LLOYD INSULATIONS (INDIA) LIMITED MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY.

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


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


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.)


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


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.


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


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


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


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


COLD ROOM FIXING DETAILS


FIXING DETAILS WITH PANELS


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- RADHA KRISHNA FOOD LANDS

M/s. EASTERN CONDIMENTS, THENI

M/s. SNOWMAN

PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI,

A/c. RADHAKRISHNA FOODLANDS PVT. LTD.

Thank You

For any further Queries please mail [email protected]

LLOYD INSULATIONS (INDIA) LIMITED MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY.

Documents

Transcript of LLOYD INSULATIONS (INDIA) LIMITED MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY.