Inviting Comments on Technical Standards and Protocols for the Frozen food Processing Industry in India A Technical Standard

Committee (TSC) has been constituted by Ministry of Food Processing Industries, Govt. of India, to develop technical standards and protocols for cold chain for subzero temperature as the same may be required for storing and IQF of perishables like fruits and vegetables, dairy products, meat products, sea food etc. and other food products. Public notice has been given to invite comments on Technical Standards and Protocols for the Frozen food Processing Industry in India which must reach MD, NHB within 20 days of Publication of this notice. Comments should be sent by registered post/ speed post super scribing on the envelop comments. Advance copy of comments may preferably be sent by email to directornhb@yahoo.com and jsjpmfpi@nic.in

CONTENTS
PartI TechnicalStandardNoNHB QUICKFREEZINGSYSTEMS SECTION1 1. 2. 3. 4. 5. 6. 7. 8. FreezingofFoods DifferenttypesofFreezingsystems TemperaturerecommendedforFreezingprocessandstorage DifferenttypesofFreezers/Stores Freezingtimefordifferentproduct/sizes ThermalInsulationforFreezer,Enclosures,Stores&otherColdSpaces. RefrigerationSystemSelection HeatLoadCalculations

SECTION2 TypicalDesignParametersforFreezing&Storage TypicalLayoutforFoodFreezing&StoragePlant Part II Technical Standard No NHB FROZEN FOOD STORAGE & SYSTEMS INTEGRATEDTOREEFERTRANSPORT SECTION1 1. 2. 3. 4. 5. StorageofFrozenFoods. StorageConditionsforFrozenFoods. ThermalInsulation&Doors. RefrigerationSystemSelection. HeatLoadCalculations.

SECTION2 TypicalDesignParametersforFrozenFoodStorage TypicalLayoutforFrozenFoodStorageplant. SECTION3(CommonforPartI&II) BasicDataSheet SECTION4(CommonforPartI&II) ProtocolforImplementationofTechnicalStandards. Annexure I ListofRelevantBISandOtherStandards Annexure II FlowChartVegetablesandFruits AnnexureIIIOfficeorderofMoFPI AnnexureIV TechnicalStandardsCoreCommitteeExperts

PartITechnicalStandardNoNHBQUICKFREEZINGSYSTEMS

1.BASICSOFFOODFREEZING
FREEZING is one of the oldest and most widely used methods of food preservation, whichallowspreservationoftaste,texture,andnutritionalvalueinfoodsbetterthanany other method. The freezing process is a combination of the beneficial effects of low temperatures at which microorganisms cannot grow, chemical reactions are reduced, andcellularmetabolicreactionsaredelayed. FreezingoffoodsisoneofthemostprominenttechnologyfollowedintheColdChain,for preservationoffoodsforlongerperiods. A large number of foods which can be processed and frozen and stored at sub zero temperature.FordistributiontothemarketandconsumersFoodFreezingandStorageis practisedinvariousfoodsectorse.g. a) b) c) d) e) f) ProcessedFruitsandVegetables MilkProducts MeatProducts MarineandSweetwaterfish PoultryProducts Readytoeatproducts

The processing methods followed in each of the products lives are different. However, thefreezingandstoragemethodsareadaptabletomostoftheproducts. SpecificweightsofUnfrozenFoodsapprox. FishFillets1000kg/m Bonelessmeat1000kg/m FruitsandVegetables700kg/m Icecream550kg/m Increaseinvolumeofproduceduringfreezingisabout6% Processingofvariousfoodsbeforefreezing Differentfoodsneeddifferenttypesofprocessesbeforetheyarefrozen Itemslikegreenpeas&cornhavetobeblanched&thencooledbeforefreezing. Pulpslikemango,tomatopureehavetobepasteurisedbeforepacking&freezing

Meat,carcasseshavetobechilledtoabout4degCbeforedeboning&makingof portions.Theprocesshallshavetobemaintainedat12to15degC. Fishproductsarechilledbeforeprocessing&freezing.

TheapplicableprocessingtechnologyhastobeadoptedasperthelocalFDArules. Theprocessoffreezingisexplainedinfigure1

SENSIBLECOOLING

TEMPERATURE

L A T E N T H E A T O F F U S I O N Z O N E

ABOVEFREEZING SENSIBLECOOLING

T I M E

Figureshowsthethreephasesoffreezing: 1)Coolingwhichremovessensibleheat,reducingthetemperatureoftheproducttothe freezingpoint. 2)Removaloftheproductslatentheatoffusion,changingthewatertoicecrystals 3) Continued cooling below the freezing point which removes more sensible heat reducing the temperature of the product to the desired or optimum frozen storage temperature. Itisessentialtounderstandthefollowingfactorsthatgoverntheultimatekeepingquality andstoragelifeoftheproduce: a) b) c) d) Compositionoftheproductanditsnature Selection,handlingandpreparationforfreezing Freezingmethods
Storageconditionspostfreezing

BELOWFREEZING

ADVANTAGESOFQUICKFREEZINGOVERSLOWFREEZING a) IcecrystalformationismuchsmallerinQuickFrozenproductsandmouthfeelis farbetter. b) QuickFreezingtakesmuchlesstimeandhencesaltdiffusionfromtheproductis farlesserandseparationofwaterfromthetissueisminimal. c) Product is quickly cooled below the TDZ (Temp. danger Zone) so that there is minimalchanceofbacteria,yeastgrowth. 2. SELECTIONOFFREEZINGMETHODS The following factors should be considered in the selection of freezing methods and systemsforspecificproducts: 1) Specialhandlingrequirements 2) Capacity 3) Freezingtimes 4) Qualityconsideration 5) Yield 6) Appearance 7) Firstcost 8) Operatingcosts 9) Automation 10)Spaceavailability 11)Upstream/downstreamprocesses. 3. THENEEDFORFREEZINGANDFROZENSTORAGE Freezinghasbeensuccessfullyemployedforthelongtermpreservationofmanyfoods, providing a significantly extended shelf life. The process involves lowering the product temperaturegenerallyto18Corbelow.Thephysicalstateoffoodmaterialischanged whenenergyisremovedbycoolingbelowfreezingtemperature.Theextremecoldsimply retardsthegrowthofmicroorganismsandslowsdownthechemicalchangesthataffect qualityorcausefoodtospoil. 4. METHODSOFFREEZING There are, mainly, two methods of freezing, generally, employed for freezing of foods andthesearedescribedasbelow. 1. SharpFreezing Thiscanbedoneusingdirectorindirectmethodofrefrigeration.The time taken in freezing is longer with possibility of cellular damage in the product.Thissystemisnotpopularatpresent.

2. QuickFreezing In this type of freezing the foods are subjected to temperatures ranging from () 30 to () 50C and the freezing occurs much faster, thereby, preventingthepossibilityofcellulardamage. Thevariousmethodsofquickfreezingare: a) DirectImmersionMethod: It involves immersion of product in the low temperature brine solution.Themethodoffersadirectcontactandfasterfreezingbutthe problem of contamination may occur unless adequate precautions are taken. b) ContactorPlateFreezing: In this system the productsare placedbetween metal plates which are refrigerated by the refrigerant passing through the hollow passages created in the plates. The equipment is called plate freezer which has a number of plates in horizontal placement or vertical placement. The products kept in the trays are placed betweentheplateswhicharethensubjectedtohydraulicpressureto ensure proper contact between the products in the plates. The freezing time, generally, varies between60 180 minutes depending ontheproductthickness.Generally,theplatefreezersaredesigned to handle product thickness from 25 mm to 80 mm. the horizontal platefreezersare,generallyusedforproductsinstandardsizesand the vertical plate freezers for freezing of bulk of fish or other products. The plate freezers are available as batch type or continuoustypefreezers. c) AirBlastFreezing Itiswidelyusedtofreezealargevarietyofproductsinstandardor irregularshapes. The freezingtime, generally,varies from 4 hrs. to 10 hrs. depending on the thickness and the shape of the product. Blast freezers are designed as batch freezers or continuous freezers in the formoftunnelsandtakefulladvantageoftheheattransferefficiencyof rapidly circulating air over the product. Air cooled by the refrigerated coils and flowing at velocities ranging from 200 to 600 m/min. is then directedovertheproductloadedintheracksortrolleys.Thismethodis wellacceptedforanumberofpackedandunpackedfooditems.

Batch Coldstoragerooms Stationaryblastcells Pushthroughtrolleys

Continuous/ProcessLine Straightbelts(twostage,multipass) Fluidizedbeds Fluidizedbelts Spiralbelts Carton(carrier)

3. CryogenicFreezing: Thesesystems are, normally, designed to work on liquid Nitrogen orsolid Carbondioxide.

5.TYPESOFFREEZERS
a) STATIONARYAIRBLASTFREEZERS BLAST FREEZERS use air as the heat transfer medium and depend on the contact between the product and the air. A wide range of blast freezer systems areavailable,including

It is the simplest freezer that can be expected to produce satisfactory results for most products.Itisaninsulatedenclosurewithrefrigerationcoilsandaxialorcentrifugalfans thatcirculateairovertheproductsinacontrolledway. Thestationaryblastcellisauniversalfreezer,becausealmostallproductscanbefrozen inablastcell. The flexibility of a blast cell makes it suitable for small quantities of varied products, however, labour requirement is relatively high and product movement is low.

b)BLASTFREEZERS(PUSHPULLTROLLEYTYPE)

TROLLEY

TROLLEY

TROLLEY

TROLLEY

This system is widely used to CRUSTFREEZE (quickchill) wrapped packages or raw poultryandforirregularlyshapedproducts.Thistypeoffreezerissimilartothestationary blastcell,exceptthatlabourcostsandproducthandlingtimearedecreased.

IQFTYPEFREEZERS c) STRAIGHTBELTFREEZERS

Theprincipaldesignisthetwostagebeltfreezerwhichconsistsoftwomeshconveyor beltsinseries. Consistoftwomeshconveyorbeltsinseries. Thefirstbeltinitiallyprecools. Secondbeltforfreezingandsensiblecoolingto()18DegCofbelow. Twostagefreezersaregenerallyoperatedat()9to()4Crefrigeranttemperaturein theprecoolsectionand()32to()40Cinthefreezingsection.Capacitiesrangefrom 0.9to45Mgofproductperhour,withfreezingtimesfrom3to50min.

d)MULTIPASSSTRAIGHTBELTFREEZERS

Largerproductswithlongerfreezingtimes(Upto60min) Highercapacityrequirements(0.5to6ton/h), Singlestraightbeltfreezerwouldrequireaverylargefloorspace. Requiredfloorspacecanbereducedbystackingbeltsaboveeachothertoformeither (1) a singlefeed/singledischarge multipass system (usually infeeds and discharge) stackedoneontopoftheother.

e) FLUIDIZEDBELTFREEZERS

Thisfreezerusesairbothasthemediumof heattransferandfortransporttheproduct flows through the freezer on a cushion of upwardflowing cold air. The technique is limited to well dewatered products of uniform size that can be readily fluidized and transported through the freezing zone. Because the principle depends on rapid crust freeingoftheproduct,theoperatingrefrigeranttemperaturemustbe O O 40 C or lower, giving air temperatures of 30 C or lower. Fluidized Belt Freezers are normally manufactured as packaged, factory assembled units with capacity ranges of 0.9to9Mg/h.Particulateproductsgenerallyhavingafreezingtime3to15min.

f) FLUIDIZEDBEDFREEZERS

P R O D U C T F L O W

A I R F L O W

F L U I D I Z E D B E D F R E E Z E R

Thisfreezerusesairbothasthemediumof heattransferandfortransporttheproduct flows through the freezer on a cushion of cold air. This design is well suited for small, uniformsizedparticulateproductssuchaspeasanddicedcarrots. The high degree of fluidization improves the heat transfer rate and allows good use of floorspace.Thetechniqueislimitedtowelldewateredproductofuniformsizethatcan be readily fluidized and transported through the freezing zone. Because the principle depends on rapid crustfreezing of the product, the operating refrigerant temperature O mustbe40 Forlower.Fluidizedbedfreezersarenormallymanufacturedaspackaged, factoryassembled units with capacity ranges of 1 to 5 ton/h. The particulate products generallyhaveafreezingtimeof3to11min.

g)SPIRALBELTFREEZERS

Thefreezerisadvantageousforproductswithlongfreezingtimes(generally10mintoh), andfor products that require gentle handling duringfreezing. An endlessconveyor belt that can be bent laterally is wrapped cylindrically, one tier below the last this is a configurationthatrequiresminimalfloorspaceforarelativelylongbelt. Thenumber of tiers in thespiralcanbevaried to accommodate differentcapacities. In addition,twoormorespiraltowerscanbeusedinseriesforproductswithlongfreezing times. Spiral freezers are available in a range of belt widths and are manufactured as packaged, modular, and fielderected models to accommodate various upstream processesandcapacityrequirements. Horizontal airflows applied to spiral freezers by axial fans mounted along on side. The fansblowairhorizontallyacrossthespiralconveyorwithminimumbafflinglimitedtotwo portionofthespiralcircumference.

