1. COLD STORAGE PROCESS BY: SHUBHADIP BISWAS IILM-GSM

2. Agriculture-major industry of india—necessity of cold store Agriculture is the major industry of India and about 70% of Indian Population is engaged in activities connected to agriculture. The total agricultural output amounts to approx.40% of the National Income. The country is producing in excess of 60 million tons of fruits and vegetables per annum. Most of the agricultural production is perishable in nature and requires certain levels of temperature and humidity to hold the horticultural production in good condition for longer periods.

3. Agriculture-major industry of india—necessity of cold stores due to lack of proper facilities of transportation and storage, about 33% of production, especially fruits and vegetables are wasted i.e. about 20 million tons or 200 lakh tons are wasted.

4. COLD STORE market cold storage infrastructure was built way back in the mid '60s mainly for potatoes and potato seeds and there was no massive investments in cold storage. There is no nationwide provider of cold storage facilities. India has a total 5316 cold storages with a capacity of 23333694 MTs. Private sector cold storages in India account for 4820 with a capacity of 222343607MTs ,cooperative sector 363 numbers with 989445 MTs, Public sector account for 133 numbers worth a capacity of 100642 MTs.

5. Cold storage companies Leading Cold chain companies with established cold chain infrastructure in India are thee state-owned Container Corporation of India (Concor), R.K. Foodland, Refcon Carriers, Indraprastha Cold Chain, Bulaki Deep Freeze, and Glacio Cold Chain. Two majors names in the cold chain industry, Snowman and Kausar, have been bought over. Hyderabad-headquartered logistics player Gati acquired Kausar India, and transportation & logistics major Gateway Distiparks acquired a controlling stake in Snowman Frozen Foods. The Future Group, meantime, has integrated backward—from food retailing to storage and transportation—with the launch of Future Logistics. XPS Cold Chain, a division of Transport Corporation of India Container Corporation of India floated Fresh & Healthy Enterprise are also the leading cold chain logistic infrastructure companies

6. Cold storage Large Cold Storages Almost 95 to 98% of these use R-717 (NH3) as refrigerant. Most of these use gravity feed flooded systems or pump-circulation methods. Only very large capacity ones with liquid pump circulation think of screw compressors. Majority of others go in for open type Reciprocating ‘Kirloskar make ‘KC’ compressors of single stage or two stage design depending on the evaporating temperatures required. ‘Kirloskar’ KC Compressors are used not only in India but also in many other countries such as Bangladesh, Sri Lanka, Nepal, the Middle East and even in Australia.

7. Cold storage The smaller capacity cold storages who use halocarbons as refrigerants mostly use R-22 or in some very few cases, for imported units use HFC’s like R-404a.

8. Commodity wise distribution

9. FEATURES Multiple Rooms Multiple Commodity Variable Temperature, Humidity Control & Air Circulation Modified Atmosphere Pre-cooling Chambers Fruit Ripening Chambers Grading, Washing, Packing, Value Additions Integration with food supply chain

10. FEATURES Material Handling & Stacking Pattern Installing Conveyor Systems or Elevators to transport bags to various floor levels for storage will cut down on valuable loading time and reduce the dependency on manual labor and costs. Stacking arrangements should be planned and marked out on the floors to optimize storage capacity and at the same insure sufficient passages for air circulation, and easy movement of operation and maintenance staff

11. FEATURES Heat Load Calculation to determine total refrigeration load – Transmission Load, heat transferred into the cold room through its walls, floor and ceiling. – Product load, heat removed from the product brought into the cold room for storage and on account of respiration. – Internal Load, Heat produced by Light, Material handling equipment,Peoplein the cold room. – Infiltration Air Load, Heat gains with warm air infiltration into the cold room through doorways and ventilation systems. – Equipment load, consist essentially of fan heat where forced air circulation is used and defrost heat

12. FEATURES Insulation The primary function of insulation is to restrict the transfer of heat from the warm ambient to the cool environment maintained in the cold stores. A well designed insulation envelope should at the same time also prevent vapor transmission from the warm humid ambient to the cold store environment. This is achieved by providing suitable vapor barriers and selecting insulation materials with low moisture permeability. If moisture passes into the insulation and makes it wet, the insulating properties are decreased and eventually the insulation envelope fails. It is a extremely important to apply the recommended thickness of insulation using the correct methodology for maximizing efficiency.

13. FEATURES Cold Store Doors Choosing and installing the right type of cold room doors is vital to improving efficiency and performance in cold stores. All cold storage doors are required to be durable to frequent operations, suitably insulated and hermetically seal when closed. Their smooth and quick action ensure less cold air loss, less condensation, less frost build up, less energy consumption and enables stored commodities to be maintained at peak perfection.

14. FEATURES Refrigeration System – Condensing Unit Compressors Condenser – Cooling Coils – Refrigerant

15. FEATURES Condensers – The refrigeration condenser is a vital component which rejects the heat into the ambient enabling the cooling process through the refrigeration cycle. They should be cleaned and maintained regularly. – Condensers should be carefully evaluated for the peak load requirements based on the “ correct ambient conditions” and “desirable operating parameters”

16. FEATURES Cooling Coil Selection & Operation Considerations are: 􀂉 Optimizing Delta T Across The Coil The difference between return air temperature and the saturated suction temperature of refrigerant is a critical factor determining the size and heat transfer capacity of the cooling coil. 􀀹 For Low humidity Delta T can be selected between 11°C to 17°C. 􀀹 For High Humidity Delta T can be selected between 2.2°C to 4.4°C.

17. FEATURES Maintaining Humidity – Once the field heat is removed and the product temperature reaches the desired holding stage condition, extra humidification can be discontinued provided, the cold store is fitted with a well designed cooling system. – Cold Sores designed with “undersized” cooling coils however require continuous humidification throughout the storage period.

