Post on 27-Mar-2015
LLOYD INSULATIONS (INDIA) LIMITED
MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY
INDIA’S 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
TemporaryStorage
MAINTAINING THE COLD CHAIN FOR PERISHABLES
SHADING TO PROTECT PRODUCE FROM SUN
COLD STORAGE FACILITIES
WHOLESALE MARKET
DISTRIBUTION CENTER
RETAIL DISPLAYS
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 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.
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) theproduce which may if necessary, be stored together
COLD STORE-SPECIFICATIONSCOLD STORE-SPECIFICATIONS THE CONDITIONS OF STORAGETHE 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 - SPECIFICATIONSCOLD STORE - SPECIFICATIONS
The EnvironmentClimate:External temperatures during 6 hour period ( from 9.00 to 15.00)•Maximum•Minimum•Annual meanRelative humidity :•Extreme valuesRainfall :• Frequency, • Degree of precipitation
COLD STORE - SPECIFICATIONSCOLD STORE - SPECIFICATIONS
The Resources AvailableEnergy resources: •nature, power, method of supplyWater resources:•origin ( river, well, sea ) •temperature and flow•chemical composition•presence or absence of mud or sandLabor resources:•local availability of labor•technical operating and control personnel•handling and general maintenance• personnel
COLD STORE - SPECIFICATIONSCOLD 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 - SPECIFICATIONSCOLD STORE - SPECIFICATIONS
NEED FOR EFFECTIVE LOW NEED FOR EFFECTIVE LOW TEMPERATURE COLD STORAGE IN TEMPERATURE COLD STORAGE IN
INDIA.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 NEED FOR LOW TEMPERATURE STORAGE (CONTD.)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.
www.lloydindia.com LLOYD INSULATIONS INDIA LIMITED 22
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+FinishApprox. 360mm wall
Use an interior lining on insulation essentially to prevent mechanical damage
Bri
ck w
all
Vapor barrier
Th
erm
al in
sula
tion
Bit
umen
Metal mesh
cem
ent p
last
er
Final finish
www.lloydindia.com LLOYD INSULATIONS INDIA LIMITED 23
CONVENTIONAL COLD STORESEXISTING SITUATIONInsulation Material – Expanded Polystyrene,
PUF in 100 – 150mm on walls, fixed between wooden framework, Polythene sheet vapour barrier.
Floor Insulation with EPS /PUFslabs – 50-100mm.
www.lloydindia.com LLOYD INSULATIONS INDIA LIMITED 24
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
www.lloydindia.com LLOYD INSULATIONS INDIA LIMITED 25
EXISTING COLD STORE – PROBLEMS, CONVENTIONAL PRACTICE
Bri
ck w
all
Vapor barrier
Th
erm
al in
sula
tion
Bit
umen
Metal mesh
cem
ent p
last
er
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
www.lloydindia.com LLOYD INSULATIONS INDIA LIMITED 26
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 System1 % OF MOISTURE
INGRESS = 5 % REDUCTION IN ‘R’ VALUE
DOUBLE MOISTURE ATTACK
www.lloydindia.com LLOYD INSULATIONS INDIA LIMITED 27
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 STOREELEMENTS 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 PRE - ENGINEERED BUILDINGSBUILDINGS
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
PEB DETAILS
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 Stable12 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 Conductivity @ +10 C -0.023 W/mK or 0.0198 Kcal/hr m deg C
Temperature Range- -180 C - +95 C
Water vapor permeability - 0.12 ng/pasm
LLOYD PANEL SYSTEM- FOAM PROPERTIES - MECHANICAL
CFC/HCFC FREE material -blowing agent Pentane
DENSITY - 40 +/- 2 Kg/m3
PIR -45+/-2 Kg/m3 Compressive Strength @
10% deformation- 2.1 kgf/cm2
Tensile Strength- 2.5Kg/cm2
Bending Strength - 3.0 kgf/cm2
Dimensional Stability (48 hours)- -25 C - 2.0% +70 C - 2%
LLOYD PANEL SYSTEM - FACINGS AVAILABLE
SS 304 with - 0.5 /0.6 mm thickness with Strippable Plastic Film
STELVATITE special Foodsafe coating of British Steel UK - 0.6 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 10 142: 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 4735- < 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 HINGEDDimensions : 900 mm x 1800 mm
1200 mm x 2000 mm
SLIDINGDimensions : 1500 mm x 2500 mm
2000 mm x 2500 mmDoors from BG Doors Holland, Metaflex India
LLOYD PANEL SYSTEM - ACCESSORIES DETAILS
Insulated Beam Foam Tape & Silicon SealantButyl SealantOne Component FoamPressure Relief ValveAluminum Extrusions with PVC profilesPVC Bump railsInner & Outer Flashing
www.lloydindia.comLLOYD INSULATIONS INDIA LIMITED 48
CONSTRUCTION OF
COLD STORAGE WITH
LLOYD PANEL SYSTEM
www.lloydindia.comLLOYD INSULATIONS INDIA LIMITED 49
COLD ROOM FIXING DETAILS
www.lloydindia.comLLOYD INSULATIONS INDIA LIMITED 50
COLD ROOM FIXING DETAILS
www.lloydindia.comLLOYD INSULATIONS INDIA LIMITED 51
COLD ROOM FIXING DETAILS
www.lloydindia.comLLOYD INSULATIONS INDIA LIMITED 52
COLD ROOM FIXING DETAILS
www.lloydindia.comLLOYD INSULATIONS INDIA LIMITED 53
FIXING DETAILS WITH PANELS
www.lloydindia.comLLOYD INSULATIONS INDIA LIMITED 54
FIXING DETAILS OF PANELS
METAL ROOFING & CLADDINGSAFAL - BANGALORE
LLOYD PANEL SYSTEM- SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM - SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM -SAFAL
LLOYD PANEL SYSTEM- RADHA KRISHNA FOOD LANDS
LLOYD PANEL SYSTEM- RADHA KRISHNA FOOD LANDS
M/s. EASTERN CONDIMENTS, THENI
M/s. EASTERN CONDIMENTS, THENI
M/s. EASTERN CONDIMENTS, THENI
M/s. SNOWMAN
M/s. SNOWMAN
M/s. SNOWMAN
PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI,
A/c. RADHAKRISHNA FOODLANDS PVT. LTD.
PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI,
A/c. RADHAKRISHNA FOODLANDS PVT. LTD.
PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI,
A/c. RADHAKRISHNA FOODLANDS PVT. LTD.
PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI,
A/c. RADHAKRISHNA FOODLANDS PVT. LTD.
Thank You
For any further Queries please mail tobjk@lloydinsulations.in