Therotationofthecageandbeltproducesarotisserieeffect,withproductmovingpast thehighvelocitycoldairnearthedischarge,aidinginuniformfreezing.

h)CONTACTPLATEFREEZERS

A CONTACT FREEZER primary means of heat transfer is conduction. The product or packageisplacedindirectcontactwitharefrigeratedsurface.Contactfreezerscanbe categorized as follows. The most common type of contact freezer is the contact plate freezer,inwhichtheproductispressedbetweenmetalplates. Refrigerant is circulated inside channels in the plates, which ensures efficient heat transferandresultsinshortfreezingtimes,providedthattheproductisagoodconductor of heat,as in the caseof fish fillets,chopped spinach, or meat .However, packages or cavitiesshouldbewellfilled,andifmetaltraysareused,theyshouldnotbedistorted.

j)CRYOGENICFREEZERS

Cryogenicfreezersuseliquidnitrogenorliquidcarbondioxide(CO2)astherefrigeration medium,andthefreezersmaybebatchcabinets,straightbeltfreezers,spiralconveyors, orliquidimmersionfreezers.

A. GENERALCONSTRUCTIONFEATURESFORTUNNELTYPEFREEZERS :

EQUIPMENTDESCRIPTION: TheIQFFluidizedBeltTunnelFreezerShouldbecomposedofaplenumchamberthatincludesthebelt,product guards,fanwithmotors,Coilsectionthatincludeswaterdefrostheader&beltwasher,Dryer. Enclosurethatincludeswalls,floor,doors,lighting,infeedanddischarge.A completeunit HighestSafetyHealth/ Hygiene/SanitationStandards. InstrictcompliancewiththeStandards,U.S.D.A,O.S.H.A,UL,C.S.A,CFIA,BRC. CONVEYORBELTORPRODUCTTRAY MOC StainlessSteel304orAcetalfoodgradematerial.Sideguides forbelttoalsobeinFoodgradematerialSS304 BELTWASHER/DRYERSYSTEM MachineshouldbeequippedwithBeltwasherinlinewithoutremovingbeltortray. Thefreezewithbeltdryerwillbeadvantage. PRODUCTINLET&DISCHARGEWALLBAFFLING&CHUTE Productinletwallbaffleandstainlesssteeldischargewallbafflechuteisprovidingtokeepairinfiltrationtominimum. FREEZEREVAPORATOR IndustrialQualityEvaporatordesignwithcontinuousplatefinwithmaterialofAluminium,Stainless Steelonly. Thisshouldplaceinapositiontobeabletocleanfromallsides. FANS&MOTOR MOCtobeAluminiumorsimilarnoncorrosive. ALLSTEELSTRUCTURE&CATWALKS,CHAMBER MOC Tobeeasytoclean&Noncorrosive.Tobeeasyforinspect,cleanandmaintenanceoffreezerandmonitor freezerperformance. ACCESSLADDER ELECTRICALCONTROLPANEL PanelisbuilttoNEMAIVandULspecification

INSULATEDENCLOSURE Theinsulatedenclosurewallsandceilingtobemadeofselfsupportingconstruction. MOC SkinofenclosureismadeofSS304bothinside&outsidewithgoodinsulatingmaterialPUF/PIR. INSULATEDFLOORSYSTEM ThefloorsystemisbuildupwithMOC SSteel304&insulatedmaterialofPUF/PIR. ALLHARDWARE Shouldbenoncorrosive LUBRICATIONFORMOTOR&BEARING Alllubricationforopenbearingordriveunittobeusedwithonlyfoodgradegreasecertifiedwhichisregisteredin Indian national chemicalsinventorylistsofsuppliers.

BGENERALCONSTRUCTIONFEATURESFORSPIRALTYPEFREEZERS DesigntoHighestpriorityforhumanhealthandenvironmentalprotection ItisdesignedtofreezeorchillanyFoodproductsuchas.Productstobeevenlyfeedfromtheproductionlinedirectly ontotheloadingfreezerbelt.ProductscanbefrozeninsinglelayersorindividuallyforI.Q.F.(IndividuallyQuickFreeze) quality. SpiralFreezertobeHighestSafetyHealth/Hygiene/SanitationStandardsinstrictcompliancewiththeStandards, U.S.D.A,O.S.H.A,UL,C.S.A,CFIA(Canadian),BRC. SpiralBelting FreezerstobeequippedwithheavydutyspiralSSteel304orFood gradeacetalbelting. BeltSupportsandSpiralFrame,Drum,etc Thebeltsupportrails,thespiralframes,Drum,etctohavenoncorrosivematerialonly. DriveSystem Thefreezerdrivesystemshouldbewithallsafetyfeatures EvaporatorCoil MOC AluminiumorStainlessSteel.Thecoiltobefurnishedwithliquid,suction,hotgasandwaterconnectionsfor easyhookup. LocationtobeeasytocleanfromAllsides. ElectricalControlPanel Standard NEMAIV,UL MOC Stainlesssteel304 constructed. EnclosureConstruction MOC Inside&OutskintobemadeupofSS304withPUF/PIRinsulationmaterial.Selfsupportingconstruction&easy tocleaningandmaintenance. BeltWasher,CenterDrumInside&OutsideWasherManifold ThefreezercanbeequippedwithBeltWasher,InsideCenterdrum&OutsideItcanalsobeconnectedaspartofthe CIPSystem HotGasDefrostSystem Thefreezercanbeequippedwithhotgasdefrost(ifavailable).

FreezerUnitbasefloor MOC SSteel304ornoncorrosivematerial.Completelyindependent&selfsupporting. ALLHARDWARE Shouldbenoncorrosive LUBRICATIONFORMOTOR&BEARING Alllubricationforopenbearingordriveunittobeusedwithonlyfoodgradegreasecertifiedwhichisregisteredin Indiannationalchemicalsinventorylistsofsuppliers.

6.FREEZINGTIMEFORDIFFERENTPRODUCTS/SIZES MostproductsneedQuickFreezinguptoacoretemperatureof()18C. FreezingTimeIncaseoflargersizedproductsthefreezingtimecouldbemuchlonger dependingontheproductsize,andotherrelatedfactors.Typicallysuchcasesarepulps packed in large sizeddrum, cattle /sheepcarcasses,foodpackinglarger than100mm thicknessetc. Generally most products to befrozen have a thicknessof notmore than 100 mm.The averagetimerequiredforfreezingfortheseproductsisgiveninthefollowingtable. METHOD PlateFreezer AirBlastBatchFreezer ContinuousAirBlastFreezer BeltFreezer FluidizedBeltorTrayFreezer CryogenicFreezer FREEZINGTIME Thefreezingtimedependsonanumberofvariables a) b) c) d) e) f) g) h) TypesofFreezers EvaporatingTemperature TypesofFoods Producethicknessandshape Typeofpackingmaterial ProductIncomingandFinalfreezingtemperature Conditionoftrays Conditionofplatesi.e.qualityoffrost APPROXIMATEFREEZINGTIMES 30120minutes 180300minutesorlonger 2030minutes 510minutes to1minute

Note: Loading unloading time for products in caseof batch freezer may be considered apartfromfreezingcycletimewhileestimatingthedailyproduction. 7.THERMALINSULATIONFORFREEZERENCLOSURES,FROZENFOODSTORES ANDCOLDSPACES. Thermal Insulationarematerialsorcombinationofmaterialsthatproperlyappliedretard the flow of heat energy by conductive, convective and / or radiative transfer modes. Thesematerialscanbeparticulate,filmorsheetblockormonolithic,openorclosedcell or composites of these materials that can be chemically bound or supported. Thermal bridgeshouldbeavoided.

FUNCTIONSOFINSULATION: 1. ConserveenergybyreducingheatlossorgainthroughFreezerenclosures,Cold Storestructures,equipmentandpiping. 2. Help control the temperature of a chemical process, a piece of equipment or a structure. 3. Prevent transmission of moisture / vapour from the surroundings to the Cold interiors. 4. Reduce temperature fluctuations within an enclosure when heating or cooling is notneededoravailable. INSULATIONMATERIALS There are various types of insulation materials used for insulating freezer enclosures, coldstoresandFrozenfoodstores,vessels,pipingetc.Theseareasfollows: a) b) c) d) e) f) g) ExpandedPolystyrene(EPS) FireretardantEPS PolyurethaneFoam(PUF)/Polyisocyanurate(PIR) ExtrudedPolystyrene(XPS) Polyethylene NitrileRubber EPDM(EthylenePropyleneDieneMonomer

Outofthesea,b,c&dareusedforinsulatedenclosures,coldstoresandFrozenfood stores.ThecurrentpracticeistousesandwichinsulatedpanelswithPUF/PIR/EPS/ XPScoreinsulation. Typee,f&garegenerallyusedforvesselsandpipinginsulation. DENSITYANDTHERMALCONDUCTIVITIESOFINSULATIONMATERIALS TypeOf insulation Material K (at100 c) w/mK IS4671 18 0.036 IS12436 38 0.023 RelevantIScode

Density(min) 3 Kg/m Expanded Polyurethane (EPS) Rigid Polyurethane (PUF) Extruded Polystyrene (XPS) Phenolicfoam

32 50

0.025 0.026

IS13204

PIPEINSULATION For piping insulation with PUF/PIR & EPS materials the following tables may be referredto:

Polyurathane(PUF)/PolyisocyanurateFoam(PIR)InsulationThickness for Pipes

O (38 CAmbientTemperature)

Nominal pipesize, mm 15 20 25 40 50 65 75 100 125 150 200 250

PipeOperatingTemperature,O C +5 25 25 25 40 40 40 40 40 40 50 50 50 7 40 40 40 40 40 40 50 50 50 65 65 65 20 40 50 50 50 50 50 65 65 65 75 75 75 30 50 50 50 50 65 65 75 75 75 75 90 90 40 50 65 65 65 75 75 75 90 90 90 100 100 50 65 65 65 65 75 75 90 90 100 100 115 115

Ref:ASHRAERefrigerationHandbook

RECOMMENDEDOVERALLHEATTRANSMISSIONCOEFFICIENTSFORFREEZER ENCLOSURE,FROZENFOODSTORE&OTHERCOLDSPACES ASPERIS661 2000.

Max.U Value,W/sq.m.K OperationalTemp.Range (deg.C) Intermediate Walls/ceilings ExposedWalls (oneitherside,or doublethickness forsandwichpanel Roofs Floors

/similarInsulation)

()40to()30(*) ()30to()20 ()20to()15 ()15to()4 ()4to2 2to10 10to16 16&above

0.13 0.17 0.21 0.23 0.27 0.35 0.47 1.28

0.4 0.47 0.47 0.47 0.58 0.93 0.93 1.47

0.11 0.14 0.17 0.21 0.24 0.29 0.28 1.05

0.17 0.2 0.23 0.27 0.29 0.47 0.64 1.63

(*) Thesefigureshavebeenextrapolated.

MINIMUMINSULATION THICKNESSFORVARIOUSINSULATIONMATERIALS O BASEDONRECOMMENDEDUVALUESFOR ()30 TO ()40 C TEMPERATUREFOR FREEZERS/STORES.

TypeOf insulation

Material

Ceiling/ roof Uvalue= ExternalU Partition* 0.24 2K value= Uvalue= W/m 2 2 0.27w/m K 0.58w/m K

Wall

Floor Uvalue= 2K 0.29W/m

P K Thickness Thickness Thickness Thickness Density (at100 mm mm mm mm 3 Kg/m c) w/mK EPS PUF XPS Phenolic foam** 15 38 3035 50 0.036 0.023 0.025 0.026 275 175 200 200 100 60 75 75 300 200 225 225 200 150 150 150

Note:*Partition (oneitherside,or doublethickness forsandwichpanel/similarInsulation)

MINIMUMINSULATIONTHICKNESSFORVARIOUSINSULATIONMATERIALS O BASEDONRECOMMENDEDUVALUESFOR () 20 TO ()30 C TEMPERATUREFOR FROZENFOODSTORES.

