS TO DISTRIBUTION CENTERS / SUPER MARKETS
NORMALLY LOCATED AT CONSUMER CENTERS AND ARE A PART OF MULTI-PURPOSE COLD STORES

17. PRE-FROZEN FOODS

18. ROUTE – F – A.C. / VENTILATED STORAGE
FARM I 
BULK
PACKING
  I
TRANSPORT I
PROCESSED
AND
PACKED FOOD
  I
AIR
CONDITIONED OR
VENTILATED
STORAGE
DISTRIBUTION
CENTER/ SUPER
MARKET / RETAILER
VENTILATED STORAGE
SOME PROCESSED AND PACKED ITEMS
NEED AIR CONDITIONED STORES
(Eg. CHOCOLATES,CONFECTIONERY
PRODUCTS, TOBACCO)
CONTROLLED VENTILATED STORES ARE BEING USED FOR ONIONS ALSO.

19. Latest technology(Irradiation)

20. DISTRIBUTION CENTERS FOOD DISTRIBUTION CENTERS
RELATIVELY A NEW CONCEPT IN INDIA
CARRY OUT THE FUNCTION OF
PROCUREMENT OF LARGE VARIETY OF FOOD AND RELATED ITEMS
INVENTORY MANAGEMENT
PROCESSING AND FREEZING FOR SOME ITEMS
LOGISTICS
THEY WOULD PLAY A VERY IMPORTANT ROLE IN THE COMING YEARS

21. A TYPICAL FOOD DISTRIBUTION CENTER NORMALLY PROVIDES FOR:
(A) DRY GOODS STORE FOR STORAGE OF NON- PERISHABLE
GOODS WITH VENTILATED AND AIR-CONDITIONED AREAS
(B) RAW MATERIAL RECEIPT AND STORAGE BLOCK
(C) PROCESSING, FREEZING AND PACKING ZONE
(D) CLEANING, DRYING, GRADING, PACKING / PRECOOLING ZONE
(E) RIPENING ROOMS
(F) COLD AND FROZEN FOOD STORAGE
(G) DELIVERY DOCK
(H) SERVICES FOR WORKMEN, UTILITY SERVICE BLOCK AND
ADMINISTRATION ETC.

22. TEMPERATURE REQUIREMENT VARIES WIDELY FROM
THE CENTER HAS TO HANDLE BOTH THE FRESH VEG AND NON-VEG FOODS WHICH HAVE TO HAVE DIFFERENT PATHS FOR PROCESSING, COOLING / FREEZING AND STORAGE.
UTILITY
SERVICE BLOCK
RAW MATERIAL RECEIPT & STORAGE BLOCK
PROCESSING & FREEZING
COLD & FROZEN FOOD STORAGE BLOCK
DRY GOODS
STORE
SERVICES
FOR WORK-MEN
CLEANING, DRYING, GRADING, PACKING / PRECOOLING BLOCK
DOCK
ADMINISTR- ATION
TYPICAL LAYOUT FOR FOOD HANDLING / PROCESSING / STORAGE AND DISTRIBUTION FACILITY
TEMPERATURE REQUIREMENT VARIES WIDELY FROM
20 DEG. C TO (-) 30 DEG. C FOR VARIOUS APPLICATIONS.

23. Current scenario in the Cold Chain sector
The perishable food production in India is estimated as:
Milk : 115 Million MT (No.1 in the world)
F & V : 200 Million MT (No.2 in the world)
Fish : 6.4 Million MT (No.6 in the world)
Meat : Largest cattle population in the world
Poultry : One of the largest in the world
current capacities of the cold storage & food processing :
Cold Storage : Around 6000 nos - Capacity : 26 Million MT
Food Processing : 5 to 6 % of production.

25. Opportunities
With the growing fruit & vegetable production there is a great potential for development of Cold Chain in F&V sector.
Food processing recognised as a Priority sector by Govt.
Incentives offered by the govt.
Multi-products Cold Stores – more and more products such as carrots, turmeric are being added in this category.
Food Parks –designed for overall development of the food handling, processing & storage facilities. Govt. promoting 30 Mega Food Parks
Terminal markets managed both by APMCs & Private players..
Pack Houses with Precooling facilities for relevant products in different regions.

26. Opportunities Controlled Atmosphere Stores for Apples, Pears etc.
Frozen food plants for fruits & vegetables, milk products, fish, meat & poultry products.
Scientific Ripening for Banana & Mango.
Development of Refrigerated Transport for processed & preserved food.
With the changing lifestyles of small nucleus families, demand for processed & refrigerated food is increasing
National & International Food chains setting up Food Malls/ Food courts & stores in various parts of the country .

27. INDIA TO BE SOURCE BASE FOR PROCESSED FOOD?

28. Govt initiatives
Excise concessions, Service Tax exemption, Govt. grants, incentives etc thru’ NHB/NHM/MoFPI/APEDA
Latest move by Govt is FDI in cold chain / retail sector - Food (Fresh & Precooled) covers 62% OF Retail.
Task force on development of cold chain
National centre for development of cold chain - NCCD

29. Govt initiatives NHB – TECHNICAL STANDARDS - TECHNICAL SCRUTINY
NCCD - TRAINING

30. Challenges in the Cold Chain sector
Lack of quality Road network in most areas.
Rising cost of land
Shortage and erratic supply of power in most areas
Rising energy costs - a cause for concern as the plants are energy intensive.
Availability of required quantity & quality of water in most regions.

31. Challenges in the Cold Chain sector
Inconsistence in quality & quantity of food production –Dependence on weather.
Excessive use of pesticides.
High initial project costs (Break-even period almost 5 to 6years)
Lack of training on good agricultural practices, pre & post harvest technology & hygiene.
Lack of availability of trained personnel for plant operation.
Lack of awareness about maintenance, hygiene, safety issues & energy efficiency aspects.

32. CHALLENGES
Article which appeared in Times Of India dtd (Front Page)

33. WHATS NEEDS TO BE DONE? EXCISE EXEMPTION PROCEDURES RELAXED
CONCESSIONAL (AGRICULTURAL) ELECTRICAL TARIFF IN ALL STATES.
A CENTRALISED REGISTRATION PROCESS FOR ALL COLD CHAIN PROJECTS.
IMPROVED ROADS & TRANSPORT FACILITIES.
SPECIAL INCENTIVES FOR USE OF
“GREEN TECHNOLOGY”’.

34. Conclusion
Conclusion
Conclusion
Conclusion
Where as huge opportunities exist in the development of Cold Chain as a whole, there are issues such as high project costs, high energy requirements & infrastructure aspects .
The need for training of personnel on operational & food safety aspects etc. has to be addressed.
There is a strong case to promote the concept of “Green Cold Chain” to ensure ecofriendly & energy efficient plant construction & operation.
Govt. initiatives with financial incentives & thrust on sound technology & energy efficiency is a welcome feature, which will hopefully, bring in a healthy development in the Cold Chain.

35. ACR PROJECT CONSULTANTS
THANK YOU
HARSHAL SURANGE
ACR PROJECT CONSULTANTS