18. FEATURES Air Circulation – Air circulation should be designed to maintain uniform temperature at all places inside the cold stores through out the period of storage. – During the pull down period, there is a need for higher air circulation to remove the field heat - the fan capacity on the cooling coils may not be adequate and additional air circulation fans may be required at suitable locations. – However, once the holding conditions are maintained the air circulation rate can be reduced to the extent of maintaining consistent temperature within 1°C.

19. FEATURES Maintaining Consistent Temperature & Humidity Conditions – The present necessity of reshuffling - “palti” - of bags within the cold rooms during the pull down period is mainly on account of poor air circulation. Hence proper design will save high labor costs and damage to produce.

20. FEATURES Requirement of Fresh Air & Energy Recovery – For maintaining quality and extending shelf life, sufficient amount of fresh air is required to flush out carbon dioxide to a level below 4000ppm ( in case of potatoes ) throughout the storage period.

21. FEATURES Ante Rooms & Air Curtains – Ambient conditions of high humidity and temperature generally always lead to condensation on the surface of the cold produce when it is directly unloaded into the open thereby wetting its surface and affecting its quality and shelf life. – Therefore ante rooms become a necessity where the produce is first unloaded and held for a period of time till the product is warmed above the dew point temperature. – To further minimize energy loss due to infiltration through doors, special devices like “air curtains” and “strip curtains” should be utilized.

22. SAMPLE OF COLD STORE Product Seed Potato 􀁺 Storage Temperature 3°C (+/-1°C) 􀁺 Plant location: Uttar Pradesh or Punjab 􀁺 Outside dry-bulb temp: +45°C (max.) 􀁺 Outside wet-bulb temp: +30°C (max.) 􀁺 Product Receiving system : Open trucks 􀁺 Product Temperature at the time of loading 20 °C to 25 °C 􀁺 Storage system : 50kg Bags stacked on Mezzanine floors

23. SAMPLE OF COLD STORE

24. SAMPLE OF COLD STORE

25. SAMPLE OF COLD STORE

26. SAMPLE OF COLD STORE

27. SAMPLE OF COLD STORE

28. SAMPLE OF COLD STORE 􀁺 Total Storage Capacity: 5000 Mt 􀁺 No of Chambers & Capacity: 4 X 1250 Mt. 􀁺 Chamber Size: 21.00 m x 16.00 m x 13.70 m (L x W x H) 􀁺 Duel Commodity Cold Store with mezzanine floors 􀁺 Loading Rate: 4% to 5% of the total storage capacity / day (equally split into four chambers) 􀁺 Pull-down time : 24 hours 􀁺 Compressors running hours : During Pull Down - 20 hours/day and During Holding – 18 hours/day

29. Cold chain Cold Chains These have already been established for flowers, meat, Ice Cream and a host of other products. Cold storages with prefab panels have been installed at major airports in the country. Container Corporation of India Ltd. (CONCOR) is setting up a countrywide--network of cold chain complexes to meet the requirements of quality fruits and vegetables in the International and Domestic markets.

30. Cold store

31. Cold store

32. Cold store

33. Single stage kc

34. Two stage kc

35. Cold store

36. Cold storage Process

37. Truck with cooling system

38. Services provided by companies providing cold store facility: Chilled and Frozen Delivery Chilled and Frozen Storage Chilled and Frozen Fulfillment Specialised Transport Specialised Logistics Field Marketing Support Express Deliveries International Deliveries

39. charging areas following charge areas which may be applicable. Indicative pricing will be provided by contact and this will be based on specific requirements- Storage – a charge per pallet per week or part thereof for storage of your goods Receipt Handling & Despatch (RH&D) – a handling charge for every pallet entering the warehouse and a charge for every pallet going out of the warehouse Pick Costs – if your stock leaves the warehouse in less than full pallet quantities you will not be charged on the dispatch, instead you will be charged a pick rate for every box picked from your pallets.

40. Contd- Container de-stuff – a charge for unloading a container and securing the product on to pallets so it can be stored safely in the warehouse Pallets – a charge for every pallet needed to hold your stock Consumables – a charge for shrinkwrap, labels or other consumables needed to secure your stock and ensure each pallet is identifiable Stock Check – the cost of a stock check is normally charged at a labour per hour rate, operative numbers will be agreed between both parties on a task basis Out of Hours – should there be a requirement to work outside of normal hours there might be an additional labor charge to cover the manpower needed for the activity

41. General Operational Guidance Customers can view their products, please speak to your Vision contact to arrange this and please give at least 24 hours notice To meet insurance and health and safety requirements customers are not allowed to pick their own stock or otherwise work in the warehouse at least 24hrs notice for any activity requirements such as booking in stock arriving at the warehouse or a booking for stock to be removed from the warehouse. On receipt of the notice they will check warehouse schedule and book an available slot for this activity. Please note at certain times the warehouse will be operating at peak activity so in order to secure a specific time for a booking please give as much notice as possible.

42. for ordering -- some basic questions. Do you require chilled, frozen or ambient storage? What area of the country would you prefer your stock to be held? Do you require transport as well as storage services? Is your stock coming in on pallets? If it is not coming in on pallets please tell if it is coming in on a 20ft or 40ft container or by other means How many pallets are you looking to store?

43. for ordering -- some basic questions: How long do you require storage for? How many pallets per month are you expecting to arrive at the warehouse? Are the pallets standard (1.2m x 1m) or euro pallets (1.2m x 0.8m) What is the max weight of one of your pallets? What is the max height of your pallets? Will your products be leaving the warehouse as full pallets or do you require box picking? How many different product lines do you have? Do you require any formal stock checks?

44. THANK YOU