TypeOf insulation

Material

P K Density (at100 3 Kg/m c) w/mK EPS PUF XPS Phenolic foam** 15 38 3035 50 0.036 0.023 0.025 0.026

Ceiling/ Floor roof Uvalue= 2K Uvalue= 0.29W/m 2K ExternalU Partition* 0.24W/m value= Uvalue= 2 2 0.27w/m K 0.58w/m K Thickness Thicknes Thickness Thickness mm smm mm mm

Wall

200 150 150 150

100 60 60 60

250 175 175 175

175 125 125 125

Note:*Partition (oneitherside,or doublethickness forsandwichpanel/similarInsulation)

PIPEINSULATION For piping insulation with PUF/PIR & EPS materials the following tables may be referredto:

Polyurathane(PUF)/PolyisocyanurateFoam(PIR)InsulationThickness for Pipes

O (38 CAmbient Temperature)

Nominal pipesize, mm 15 20 25 40 50 65 75 100 125 150 200 250

PipeOperatingTemperature,O C +5 25 25 25 40 40 40 40 40 40 50 50 50 7 40 40 40 40 40 40 50 50 50 65 65 65 20 40 50 50 50 50 50 65 65 65 75 75 75 30 50 50 50 50 65 65 75 75 75 75 90 90 40 50 65 65 65 75 75 75 90 90 90 100 100 50 65 65 65 65 75 75 90 90 100 100 115 115

Ref:ASHRAERefrigerationHandbook

PolystyreneFoam(EPS)InsulationThickness for Pipes

O (38 CAmbientTemperature)

Nominal pipesize, mm 15 20 25 40 50 65 75 100 125 150 200 250

PipeOperatingTemperature,O C +5 40 40 40 50 50 50 65 65 65 65 65 75 7 50 50 50 50 65 65 75 75 75 90 75 90 20 65 65 65 65 75 75 90 90 90 90 115 115 30 65 65 75 75 75 75 90 100 100 115 115 125 40 65 75 75 75 90 90 100 115 115 115 125 140 50 75 75 90 90 100 100 115 115 125 125 140 150

Ref:ASHRAERefrigerationHandbook METHODOFAPPLICATION ForConventionalInsulation Walls&Ceiling 1. PrimerCoatfollowedbytwolayersofbitumen 2. Fixingaluminiumfoilmin.50microns 3. Fixingwoodenpegsatsuitableintervals 4. Fixingtwolayersofinsulationwithstaggeredjoints 5. FixingG.Ssheetrunnersoverthepegsinlongitudinal&lateraldirections 6. Fixingprofiled&precoatedg.s.sheets,0.5/0.6mmthickovertherunnerswith properfinishingofjoints.AlternativelyFRPsheetscanbeused. Floor 1. Layingofpolythenesheet,min.250microns,asvapourbarrier 2. Fixinginsulationslabsintwolayerswithbitumenasadhesiveforthefirstlayer 3. Coveringwithtarfelt

4. LayingPCC/tremixof75mm/100mmthickness/withEpoxy/otherfloorfinish.

ForInsulatedPanelStructure Walls&Ceiling 1. Perimeteroftheplinthtobeinlevelforpanelinstallation 2. Panelstohavecamlockortongue/grovejoints 3. Sheetmetalflashingtobeprovidedonallconcrete/wallceilingjointsinternally& externally.PVCcovingorconcretecurbingtobeprovidedonwallfloorjoints. 4. HorizontalTiebracingstobeprovidedbetweenverticalwallpanels&external columns,totakecareofwindloads 5. AdequatenumbersofPressurereliefportstobeprovidedonallchamberswith electricalconnection 6. Insulateddoorsshallbesuitableforpanelmounting

CONSTRUCTIONFEATURES Construction Features The general convention of conventional construction is as follows: Foundation:SuperstructureandFoundation(whichmaybeconventionalFootingType, Pile Foundation, Raft Foundation etc) to be designed by qualified & licensedstructural/civilengineer.ThedesignshallmeettheBISstandards andrelevantseismiczonenormsforearthquakeproofdesigns. ColdChamber: Walls Minimum 230 mm Brick walls / solid concrete blocks with sandcement plaster. However, in RCC structure or prefabricated structure insulated panelboardsmayalsobeprovidedinplaceofmasonrywalls. RCC slabs or Truss Roof with G.S / Precoated G.S.Sheet cover. RCC slab to have proper water proofing with reflective colour paint / China mosaicfinish.Slabtohaveproperslopeforrainwaterdrainage. Incaseoftrussroof,provisiontobemadeforfixinginsulatedpanelsonthe ceiling & supporting ofcoolingunitsfrom the trusses(alternatively cooling unitscanbesupportedonfloormountedframestructureontopfloor). ProvisionforFRPsheetsfornaturallightingtobemadeinroofsheetingat certainlocations.Forventilationofattic,provisionofridgemonitororturbo ventilators(whichrequirenoelectricpower)canbemade.Alternativelyroof canalsobedesignedbyinstallinginsulatedroofpanelswithproperslope& sealing of longitudinal & lateral joints. The work to be handled by experiencedagenciestoensureatroublefreeroofstructure.Theroofmay bekeptwalkableformaintenance. Floor The floor comprises of base concrete, in cold stores with suitably lower levels incoldchambers. Thelevel difference betweencoldchambers and ante room to be equal tothe thickness offloor insulation plusthe layer of PCCortremixfinish.

Roof

Curbs Mediumtolargesizecoldstoragesusedforbulkstorageorwarehousingwithaconcrete floor should have a concrete or steel curb, approximately 20 cm high by 15 cm deep placedalongtheinsideperimeteroftheroom. Thecurbprotectstheinsulatedpanelsfromdamagebyaforkliftorstoredproductsand alsomaintainsrefrigerationefficiencybykeepingtheproductsawayfromthewalls,thus allowingcirculationforcoolairallaroundtheproduct.

Interfloors ThebasicstructurecanbeRCCcolumns&beamsorsteelcolumns&steel beams Grating Woodenbatten gratingorsteel grating using flats /square tubes etc.The 2 interfloors have to be designed for a product loading of 900 kg/m min. WhereACunitsarelocatedontopfloor,thestructurehastobesuitablefor theunitstatic&dynamicloads.

AnteRoom In case of Multifloor stores, Anteroom should preferably be designed to accommodate staircase, electrical hoist cage and have wider doors. Provision for fire escapestair &exits to bemade as per local norms.The interfloorsinanteroomtohavedoorstoeachcoldroomoneachfloor. Strip curtains for cold rooms and Air Curtains for external outlets/ inlets Strip curtains are quite common for reducing infiltration of air during loading/ unloading. Air curtains need power for operation but are more effective if properlyinstalled. Rodentproofcivilstructureandproperdrainageofwatertobeensured. Roomsformachines,Electricalsetc. Dock Loading & unloadingdock shall be designed with RCC slab roof or sheet roofing. However the machine roof can have RCC slabroof to accommodate the evaporative condensers, pump sets, water tank, water softener etc. Thedock area to accommodatesuitably sized office & toilet for staff&labour.

InsulatedDoors Thefreezerandfrozenfoodstorecanbeswingorslidingtype.The doors shall have heating element on all sides. Water floor heatingshould be provided on the front side of the door. The heaters should have automatictemperaturecontrolandshouldbelowvoltagetype.Allthedoor hardwareshallberustandcorrosionproof. Accesstoacoldstoremustbethroughaninsulateddoordesignedwithinsulation equivalent in value to that of the wall insulation and constructed using a rigid frame or a heavy duty metal channel incorporatinga thermal break betweenthe internal and external temperatures. Door frames should be of material not only capableofsupportingthedoor,butalsoconstructedtoensuretheintegrityofthe wallpanelstowhichtheframesarefitted. Where doors are installed in a sub freezing room, heater elements must be providedondoorsordoorframestopreventstrikingduetoicebuildup. All door hardware should be corrosion resistant and large enough to ensure the easyoperationofdoors.

Since doors are subject to frequent handling and abuse they must be extremely well designed, rugged and manufactured by specialist insulated door manufacturers, particularly since the variety of door designs is vast and outside therangeofallinsulatedpanelmanufacturers. Alldoorsinstalledincoldstoremustbeprotectedfromdamagebyforklifttrucks movinginandoutofdoorsathighspeeds.Thecommonestformofprotectionisin theshapeofagoalpost,securelyboltedtothreefloors.Allsuchprotectionbarriers shouldbeboldlypaintedinblackandyellowstripesforeasyidentification.

Ancillaries Underground fresh water storage, storage for fire fighting, water supply & sanitaryarrangements,compoundwall/fencing,maingate,security,small canteen/electricalsubstation&D.G.setplatform,roads&parkingplace forvehiclesetc.Greenlandscapingwithbenchesforlabourersisdesirable. Pressure Relief Valves: Pressure Relief Valves for insulated panel structure to take care of the pressure changes either inside or outside a low temperature coldroom,havetobeprovidedonwallorroofpanels.ThePressureRelief Valveshavetobepanelmountedtypeandcompletewithelectricalheating elementtoeliminatefrosting. Coving Thefoodindustryfrownswhentheyseesharpcorners,whereverwallsmeetoralongthe cornersformedbyceilingandwallpanelsorfloorandwallpanels.Cornerstendtocollect dirt and small pieces of stored products and are difficult to keep clean and become a breedingareaforbacteriawhenfoodproductsdeteriorate. RoundedcornersorcovingsmadeofPVC,aluminiumorstainlesssteelcanbeusedfor thewall/wallorceilingpaneljoints. FloorChannels PVCchannelscanbeusedforboltingonafinishedconcreteflooralongtheperimeterof theroomandusedtoprovideasupporttothewallpanelsinstalledonthefloor.Different widthsofsuchchannelsareavailabletosuitvaryingpanelthickness. LOADING/UNLOADINGDOCKS Used for in loading of products to be stored as well as out loading the refrigerated productsfromandtodeliverytrucks.Theyshouldbeasspaciousaspossiblebecauseof thehighactivitylevels.Theyshouldalsobewelllitandtemperaturecontrolledtoabout5 C.theloadingdockactsasabufferbetweenthetemperaturecontrolledareasandthe ambient.

LoadingLevellers Sinceavarietyoftruckswillbebringinginandtakingouttheproducts,itisnecessaryto provide a dockleveller thatcancope with differingfloor heightsof trucks. As aguide, thedocklevellershouldbelongenoughtokeeptheslopedowntothelowestvehicleno morethan10%. Docklevellerscanbeelectrohydraulicallyoperatedormanual.Theycanhaveafixedlip, afoldingliporahydraulicallyoperatedlip.The morevehiclemovementsthereare,the betteristhecaseforhydraulicassistancetoraiseandlowertheleveller. DockSeals,DockSheltersandDockDoors. To provide a goodseal between the truck door opening and the loadingdock, a dock sealwithastationaryfoamfilledheaderprovidesatightsealatthesidesandtopofthe truck. If the dimensions of thevehicle are known and unlikely to vary, these stationary sealsprovideareasonablytightsealpreventinghothumidairfromtheoutsideinfiltrating intothedockarea. Withvaryingsizes,inflatabledocksealsusingabuiltinsmallblowercanmakeuniversal sealingofallsizesofvehiclesapossibility.Sincesuchinflatablesealscanbeexpensive, adockshelterwithrubberflapsonthesidesandtopofthesheltercanprovideasnugfit betweenvaryingvehiclesizesandthedock. In order to seal off the loading dock from several truck access openings, a segmented manualorpoweroperatedoverheaddoorshouldbeinstalledateachdocksealordock shelter,forsecurityreasons,openableonlyfromtheinsideofthedockarea.

BUILDINGW ALL

TYPDOORWIDTH(2450)

DOCKSEAL

"A"

OUTSIDE
TYPDOOR HEIGHT (2750)

INSIDE

LAMINATED BUMPERS

TRUCK APPROACH

DOCKLEVELER

HYDRAULICDOCKLEVELER

"A"

Note:
1)HYRDAULICPOWERPACKISLOCATEDINSIDETHEDOCKLEVELERPIT. 2)CONTROLPANELISLOCATEDINSIDETHEBUILDING.

8.REFRIGERATIONSYSTEMSELECTION AlltheFreezingsystemsoperateatevaporatingtemperatureintherangeof()35Cto ()45C. a. COMPRESSORSYSTEM Thesystemrequiresatwostagerefrigerationplantofoneofthefollowingtypes: a) CombinationofLowandHighCompressor b) Compound(twostage)Compressor c) Cascadesystem ProvisionofstandbyCompressorisdesirableespecially,incaseoflargerplants. The Compressors can be Reciprocating or Screw type. The Reciprocating Compressors shall have capacity control in steps or through VFD. The Screw Compressor should preferably have step less capacity control. The energy efficiencyoftheCompressorsisthemostimportantfactorfortheselectionofthe Compressors. NOTE: For evaporating temperatures below () 30C CO2 / NH3 cascade refrigeration system canbeconsidered. b. TYPESOFCONDENSERS Condenserscanbe: a) EvaporativeCondenser b) AtmosphericCondenser c) ShellandTube/PHECondenserwithcoolingtowersforwatercooling. d) AirCooledCondenserstobeusedforHFCsystemsincasesoftwaterisnot available.CondenserAirPrecoolingsystemshouldbeincorporatedalongwith Air cooledcondensers for energy saving. Aircooledcondensers workbestin openareaswithlotsofventilation,butcanbeprotectedfromrainbyproviding shed. Waterneedstobesoftqualityanddecontaminatedforwhichwatersoftening/ other relevant equipment has to be installed for the makeup water. The Condenser should be selected for the lowest possible Condensing temperature. Generally, a condensing max temperature of 38C (or lower, if possible)isrecommended. Evaporative condensers offer better energy efficiency as compared to other types. Atmospheric / Evaporative Condensers should be kept in open areas whereairflowisnotrestricted.

c. TYPESOFAIRCOOLINGUNITS TheaircoolingunitusedinAirBlastFreezingsystemsshallhavefinnedcoils andheavydutyaxialflowfans.TheAirCoolingunitsshallbeeitherlocatedon thefloororoverheaddependingonthefreezerdesign. Ammonia coils are typically MS hot dip galvanised or SS/ aluminium tubes with Aluminiumfins.ThecoolingunitsforHFCrefrigerantshavecoilswithcoppertubesand aluminiumfins.CoilswithAluminiumtubesandAluminiumfinscanalsobeused.The finspacingonthesecoilsshouldbeintherangeof10mm25mm.Acombinationof finspacingsinthisrangecanalsobeusedoverthecoildepth. d. AIRPURGER(MANUALORAUTOMATIC) It is desirable to remove air and other non condensable gases from the refrigeration circuit to keep the compressor head pressures lower and also improve heat transfer coefficients. LIQUIDFEED Theliquidfeedcanbe a) DirectExpansionIncaseofHFCsystem b) GravityfeedIncaseofAmmoniasystem c) Refrigerantpumprecirculation(Overfeed)IncaseofAmmonia/HFC TheDirectExpansionsystemresultsinabout20%lowercapacityoffreezing. DEFROSTING Defrostingsystemcanbeofthefollowingtypes: a) b) c) d) WaterDefrosting HotgasDefrosting OffCycleDefrosting((Betweenshifts) ElectricaldefrostingcanbeusedinHFC(Freon)basedsystems

e. TESTINGANDCOMMISSIONINGTHESYSTEM Installation, Testing & Commissioning should be carried out as per BIS standards. ASHRAEstandardsmaybereferredtoasguidelinesbutnotmandatory. f. EQUIPMENTDERATINGATHIGHERAMBIENT A designer should match the loads with the derated equipment capacity at higher ambientconditions.

GENERALSPECIFICATIONSFORREFRIGERATIONSYSTEM BriefSpecificationsforEquipment/Materials/Services i. RefrigerationCompressors&Motors

CompressorArrangement

Type

A combination of low stage and high stage compressors or compound compressors. Standby compressorpreferredincaseoflargerunits.Incase of HFC refrigerant two stage compressors or rack systemcanbeused. For ammonia as refrigerant, reciprocating, multi cylinder complete with watercooled head / jackets, withaccessories like oil separators,capacity control & unloaded start. Alternatively screw compressor, open type with accessories can be provided. For HCFC / HFC, reciprocating. / scroll / screw can be provided.IfAircooledcylinderheadsaretobeused for low stage compressors adequate ventilation shouldbeprovidedfortheplantroom.

Capacityatcriticaloperating TobeconfiguredinKw conditions To be configured in kW, RPM, type of insulation, EstimatedMotorrating InputACpowersupply ii.EvaporativeCondenserforAmmonia/HFC: Coilsection Hot dip galvanised M.S. pipes / CDW Boiler qualitytubes/S.S.304tubes With2/3AxialFlowFanswithCastAluminium/ S.S / GRP impellers, complete with TEFC Sq. cage motors, Class F insulation & IP55 protection S.S.304 /M.S. Epoxy coated with necessary connections Water spray arrangement, air inlet grilles, eliminatorsofsuitabledesign with removable G.S sheet panels & inspection windowsetc.

Fansection

Watersumptank Otherprovisions Unitcasing

Estimated Heat rejection capacity TobeconfiguredinKW at 38 deg C condensing & and applicableWBtemp SuggestedStandard ARIStd490

Aircooled/watercooledcondenserforHFC. Capacity Size TobeconfiguredinKW Tobefurnished

iii.)GasandLiquidIntercooler GasIntercoolerandLiquidSubcooler M.S. Construction with gas inlet and outletconnections,liquidsubcoolingcoil and liquid injection connection to be provided.

iv.H.P.ReceiverforAmmonia/HFC: HorizontalReceivercomplete Capacity MaterialofConstruction With necessary connections, reflex type levelgaugeetc. Tobeconfigured Boilerqualitysteelplates 2 Nos. (Two Nos. are suggested in case some States regulations call for Pressure testing of high pressure vessels on a periodicbasis) ANSI/ARI495/BISCodeIS2825

Quantity

SuggestedStandard

v.AirCoolingUnitsforAirBlastFreezers/DeepFreezechambers. a)Finnedcoolingcoil Coildesigntobesuitableforgravityfeed/pumpre circulation/overfeedsystemforammonia&DX operationforHFCasperdesign Hot dip galvanised coil with M.S. pipes CDW Boiler quality tubes ASTM A 214 with MS fins / S.S.304 tubes &Aluminium fins / Aluminium Tubes & Aluminiumfinswithproperbondingsystemwithbullet drawnexpansion/equivalentexpansionforAmmonia ForHFC/HCFCcoilswithcoppertubes&aluminium finsoraluminiumtubeswithaluminiumfinswithbullet drawnorequivalentexpansionmaybeused.

M.O.C

Finspacing b)AxialFlowfans

Inrangeof10to25mminstepsinthecoildepth. With cast aluminium / S.S. / FRP impellers, with variablepitch, TEFC Squirrelcage motors withclass Finsulation,IP55protection Vertical / horizontal with necessary connections (in caseofgravityfeedunits)forAmmonia G.S. sheetduly painted, drain pan ofG.S /M.S with epoxypaint Water/Hotgas/Air Drainpan,Drainpipe,Fancasing

c)Accumulator d)Unitcasing e)Defrostingarrangement f)Electricalheattracing Unitcapacities Numberperchamber

Tobeconfigured

Estimatedcapacityeachat Tobeconfigured criticaloperatingconditions Estimatedcoilsurfacearea Tobeconfigured Estimatedairflowcapacity withadequateexternal staticpressure Tobeconfigured

vi.RefrigerantPiping,Fittings&Valves Piping Interconnectingpipingbetween compressor,condenser,receiverand coolingunits M.S.blackpipingconformingtoIS1239/ ASTM A Gr.106B for 40 NB & smaller sizes / ASTM A Gr.53B for 50 NB & largersizesincaseofammoniaplants. ForLowtemprefrigerantlinebelow()30 Deg C upto () 45 Deg C SA 333 Gr 1, Grade6tobeused.ForAmmoniafittings shallbeofforgedsteel.ForHFC/HCFC, hardCopperpipingtypeL Pipingasper. ANSIguidelinesandpressurevesselsas per BIS Code IS 2825). Reference to ASHRAEB31.5recommended.

vii.WaterPiping,Fittings&Valves

Pipingshallbeusedfor a.Condenserwatercirculation b.Compressorcooling c.Defrosting d.Drainlines

PipingtobeG.IclassBorsizesupto65 NB & M.S. black pipe conforming to IS 1239. Valves up to 40 NB to be Gate / Globe type. Valves50NB/largertobebutterflytype.

viii.WaterPumpsets Waterflowcapacitytotakecareof condenserwaterflow&compressor head/jacketcooling Capacity At least 2 nos. operational during peak loadand1nostandby Tobeconfigured

ix.Thermalinsulationforrefrigerantpipingetc. a. EPSpipesection b. PUFpipesection With 0.6 mm Aluminium or 0.5 mm G.S.precoatedsheetcladding c. Nitrile Rubber / EPDM / chemically cross linked polyethylene pipe section/otheracceptablematerials with woven glass cloth with UV treatedpigmentedepoxyCoating x.Controls. Temp Indicators cum controllers for individual freezers and chambers. Temperature scanners and a centralized temperatureindicationinmachineroom Liquidlevelcontrols,solenoidvalvesetc. Recommendedincaseofcontinuous freezersanddeepfreezechambers. Foroverallcontrolofvariousparameters

Materialforinsulationforrefrigerant suctionline,accumulatorsetc.

Temperaturecontrol

Refrigerantflowcontrols DefrostControlsforautomatic defrostingifrequired PLCcontrolsystems

Note. Location for installing the sensors will depend on site conditions and stacking patternetc.ThereforeProgrammableLogicControllers(PLC)isrecommendedforlarge unitswiththedisplaypointinthemanagerscabin. xi.Installation,Testing&Commissioning Installation Theplant shallbe installed, tested & commissioned as per IS 660 / ASHRAE.Std15.

GeneralNotes: 1. Incaserefrigerantpumpingsystem(overfeedsystem)isuseditwillincorporate thefollowingcomponents. a. Centralised L.Preceiver b. Refrigerantpumpsincludingstandby c. Refrigerantflow&safetycontrols d. Interconnectingpipingbothsupply&returnlinesshallbeinsulated.Inthiscase theindividualaccumulatorsforACunits&levelcontrolsetc.arenotrequired.

ELECTRICALINSTALLATIONS PowerFactornotlessthan0.95 Transformerofminimumrequiredcapacity Substationwithadequaterating Substationwitharatingadequate capacity a. Step down transformer suitable for incoming H.T. voltage / 433 V as per IS 2026/otherapplicablestandards b.Twopole/fourpolestructureasperlocal requirements c. Outdoor type metering cubicle with approvedmeter,CTs/PTsetc. d.Earthlingstationasperrequirement e. Switchyard fencing with gates as per ElectricalBoardrequirements

D.G.Setforstandbypower Estimated Rating: as per design. One big for pull down period and one small forholdingperiodmaybeused.Theuse ofDieselenginesoncompressorsisleft tothepromotertoassessbutkeepingin viewoverallCoPoftheplant.

D.G.setcompletewithaccessories andwithweatherproofandnoiseproof canopyasperlocalpollutioncontrol norms

Mainpowerdistributionpanel Main power distributionpanel with changeover facility for normal electricsupply &D.G. setsupply.Withongoingfeedersforvariouselectricalpanels. Electricpanels a.Refrigeration b.Lighting,Electrichoist,Fans c. APFC (automatic power factor correction)panel d.Watersupply,firefightingetc.

Electricpanelsfor

Power&Controlcablingetc Aluminium armoured conductors for PowerandControlcabling,earthingetc main power lines & equipment lines forvariouselectricalcircuits & copper conductors for lighting, controlwiringetc. vi. Lighting

Lightingin a. Freezers, Process Halls, Packing Room, ante room, Dockandoutsideareas. b.Otherareas c.Outsideareas

Forfreezer&frozenfoodstoresS.V.Lamps /LEDLamps. FormediumtempcoldstoresCFL/LEDwith vapourprooffittings. For process / other areas T 5 type TL / CFL/LEDLamps.

SAFETYMEASURES Ammonia sensors at proper places and Machine room near ACUs & machineroom Emergency ventilation for machine room Safetyreleaseofrefrigeranttowater accidental sump Ammoniamasks Firstaidkit Instructions for handling emergencies. Resettable dual safety valves for all pressurevessels. ProvisionforFaceWashing Quick oil drain valve on receivers

Provision for handling leakageofammonia

andotherequipment. Fire sensors in suitable places and machinerooms&machineroom. Dry & water based fire fighting systemsasperspecsbelow. Sprinklersforhighpressureandlow pressurereceivers. May besolarPV cells with batteries &controller To be provided with switches near all cold store doors and alarms locatedincommonpublicareas

Fireprotection

Emergencylightingsystem

Emergencyalarmsystem

Lightningarrestorsforthebuildingasperlocalregulations

FireFighting a) DryType Fire fighting equipment necessary i)Drychemicalpowdertype5.0KgCap for with ISI Mark Fire Extinguisher completewithwallmountingbracket. extinguishing liquid, solid and ii) Carbon DiOxide (CO2) type 4.5 Kg. electricalfire: capacity Fire Extinguisher complete withwallmountingbracket. iii')G.I.FireBuckets iv)M.S.StandforFireBuckets

b) Waterbased(mandatoryiflocalcodesoprescribes)

Systemshallcompriseof

i)2setsofWatersupplypumps. ii)2setsFirefightingpumps iii) G.I. piping, class C with necessary fittings & valves iv)RubberHosereel v)CanvasHosepipe vi)M.S.Fabricatedhoseboxwithkey vii) any other requirements as per local fire officer.

CoefficientofPerformance(COP)Foroptimumenergyefficiencytheplantshouldbe selectedwithbestpossibleCOP. Operation & Maintenance Plant design must be accompanied by Operation & MaintenanceManualforplantoperatorwhichshouldcoverfollowingpointsinEnglishas wellasHindilanguages No.ofoperatinghours Trainingofoperators Monitoring&controltemperature,humidity,CO2 Doorsealscheckingmethods Maintenanceofequipment/coldstore Hygieneissues Variation/amendmentClause The standards prescribed above are not intended to prevent or discourage variations arising out of new concepts, innovations and R & D in building design & construction, thermalinsulationandcooling&refrigerationtechnologyetc.However,anyvariationsor deviations from the above prescribed standardsmust be supported by scientific / technicaldetailsforpriorapprovalofthecompetentauthority,onthebasisofmeritwho may decide the proposal in view of relevant technical details including critical storage requirements,energy efficiency (coefficient of performance),availability of Standards, environmental concerns, safety etc. Similarly, periodic amendment of standards for general application may also be undertaken by the National Horticulture Board in consultationwithacommitteeofsubjectmatterexpertsdulyconstitutedforthispurpose.

9. REFRIGERATIONSYSTEMSLOADCALCULATIONS
TotalRefrigerationLoadHeatLoadCalculation Procedureforloadcalculation Procedures laid out byASHRAE Fundamentals and Refrigeration handbooksmay be followed.ASHRAE refrigeration handbook elaborates a more traditional approach. Thus, based on the overall impact/ sensitivity of important parameters, someestimatescanbemade.Designersalsotendtotakeasafetyfactorof510% ontheestimatedloads. Ambientconditions 0.4%annualdesignconditionsofthatlocationasperASHRAE/ISHRAEdatamay be used for holding period. For the loading and pull down periods, 0.4% design conditionsforthosemonthsmaybetaken. TheRefrigerationloadforfreezingshallinclude a) TheTransmissiongainsthroughthefreezerenclosure b) Thefanmotorload,incaseofBlastandIQFtypefreezers c) Loadsduetomechanicalconveyors d) Productcoolingandfreezingload e) Anyotherloadifapplicable ProductIncomingtemperature ItdependsontheprocessfollowedandtheChilling/Precoolingmethod.Generally theproducttemperaturesenteringthefreezermaybeintherangeof1020DegC. FinalProductTemperature Unless otherwise specified the final core temperature of the product after freezing canbeconsideredas()18DegC.Howeverinsomecasestheprocessorsspecify lowertemperaturesof()23to()25DegC ProductLoad Theproductloadduringthefreezingprocessshallcompriseof

a) Theloadduringcoolingofproductuptofreezingtemperature b) Thelatentheatoffusion c) Thesubcoolingofproductfromfreezingtemperaturetothefinaltemperatureof

thefrozenproduct.

HeatLoadCalculationofCoolingSystemSummary HeatLoadCalculationsSummaryforFreezer Ambient FreezingsuctionRoomTempOC IncomingProductTemp FinalProductTemp(Core) Productloadperbatchorperhour ProcessingHallConditionsDBtemp CRH% TransmissionLoadKW Productloadincluding a)Initialcooling b)Freezing c)SubcoolingtofinalstageTemp. LoadduetoBeltconveyor/other Mechanisminfreezer FanmotorloadincaseofAirBlast Freezer(kW) Totalload Safetyfactor TotalRefrigerationLoad(kW) NOTE1:Separatesheetsbesubmittedfordifferentfreezers. NOTE 2: A good order of magnitudeestimate of totalRefrigerationload for IQFis 155 kWofRefrigeration/MTofproduct/hour.Incaseofsmallfreezersthecapacitymaybe 1015%higher. PackagingMaterialsofFrozenFoods Packaging materials of frozen foods impose special requirements. Selection of these materialsshouldincludeconsiderationoftheirintendedproductuseandstorageperiod. Thesematerialsshouldresistwatervapourpermeabilityfromcondensationoccurringas aresultoffrozenfoodsurfacesbeingaffectedbycoldersurfacesinfreezersandstorage rooms. These packaging materials should be strong, have a degree of flexibility, or should not be completely filled. Materials also should protect against light and air penetration. Vacuum packaging or gas flushing will when chosen, act to retard deteriorationofcertainproducts.

FoodSafetySystems Food safety and quality in agricultural food products is maintained throughout the food continuum, including primary producers, processors and other partners such as transporters, distributors, retailers including restaurants and even manufacturers of packagingmaterialsandice. It was designed to encourage the establishment and maintenance of Hazard Analysis CriticalControlPoint(HACCP)basedsystemsinregisteredagriculturalfoodprocessing establishments. The food industry sector already has developed generic models for many commodities includingonespecifictocoldstorage/freezerfacilities(meat,nonmeat,food,nonfood). ThismodelisbasedonHACCP,usingthisapproachtofullycontrolhazards(biological, chemicalandphysical)withprerequisiteprograms,andwhennecessary,CriticalControl Points(CCP). Anindustry/governmentstandardof()18C(0F)orcolderhasbeenadopted.Stored andtransportedproductideallyshouldbeat()18C(0F)orcolder. Temperaturecontrolisnottheonlyfactorthatinfluencesthesafetyoffoodsthroughout itsjourneyalongthecontinuum.Eachsector,frommanufacturer,warehouse,distributor, transportertoretailer,ischargedwiththeresponsibilityofadheringtoandusingproper handling techniques. These are comprised of codes of practice, good manufacturing practices, codes of hygiene, and acceptable industry practices where no legislation exists.

SECTION2 TypicalDesignParameters&Layoutforfoodfreezing&StoragePlant 1) PlantLocation 2) Outsidedrybulbtemp 3) Outsidewetbulbtemp 4) Powersupply 5) ControlPowersupply 6) Productreceivingsystem covered/container 7) Producttemperatureatthetimeofloading 8) Storagesystem 9) Typeofproducts 10)Sizeofproduct,mm&Weight,kg 11)Typeofprocessingbeforefreezing 12)TypesofFreezers 13)Estimatedtimeoffreezingperbatchforbatchfreezers 14)Estimatedfreezingcapacityperhourforcontinuousfreezers 15)Producttemperaturebeforefreezing 16)Finaltemperatureafterfreezing 17)Typeofsizeofpackagesforstorage 18)NooffrozenfoodstorageDeepFreeze 19)Chambersizes&theircapacities 20)LoadingRate%ofstoragecapacity 21)Designstoragetemperaturewithtolerance 22)ProcessHall 23)DesignConditions a. DBTemperature b. RH 24)PackingHall a. DBTemperature b. RH 25)AnteRoom 26)Dock 27)Compressorrunninghoursduringpeakseasonhoursperday 28)Compressorrunninghourduringholdinghoursperday OTHERCONSIDERATIONS Heatloadincaseofbatchfreezersshallbedoneonthebasisofbatchduration. Theheatloadin caseofcontinuousfreezersshallbedoneonperhourbasis. Theairvelocityintheairblastfreezersshallbeintherangeof5m/sto10perm/s. Thefreezingloadincaseofmostproductswouldbeintherangeof110to116 w/kgofproduct.Howeverproperloadcalculationshouldbedoneforeachtypeof product&freezingsystem.

TYPICAL DESIGN PARAMETERS AND LAYOUT OF FOOD FREEZING AND STORAGEPLANT

PartIITechnicalStandardNoNHBFrozenFoodStorage&Systems IntegratedtoReeferTransport SECTION1

1. THENEEDFORFREEZINGANDFROZENSTORAGE Freezinghasbeensuccessfullyemployedforthelongtermpreservationofmanyfoods, providing a significantly extended shelf life. The process involves lowering the product temperaturegenerallyto18Corbelow.Thephysicalstateoffoodmaterialischanged whenenergyisremovedbycoolingbelowfreezingtemperature.Theextremecoldsimply retardsthegrowthofmicroorganismsandslowsdownthechemicalchangesthataffect qualityorcausefoodtospoil. 2. FROZENFOODSTORES Therearenumberofcommoditieswhichhavetobeprocessedandfrozenforpreserving themforlongperiodsoftime.TheseincludeGreenPeas,Corn,Okra(LadiesFingers), mixed vegetables, Mango Pulp & Slices, Pineapple Slices, Tomato Puree etc. Other itemsareicecream,butter,fishandmeatproducts.Thefrozenfoodstoresaregenerally designed for a temperature () 20 BC to 2 BC for most foods but for items like ice creamlowertemperatureintherangeof()25BCto()30BCarespecified. Thefrozenfoodstoresare,normally,apartofthefoodprocessingandfreezingcomplex. However they could be set up as a part of multipurpose cold store or as independent unitstoofferfacilitiesforstorageofproducts,alreadyfrozenatthefoodfreezingplants. 3.STORAGETEMPERATURECHART

PRODUCT

STORAGE TEMP;0C
()30to()20 ()20 ()20 ()20 ()23 ()30to()25

RELATIVE HUMIDITY,%
90to95 90to95 90to95 90to95 70to85 90to95

APPROXIMATE A STORAGELIFE
6to12month 6to12month 4to8month 12month 12to20month 3to23month

FrozenFish Beef,Frozen PorkFrozen Poultry,frozen Butterfrozen Icecream,10%fat

LambFrozen HamFrozen FrozenFruit&Veg. Products Readytoeatfoods

()20 ()20 ()18to()20 ()18to()20

90to95 90to95

8to12month 6to8month 6to9month 6to9month

4.THERMALINSULATION Thermal Insulationarematerialsorcombinationofmaterialsthatproperlyappliedretard the flow of heat energy by conductive, convective and / or radioactive transfer modes. Thesematerialscanbeparticulate,filmorsheetblockormonolithic,openorclosedcell orcompositesofthesematerialsthatcanbechemicallyboundorsupported. FUNCTIONSOFINSULATION: 1. Conserve energy by reducing heat loss or gain through Freezer enclosures, Cold Storestructures,equipmentandpiping. 2. Help control the temperature of a chemical process, a piece of equipment or a structure. 3. Prevent transmission of moisture / vapour from the surroundings to the Cold interiors. 4. Reducetemperaturefluctuationswithinanenclosurewhenheatingorcoolingisnot neededoravailable. INSULATIONMATERIALS There are various types of insulation materials used for insulating freezer enclosures, coldstoresanddeepfreezers,vessels,pipingetc.Theseareasfollows: a) b) c) d) e) f) g) ExpandedPolystyrene(EPS) FireretardantEPS PolyurethaneFoam(PUF)/Polyisocyanurate(PIR) ExtrudedPolystyrene(XPS) Polyethylene NitrileRubber EPDM(EthylenePropyleneDieneMonomer

Outofthesea,b,c&dareusedforinsulatedenclosures,coldstoresanddeepfreezers. The current practice is to use sandwich insulated panels with PUF / PIR / EPS / XPS coreinsulation.

DENSITYANDTHERMALCONDUCTIVITIESOFINSULATIONMATERIALS

TypeOf insulation

Material

RelevantIScode

Density(min) 3 Kg/m Expanded Polyurethane (EPS) Rigid Polyurethane (PUF) Extruded Polystyrene (XPS) Phenolicfoam

K (at100 c) w/mK IS4671

18

0.036 IS12436

38

0.023

32 50

0.025 0.026

IS13204

RECOMMENDEDOVERALLHEATTRANSMISSION COEFFICIENTSFORFREEZER ENCLOSURE,FROZENFOODSTORE&OTHERCOLDSPACES ASPERIS661 2000.

Max.UValue,W/sq.m.K Intermediate Walls/ceilings ExposedWalls (oneitherside,or doublethickness forsandwich panel /similarInsulation) Roofs Floors

OperationalTemp.Range (deg.C)

()40to()30(*) ()30to()20

0.13 0.17

0.4 0.47

0.11 0.14

0.17 0.2

()20to()15 ()15to()4 ()4to2 2to10 10to16 16&above

0.21 0.23 0.27 0.35 0.47 1.28

0.47 0.47 0.58 0.93 0.93 1.47

0.17 0.21 0.24 0.29 0.28 1.05

0.23 0.27 0.29 0.47 0.64 1.63

(*) Thesefigureshavebeenextrapolated.

MINIMUMINSULATIONTHICKNESSFORVARIOUSINSULATIONMATERIALS O BASEDONRECOMMENDEDUVALUESFOR ()30 TO ()40 C TEMPERATUREFOR FREEZERS/STORES.

TypeOf insulation

Material

P K Density (at100 3 Kg/m c) w/mK EPS PUF XPS Phenolic foam** 15 38 3035 50 0.036 0.023 0.025 0.026

Ceiling/ Floor roof Uvalue= 2K Uvalue= 0.29W/m 2K ExternalU Partition 0.24W/m value= Uvalue= 2 2 0.27w/m K 0.58w/m K Thickness Thicknes Thickness Thickness mm smm mm mm

Wall

275 175 200 200

100 60 75 75

300 200 225 225

200 150 150 150

MINIMUMINSULATIONTHICKNESSFORVARIOUSINSULATIONMATERIALS O BASEDONRECOMMENDEDUVALUESFOR ()20 TO ()30 C TEMPERATUREFOR FROZENFOODSTORES.

TypeOf insulation

Material

P K Density (at100 3 Kg/m c) w/mK EPS PUF XPS Phenolic foam** 15 38 3035 50 0.036 0.023 0.025 0.026

Ceiling/ Floor roof Uvalue= 2K Uvalue= 0.29W/m 2K ExternalU Partition 0.24W/m value= Uvalue= 2 2 0.27w/m K 0.58w/m K Thickness Thicknes Thickness Thickness mm smm mm mm

Wall

200 150 150 150

100 60 60 60

250 175 175 175

175 125 125 125

PIPEINSULATION

ForpipinginsulationwithPUF/PIR&EPSmaterialsthefollowingtablesmaybe referredto:

Polyurathane(PUF)/PolyisocyanurateFoam(PIR)InsulationThickness for Pipes

O (38 CAmbientTemperature)

Nominal pipesize, mm 15

PipeOperatingTemperature,OC +5 25 7 40 20 40 30 50 40 50 50 65

20

25

40

50 50 50 50 50 65 65 65 75 75 75

50 50 50 65 65 75 75 75 75 90 90

65 65 65 75 75 75 90 90 90 100 100

65 65 65 75 75 90 90 100 100 115 115

25 25 40 40 40 40 50 40 40 65 40 40 75 40 50 100 40 50 125 40 50 150 50 65 200 50 65 250 50 65 Ref:ASHRAERefrigerationHandbook

PolystyreneFoam(EPS)InsulationThickness for Pipes

O (38 CAmbientTemperature)

Nominal pipesize, mm 15 20

PipeOperatingTemperature,OC +5 40 40 7 50 50 20 65 65 65 65 75 75 90 90 90 90 115 115 30 65 65 75 75 75 75 90 100 100 115 115 125 40 65 75 75 75 90 90 100 115 115 115 125 140 50 75 75 90 90 100 100 115 115 125 125 140 150

25 40 50 40 50 50 50 50 65 65 50 65 75 65 75 100 65 75 125 65 75 150 65 90 200 65 75 250 75 90 Ref:ASHRAERefrigerationsHandbook

METHODOFAPPLICATION ForConventionalInsulation Walls&Ceiling 1. PrimerCoatfollowedbytwolayersofbitumen 2. Fixingaluminiumfoilmin.50microns 3. Fixingwoodenpegsatsuitableintervals 4. Fixingtwolayersofinsulationwithstaggeredjoints 5. FixingG.Ssheetrunnersoverthepegsinlongitudinal&lateraldirections 6. Fixingprofiled&precoatedG.S.sheets,0.5/0.6mmthickovertherunnerswith properfinishingofjoints.AlternativelyFRPsheetscanbeused. Floor 1.Layingofpolythenesheet,min.250microns,asvapourbarrier 2.Fixinginsulationslabsintwolayerswithbitumenasadhesiveforthefirstlayer 3.Coveringwithtarfelt 4.LayingPCC/tremixof75mm/100mmthickness/withEpoxy/otherfloorfinish. ForInsulatedPanelStructure Walls&Ceiling 1. Perimeteroftheplinthtobeinlevelforpanelinstallation 2. Panelstohavecamlockortongue/grovejoints 3. Sheetmetalflashingtobeprovidedonallconcrete/wallceilingjointsinternally& externally.PVCcovingorconcretecurbingtobeprovidedonwallfloorjoints. 4. Horizontal Tie bracings to be provided between vertical wall panels & external columns,totakecareofwindloads 5. Adequate numbers of Pressure relief ports to be provided on all chambers with electricalconnection 6. Insulateddoorsshallbesuitableforpanelmounting

UNDERFLOORHEATING Consideringthepossibilityoffreezingofsubsoilwaterunderthefloor(phenomenon called frost hieve), it is necessary to provide under floor heating in one of the followingways. a) b) c) ProvidingAirventpipesinwarmerclimatezones. Providingpipingnetworkforcirculationofheatedglycol. Providingelectricalheattracingwithtemperaturecontrol.

NOTE: Ventpipesshouldhaveendsprovidedwithcleanablemeshcovers.Pipesshould belaidwithproperslopefordrainingcondensate,whichmaybeformedinthepipes.

TYPICALVIEWOFUNDERFLOORVENTPIPES

VAPO R R ETAR ER D

IN LATIO SU N INS ULATIO N

R FSU R OO PPO TSTEEL

VAPO ETAR ER RR D

C U IO O SH N C LOSU E R TR K UC DO K C R IGER EFR ETED TR C U K

FR EEZER V APOR R ETAR ER D FLO OR SLAB

FLOO RINS TIO ULA N

H EATING PIPES/C ILS O

HR O IZON TALSLID G IN FR EEZER OO D R

VER ALSLID G TIC IN DO KD R C OO S

STACKINGARRANGEMENT FrozenFoodstorescanbeconstructedfordifferentproductloadingpractices.e.g. 1) Multifloorstoresformanualloading/unloading. 2) Singlefloorstoreswithracksforpalletizedloading/unloadingbothstationaryand mobilerackcanbedonewithforklifttrucks. 3) Single floor structure with racks for Semi manual operation with reach in type orderpickers. CONSTRUCTIONFEATURES Construction Features The general convention of conventional construction is as follows: Foundation:SuperstructureandFoundation(whichmaybeconventionalFootingType, Pile Foundation, Raft Foundation etc) to be designed by qualified & licensedstructural/civilengineer.ThedesignshallmeettheBISstandards andrelevantseismiczonenormsforearthquakeproofdesigns. ColdChamber: Walls Minimum 230 mm Brick walls / solid concrete blocks with sandcement plaster. However, in RCC structure or prefabricated structure insulated panelboardsmayalsobeprovidedinplaceofmasonrywalls. RCC slabs or Truss Roof with G.S / Precoated G.S.Sheet cover. RCC slab to have proper water proofing with reflective colour paint / China mosaicfinish.Slabtohaveproperslopeforrainwaterdrainage. Incaseoftrussroof,provisiontobemadeforfixinginsulatedpanelsonthe ceiling & supporting ofcoolingunitsfrom the trusses(alternatively cooling unitscanbesupportedonfloormountedframestructureontopfloor). ProvisionforFRPsheetsfornaturallightingtobemadeinroofsheetingat certainlocations.Forventilationofattic,provisionofridgemonitororturbo ventilators(whichrequirenoelectricpower)canbemade.Alternativelyroof canalsobedesignedbyinstallinginsulatedroofpanelswithproperslope& sealing of longitudinal & lateral joints. The work to be handled by experiencedagenciestoensureatroublefreeroofstructure.Theroofmay bekeptwalkableformaintenance. Floor The floor comprises of base concrete, in cold stores with suitably lower levels incoldchambers. Thelevel difference betweencoldchambers and ante room to be equal tothe thickness offloor insulation plusthe layer of PCCortremixfinish.

Roof

Interfloors ThebasicstructurecanbeRCCcolumns&beamsorsteelcolumns&steel beams Grating Woodenbatten gratingorsteel grating using flats /square tubes etc.The 2 interfloors have to be designed for a product loading of 900 kg/m min. WhereACunitsarelocatedontopfloor,thestructurehastobesuitablefor theunitstatic&dynamicloads.

AnteRoom In case of Multifloor stores, Anteroom should preferably be designed to accommodate staircase, electrical hoist cage and have wider doors. Provision for fire escapestair &exits to bemade asper local norms.The interfloorsinanteroomtohavedoorstoeachcoldroomoneachfloor. Strip curtains for cold rooms and Air Curtains for external outlets/ inlets Strip curtains are quite common for reducing infiltration of air during loading/ unloading. Air curtains need power for operation but are more effective if properlyinstalled. Rodentproofcivilstructureandproperdrainageofwatertobeensured. Roomsformachines,Electricalsetc. Dock Loading & unloadingdockshall bedesigned with RCC slab roof or sheet roofing. However the machine roof can have RCC slabroof to accommodate the evaporative condensers, pump sets, water tank, water softener etc. Thedock area to accommodatesuitably sized office & toilet for staff&labour.

InsulatedDoors Thefreezerandfrozenfoodstorecanbeswingorslidingtype.The doors shall have heating element on all sides. Water floor heatingshould be provided on the front side of the door. The heaters should have automatictemperaturecontrolandshouldbelowvoltagetype.Allthedoor hardwareshallberustandcorrosionproof. Ancillaries Underground fresh water storage, storage for fire fighting, water supply & sanitaryarrangements,compoundwall/fencing,maingate,security,small canteen/electricalsubstation&D.G.setplatform,roads&parkingplace forvehiclesetc.Greenlandscapingwithbenchesforlabourersisdesirable.

8.REFRIGERATIONSYSTEMSELECTION AlltheRefrigerationsystemforFrozenFoodStoresoperateatevaporatingtemperature intherangeof()25Cto()30C. a. COMPRESSORSYSTEM Thesystemrequiresatwostagerefrigerationplantofoneofthefollowingtypes: a) CombinationofLowandHighCompressor b) Compound(twostage)Compressor c) Cascadesystem ProvisionofstandbyCompressorisdesirableespecially,incaseoflargerplants. The Compressors can be Reciprocating or Screw type. The Reciprocating Compressors shall have capacity control in steps or through VFD. The Screw Compressor should preferably have step less capacity control. The energy efficiencyoftheCompressorsisthemostimportantfactorfortheselectionofthe Compressors. NOTE: For evaporating temperatures below () 30C CO2 / NH3 cascade refrigeration system canbeconsidered. 2. TYPESOFCONDENSERS Condenserscanbe: a) EvaporativeCondenser b) AtmosphericCondenser c) ShellandTube/PHECondenserwithcoolingtowersforwatercooling. d) AirCooledCondenserstobeusedforHFCsystemsincasesoftwaterisnot available.CondenserAirPrecoolingsystemshouldbeincorporatedalongwith Aircooledcondensersforenergysaving. Waterneedstobesoftqualityforwhichwatersofteninghastobeinstalledfor themakeupwater.TheCondensershouldbeselectedforthelowestpossible Condensing temperature. Generally, a condensing temperature of 38C (or lower,ifpossible)isrecommended. Evaporative condensers offer better energy efficiency as compared to other types. 3. TYPESOFAIRCOOLINGUNITS TheaircoolingunitusedinAirBlastFreezingsystemsshallhavefinnedcoils andheavydutyaxialflowfans.TheAirCoolingunitsshallbeeitherlocatedon thefloororoverheaddependingonthefreezerdesign.

AmmoniacoilsaretypicallyMShotdipgalvanisedorSS/aluminiumtubeswith Aluminium fins.The coolingunits for HFCrefrigerants havecoils withcopper tubesandaluminiumfins.CoilswithAluminiumtubesandAluminiumfinscan alsobeused.Thefinspacingonthesecoilsshouldbeintherangeof8mm 12mm.Acombinationoffinspacingsinthisrangecanalsobeusedoverthe coildepth. 4. AIRPURGER(MANUALORAUTOMATIC) It is desirable to remove air and other non condensable gases from the refrigeration circuit to keep the compressor head pressures lower and also improve heat transfer coefficients. LIQUIDFEED Theliquidfeedcanbe a) DirectExpansionIncaseofHFCsystem b) GravityfeedIncaseofAmmoniasystem c) Refrigerantpumprecirculation(Overfeed)IncaseofAmmonia/HFC TheDirectExpansionsystemresultsinabout20%lowercapacityoffreezing. DEFROSTING Defrostingsystemcanbeofthefollowingtypes: a) WaterDefrosting b) HotgasDefrosting c) OffCycleDefrosting((Betweenshifts) 5. TESTINGANDCOMMISSIONINGTHESYSTEM Installation, Testing & Commissioning should be carried out as per BIS standards. ASHRAEstandardsmaybereferredtoasguidelinesbutnotmandatory. 6. EQUIPMENTDERATINGATHIGHERAMBIENT A designer should match the loads with the derated equipment capacity at higher ambientconditions.

GENERALSPECIFICATIONSFORREFRIGERATIONSYSTEM BriefSpecificationsforEquipment/Materials/Services i. RefrigerationCompressors&Motors

CompressorArrangement

Type

A combination of low stage and high stage compressors or compound compressors. Standby compressorpreferredincaseoflargerunits.Incase of HFC refrigerant two stage compressors or rack systemcanbeused.Singlestagecompressorscan alsobeusedincaseofscrewcompressors For ammonia as refrigerant, reciprocating, multi cylinder complete with watercooled head / jackets, withaccessories like oil separators,capacity control & unloaded start. Alternatively screw compressor, open type with accessories can be provided. For HFC,reciprocating./scroll/screwcanbeprovided. If Air cooled cylinder heads are to be used for low stage compressors adequate ventilation should be providedfortheplantroom.

Capacityatcriticaloperating TobeconfiguredinkW conditions To be configured in kW, RPM, type of insulation, EstimatedMotorrating InputACpowersupply ii.EvaporativeCondenserforAmmonia/HFC: Coilsection Hot dip galvanised M.S. pipes / CDW Boiler qualitytubes/S.S.304tubes With2/3AxialFlowFanswithCastAluminium/ S.S / GRP impellers, complete with TEFC Sq. cage motors, Class F insulation & IP55 protection S.S.304/M.S.Epoxycoatedwithnecessary connections Water spray arrangement, air inlet grilles, eliminatorsofsuitabledesign with removable G.S sheet panels & inspection windowsetc.

Fansection

Watersumptank Otherprovisions Unitcasing

Estimated Heat rejection capacity TobeconfiguredinKW at 38 deg C condensing & and applicableWBtemp SuggestedStandard ARIStd490

AirCooled/WaterCooledCondenserforHFC. Capacity Size TobeconfiguredinKW Tobefurnished

iii.)GasandLiquidIntercooler GasIntercoolerandLiquidSubcooler M.S. Construction with gas inlet and outletconnections,liquidsubcoolingcoil and liquid injection connection to be provided.

iv.H.P.ReceiverforAmmonia/HFC: HorizontalReceivercomplete Capacity MaterialofConstruction With necessary connections, reflex type levelgaugeetc. Tobeconfigured Boilerqualitysteelplates 2 Nos. (Two Nos. are suggested in case some States regulations call for Pressure testing of high pressure vessels on a periodicbasis) ANSI/ARI495/BISCodeIS2825

Quantity

SuggestedStandard

v.AirCoolingUnitsforFrozenFoodStores. a)Finnedcoolingcoil Coil design to besuitable for gravity feed /pump re circulation/overfeed system for ammonia & DX operationforHFCasperdesign Hot dip galvanised coil with M.S. pipes CDW Boiler quality tubes ASTM A 214 with MS fins / S.S.304 tubes &Aluminium fins / Aluminium Tubes & Aluminiumfinswithproperbondingsystemwithbullet drawnexpansion/equivalentexpansionforAmmonia ForHFC/HCFCcoilswithcoppertubes&aluminium finsoraluminiumtubeswithaluminiumfinswithbullet drawnorequivalentexpansionmaybeused. Inrangeof8to12mminstepsinthecoildepth.

M.O.C

Finspacing

b)AxialFlowfans

With cast aluminium / S.S. / FRP impellers, with variablepitch, TEFC Squirrelcage motors withclass Finsulation,IP55protection Vertical / horizontal with necessary connections (in caseofgravityfeedunits)forAmmonia G.S. sheetduly painted, drain pan ofG.S /M.S with epoxypaint Water/Hotgas/Air Drainpan,Drainpipe,Fancasing

c)Accumulator d)Unitcasing e)Defrostingarrangement f)Electricalheattracing Unitcapacities Numberperchamber

Tobeconfigured

Estimatedcapacityeachat Tobeconfigured criticaloperatingconditions Estimatedcoilsurfacearea Tobeconfigured Estimatedairflowcapacity withadequateexternal staticpressure Tobeconfigured

vi.RefrigerantPiping,Fittings&Valves Piping Interconnectingpipingbetween compressor,condenser,receiverand coolingunits M.S.blackpipingconformingtoIS1239/ ASTM A Gr.106B for 40 NB & smaller sizes / ASTM A Gr.53B for 50 NB & largersizesincaseofammoniaplants. ForLowtemprefrigerantlinebelow()30 Deg C upto () 45 Deg C SA 333 Gr 1, Grade6tobeused.ForAmmoniafittings shallbeofforgedsteel.ForHFC/HCFC, hardCopperpipingtypeL Pipingasper. ANSIguidelinesandpressurevesselsas per BIS Code IS 2825). Reference to ASHRAEB31.5recommended.

vii.WaterPiping,Fittings&Valves

Pipingshallbeusedfor a.Condenserwatercirculation b.Compressorcooling c.Defrosting d.Drainlines

PipingtobeG.IclassBorsizesupto65 NB & M.S. black pipe conforming to IS 1239. Valves up to 40 NB to be Gate / Globe type. Valves50NB/largertobebutterflytype.

viii.WaterPumpsets Waterflowcapacitytotakecareof condenserwaterflow&compressor head/jacketcooling Capacity At least 2 nos. operational during peak loadand1nostandby Tobeconfigured

ix.Thermalinsulationforrefrigerantpipingetc. a. EPSpipesection b. PUFpipesection With0.6mmAluminiumor0.5mm G.S.precoatedsheetcladding c. Nitrile Rubber / EPDM / chemically cross linked polyethylene pipe section / other acceptable materials with woven glass cloth with UV treated pigmented epoxy Coating

Materialforinsulationforrefrigerant suctionline,accumulatorsetc.

x.Controls. Temp Indicators cum controllers for individual freezers and chambers. Temperature scanners and a centralized temperatureindicationinmachineroom Liquidlevelcontrols,solenoidvalvesetc.

Temperaturecontrol

Refrigerantflowcontrols

DefrostControlsforautomatic defrostingifrequired PLCcontrolsystems

Recommended in case of continuous freezersanddeepfreezechambers. Foroverallcontrolofvariousparameters

Note. Location for installing the sensors will depend on site conditions and stacking patternetc.ThereforeProgrammableLogicControllers(PLC)isrecommendedforlarge unitswiththedisplaypointinthemanagerscabin. xi.Installation,Testing&Commissioning Installation Theplant shallbe installed, tested & commissioned as per IS 660 / ASHRAE.Std15.

GeneralNotes: 1. Incaserefrigerantpumpingsystem(overfeedsystem)isuseditwillincorporatethe followingcomponents. a. Centralised L.Preceiver b. Refrigerantpumpsincludingstandby c. Refrigerantflow&safetycontrols d. Interconnectingpipingbothsupply&returnlinesshallbeinsulated.Inthis case the individual accumulators for AC units & level controls etc. are not required. ELECTRICALINSTALLATIONS PowerFactornotlessthan0.95 Transformerofminimumrequiredcapacity

i.Substationwithadequaterating Substationwitharatingadequate capacity a. Step down transformer suitable for incoming H.T. voltage / 415 V as per IS 2026/otherapplicablestandards b.Twopole/fourpolestructureasperlocal requirements c. Outdoor type metering cubicle with approvedmeter,CTs/PTsetc. d.Earthlingstationasperrequirement e. Switchyard fencing with gates as per ElectricalBoardrequirements

ii.D.G.Setforstandbypower Estimated Rating: as per design. One big for pull down period and one small forholdingperiodmaybeused.Theuse ofDieselenginesoncompressorsisleft tothepromotertoassessbutkeepingin viewoverallCOPoftheplant.

D.G.setcompletewithaccessories andwithweatherproofandnoiseproof canopyasperlocalpollutioncontrol norms

Iii.Mainpowerdistributionpanel Main power distributionpanel with changeover facility for normal electricsupply &D.G. setsupply.Withongoingfeedersforvariouselectricalpanels. Iv.Electricpanels a.Refrigeration b.Lighting,Electrichoist,Fans c.APFC(automaticpowerfactor correction)panel d.Watersupply,firefightingetc.

Electricpanelsfor

V.Power&Controlcablingetc Aluminiumarmouredcablesformain PowerandControlcabling,earthingetc power lines & equipment lines & forvariouselectricalcircuits copper conductors for lighting, controlwiringetc. i. Lighting

Lightingin a.Freezers,ProcessHalls, PackingRoom,anteroom, Dockandoutsideareas. b.Otherareas c.Outsideareas

Forfreezer&frozenfoodstoresS.V.Lamps /LEDLamps. FormediumtempcoldstoresCFL/LEDwith vapourprooffittings. Forprocess/otherareasT5typeTL/ CFL/LEDLamps.

SAFETYMEASURES Provisionforhandlingaccidental leakageofammonia Ammonia sensors at proper places and Machine room near ACUs & machineroom

Fireprotection

Emergencylightingsystem

Emergency ventilation for machine room Safetyreleaseofrefrigeranttowater sump Ammoniamasks Firstaidkit Instructions for handling emergencies. Resettable dual safety valves for all pressurevessels. ProvisionforFaceWashing Quick oil drain valve on receivers andotherequipment. Fire sensors in suitable places and machinerooms&machineroom. Dry & water based fire fighting systemsasperspecsbelow. Sprinklersforhighpressureandlow pressurereceivers. May besolarPV cells with batteries &controller To be provided with switches near all cold store doors and alarms locatedincommonpublicareas

Emergencyalarmsystem

Lightningarrestorsforthebuildingasperlocalregulations

FireFighting a)DryType Fire fighting equipment necessary i)Drychemicalpowdertype5.0KgCap for extinguishing liquid, solid and with ISI Mark Fire Extinguisher electricalfire: completewithwallmountingbracket. ii) Carbon DiOxide (CO2) type 4.5 Kg. Capacity Fire Extinguisher complete withwallmountingbracket. iii')G.I.FireBuckets iv)M.S.StandforFireBuckets

b)Waterbased(mandatoryiflocalcodesoprescribes)

Systemshallcompriseof

i)2setsofWatersupplypumps. ii)2setsFirefightingpumps iii) G.I. piping, class C with necessary fittings & valves iv)RubberHosereel v)CanvasHosepipe vi)M.S.Fabricatedhoseboxwithkey vii) any other requirements as per local fire officer.

CoefficientofPerformance(COP)Foroptimumenergyefficiencytheplantshouldbe selectedwithbestpossibleCOP. Operation & Maintenance Plant design must be accompanied by Operation & MaintenanceManualforplantoperatorwhichshouldcoverfollowingpointsinEnglishas wellasHindilanguages No.ofoperatinghours Trainingofoperators Monitoring&controltemperature,humidity,CO2 Doorsealscheckingmethods Maintenanceofequipment/coldstore Hygieneissues Variation/amendmentClause The standards prescribed above are not intended to prevent or discourage variations arising out of new concepts, innovations and R & D in building design & construction, thermalinsulationandcooling&refrigerationtechnologyetc.However,anyvariationsor deviations from the above prescribed standardsmust be supported by scientific / technicaldetailsforpriorapprovalofthecompetentauthority,onthebasisofmeritwho may decide the proposal in view of relevant technical details including critical storage requirements,energy efficiency (coefficient of performance),availability of Standards, environmental concerns, safety etc. Similarly, periodic amendment of standards for general application may also be undertaken by the National Horticulture Board in consultationwithacommitteeofsubjectmatterexpertsdulyconstitutedforthispurpose.

REFRIGERATIONSYSTEMSLOADCALCULATIONS TotalRefrigerationLoadHeatLoadCalculation Procedureforloadcalculation Procedures laid out byASHRAE Fundamentals and Refrigeration handbooksmay be followed. ASHRAE refrigeration handbook elaborates a more traditional approach. Thus, based on the overall impact/ sensitivity of important parameters, someestimatescanbemade.Designersalsotendtotakeasafetyfactorof510% ontheestimatedloads. Ambientconditions 0.4%annualdesignconditionsofthatlocationasperASHRAE/ISHRAEdatamay be used for holding period. For the loading and pull down periods, 0.4% design conditionsforthosemonthsmaybetaken. TheRefrigerationloadforfreezingshallinclude f) TheTransmissiongainsthroughthewalls/ceiling/floor g) ThefanmotorloadofACUnits. h) Loadsduetomaterialhandlingequipment. i) Productcoolingloadifany. j) Airchangeload. k) Loadduetoworkmen. ProductIncomingtemperature ItdependsontheprocessfollowedandtheChilling/Precoolingmethod.Generally theproduct temperatures enteringthestorage may bein therange of ()15 to () 18Corlower. FinalProductTemperature Unlessotherwisespecifiedthefinalcoretemperatureoftheproductafter freezingcanbeconsideredas()18DegC.Howeverinsomecasesthe processorsspecifylowertemperaturesof()23to()25DegC. ProductLoad Theproductloadinthestorageshallcompriseof a) The load during cooling of product from incoming temperature upto storage temperature.

HeatLoadCalculationofCoolingSystemSummary HeatLoadCalculationsSummaryfor FrozenFoodStores AmbientConditions Temperature(C) RH% FrozenStoreTempOC IncomingProductTemp ProcessingHallConditionsDBtemp CRH% TransmissionLoadKW ProductloadincludingSubcoolingto finalstageTemp(kW) Loadduetomaterialhandling equipment.(kW) Airchangeload.(kW) Loadduetoworkmen.(kW) FanmotorforACUs(kW) Totalload (kW) Safetyfactor% TotalRefrigerationLoad(kW) NOTE1:Separatesheetsbesubmittedfordifferentfreezers.

SECTION2

TypicalDesignParameters&LayoutforFrozenFood&StoragePlant
1. PlantLocation 2. Outsidedrybulbtemp 3. Outsidewetbulbtemp 4. Powersupply 5. ControlPowersupply 6. Productreceivingsystem ReeferVans/Containers 7. Producttemperatureatthetimeofloading 8. Storagesystem 9. Typeofproducts 10. Typeofsizeofpackagesforstorage 11. NooffrozenfoodstorageChambers 12. Chambersizes&theircapacities 13. LoadingRate%ofstoragecapacity 14. AnteRoomDesignTemp0C 15. DockDesignTemp0 C 16. Compressorrunninghoursduringpeakseasonhoursperday 17. Compressorrunninghourduringholdinghoursperday.

OTHERCONSIDERATIONS

Ideally, there should not be any product cooling load in Frozen Food stores. However,duetotransportandhandlingofproductbeforestorage,manytimesthe products arrive at temperatureof () 15 Cto () 16C. Considering thisload for subcoolingofproductfromtheincomingtemperaturetostoragetemperaturehas tobeconsidered.

TYPICALLAYOUTOFFROZENFOODSTORAGE

DOCK

MACHINE

ROOM

TRUCK DOCK

OFFICE AREA

INDULATEDDOCKDOORS& SEALPADS

RAMPUP

BATTERY CHARGING

SECTION3(CommonforPartI&II) BASICDATASHEET A.Identification NameofFrozenFoodProject LocationofPlant Area/VillageTown

DistrictState NameofPromoterCompany/Owner Typeofcompany (Proprietorship/Partnership/Pvt.Ltd. Ltd) PostaladdressofPromoter Tel/FaxMob.No.Email.

Presentactivityinbrief NameofCEO/MD NameofManager/ContactPerson Phone/MobileNo.

A. BasicFreezerDesignConsiderations i)CommodityStorageRequirements TypeofCommodities/Produce Ideal/RecommendedStorage Conditions Typeofproducts Sizesofproducts

Refrigerantdutyatthedesignoperating conditions(kW) EvaporatingTemp(DegC) CondensingTemp(DegC) Averageweights,kgofproducts TypeofpackingMaterial,thickness (mm,micron) IncomingTemperature(DBinOC) Finalproductcoretemp(DegC) Period of Freezing (mins / hours)
This point tobe filled in only for IQF

Type of Freezer proposed Plate/AirBlast/Batch/IQF Capacity of freezer / batch (in caseofbatchfreezer) Capacity of freezer / hour (in caseofcontinuousfreezer) Total Estimated Capacityperday Freezing

Power requirement for belts/conveyor in the freezer (kW) Frozen Food Storage Facilities provided Sizeofthestores No.ofstores Estimatedstoragecapacity(MT) Typeofstoragesystem a) Multifloor

b) Singe0floorwithpalletloading c) Racksystem TypesofRacksSingle/Doubledeep/ drivein/driveout/mobile

iii)DeepFreezeChamberSizingandCapacity No.ofchambers: Two Type:Mezzanine/Palletized Mezzanine MaxHeightofBuilding 15.20Meter Details FFS1 FFS2 FFS3 FFS4

TotalCapacityofEach DeepFreezeChamber (MT) InternalChamber Dimensions Lx BxH (m) No.ofmezzaninefloors XHeight(m)perfloor Size&WeightofBagsor Boxesbeingstored TotalnumberofBags/Boxes storedineachChamber

iv)AnteRoom&ProcessAreas Details AnteRoom ProcessingArea Receivingdock Length(m) Width(m) Height(m)

Dispatchdock PackingArea

v)MachineRoom&UtilityAreas Details MachineRoom OfficeArea Toilets&Changingrooms

Anyother(LabourRestRoom)

Length(m)

Width(m)

Height(m)

vi)Building&ConstructionDetails Typeofconstruction: Civil/ PreengineeredBuilding

TypeofExternalwallsofcold chambers TypeofInternal/Partitionwalls TypeofRoof/Ceiling TypeofInternalstructure/ Racks Typeofmezzaninegrating TypesofLightingfixturesin coldChambers TypesofLightingfixturesin Process&OtherAreas
Processhallconstructionandsanitaryfeatures Pertaining onlyfor IQF
Therearevariousnational&internationalguidelinessuchasAPEDA,whicharetobe followedforrelevantdetails. WaterqualityusedforprocessingaswellasdefrostingodACUs/Freezersshouldbe properlytreatedandpotable.

vii)InsulationandVaporBarrier TypeofInsulation:InsulatingSheets/ MetalSkinCompositepanels TypeofInsulation Wall External Typeofmaterial EPS /MetalSkin PUFCompositePanels/XPS/ PUR,Others RelevantISCode
3 Density (kg/m )

Ceiling/Roof Floor Internal

ThermalConductivityat+10C kvalue(W/m.K) Thermaldiffusivitym2/h Watervapourtransmission 2 rate,ng/Pa.sm,Max.g/m hhmm/g Waterabsorptionafter24h immersion,percentageby mass. RelevantISCodeofPractice forThermalInsulationofCold Store TotalInsulationThickness (mm) No.oflayers& Thickness/layer(mm) Typeofvaporbarrier& thickness(microns) TypeofBituminous/Sticking Compound

TypeofCladding/ Covering/ExternalFinish Locking/Fixing&Sealing SystemincaseofMetalSkin CompositePanels Anyotherinfo

viii)Freezer/FrozenfoodstoreDoors&StripCurtains TypeofInsulation No.OfInsulateddoors Typehinged/sliding InsulationMaterial EPS/PUF/Others ThicknessofInsulation(mm) Typeofcladding Sizeofdooropening ProvisionofStripcurtains nos.&overlap% Aircurtains,ifany Others ix)MaterialHandling ProposedPractice: Manual/SemiAutomated/Automated Procedure MaterialHandlingProcedures &Equipments CapofElectricElevator Ratingofmotor(kW) BriefDescription Details

TypeofliftingdevicesForklift truck,Reachintruck Capacityinkg Liftingheight Powerrequired Anyotherdevice

x)Grading,SortingWashing&Packing/Preprocessing/Processing/DeboningLine (optional) ProposedPractice: Manual/SemiAutomated/Automated Procedure ProcessLine TotalConnectedElectrical Load(kW)ofProcessinglines Pleaseattach a Plan & Layoutof the proposed Cold Store unit in accordanceto the Statutory Building ByLaws and BIS Building Codes & Standards duly approvedbyaRegisteredArchitectandStructuralEngineer.Thedrawingsshould detailoutinsulationtype,thickness,andfixingmethodologyinsectionaldetails. Pleaseattachdetailedheatloadcalculationsheetsoftheproposedcoldstoreunit in accordance to the prescribed Technical Standards and Guidelines duly approvedbyaCertifiedEngineer. BriefDescription

D. CoolingSystemDesign&EquipmentSelection
i)CoolingSystemConfiguration TypeofRefrigerant TypeofSystem Typeofcompressor Typeofcapacitycontrol Typeofcondenser Ammonia/HFC(Freon)/Others DirectExp/GravityFeed/Overfeed Reciprocating / Screw /Scroll/Others AutomaticInsteps / Stepless Atmospheric/Evaporative/Shell&Tube/Plate HeatExchanger/ Other

CoolingTowers(ifapplicable) Typeofcoolingcoil Typeofdefrosting HumidificationSystem&Control (BriefDescription)

FRPInducedDraft/Others Ceilingsuspended / FloorMounted/Others Air/Water / Electric / Hotgas

ii)CompressorDetail CompressorNos. Comp.Operating RefrigerationMotor TotalElectricRemarks Make& RPM Parameters Capacity Rating.Power.(BkW)Working Model Evap.SST./ /Standby Cond.Temp (KW) (KW) O ( C) iii)CondenserDetails Condenser Nos Operating Condenser Electric Total Parameters Electric . Capacity Make& Fan Cond.Temp.(SDT)/ Model /Pump Power in/outwater (BkW) (kW) Motor O temp( C)&flow Rating (lps) (kW) Remarks Working /Standby

iv)CoolingTowerDetails(ifapplicable) Cooling Nos. Operating Cooling Fan&Pump Total ParametersDB& Tower Capacity Electric Tower WBTemp,in/out Capacity (CMH/LPS)& Power Make& O watertemp( C) (KW) Motor(kW) (BkW) Model Remarks Working /Standby

v)AirCoolingUnits(ACU) Nos. Operating Cooling No.offansTotalAir ACU Parameters Capacity perACU Flow Make& Evap.(SST) (CMH)& Model O &TD*( C) (kW) ExtStatic pressure (mmwg) Material Fin Total ofCoil spacingFan Tubes &Fins (mm) Electric Power (BKW)

(*) TD Temperature difference between Evap. (SST) OC & Return Air (at coil inlet). Please attach Detailed Technical Data Sheets of each equipment namely Compressors, Condensers, Cooling Towers, Air Cooling Units giving General Layout, Dimensions, Material of Construction, Rated Capacity, Operating Parameters and COP (please note that the Air Cooling Unit data sheet should include heat transfer area, fin spacing, no. of rows, air flow, face velocity, fan static, air throw, Fan Motor BKW/KW, fin spacing, etc ) duly Certified by the respective equipment manufacturers with reference to the Relevant Codes & Standards.

E. ElectricalInstallation
TotalConnectedload(kW) Estimatedpowerrequirement atPeakLoadPeriod(BkW) Estimatedpowerrequirement atHoldingLoadPeriod(BkW) Estimatedpowerrequirement atLeanLoadPeriod(BkW) CapacityofTransformer(KVA)

SizeofCapacitorforpower factorcorrection Type:Manual/Automatic

Make&Capacityofstandby D.G.Set(KVA)

F. SafetyProvisions
DetailsofFireFighting equipment

SafetydevicesLP/HPcutouts,safetyvalves, shutoffvalvesetc. DetailsofEmergencyalarmsystem &Pushbuttonsystemincoldchambers EmergencylightinginColdchambers&other essentialareaswithinverterbackup Lighteningarrestorsasperlocalregulations Facewashandeyeshowerprovisionnearthe exitinsideoroutsidetheplantroom Anyothersafetyprovisions

G.Codes&StandardsFollowed
BuildingDesign&Structure ConstructionMaterials ThermalInsulation&Application RefrigerationEquipment& Systems

Electrical&MechanicalSystems FoodSafety Others

H. EnergySavingEquipment&Measures
BriefDescriptionandSavings DetailsofEnergySaving devices LightFixturesSodiumvapour/ CFL/LED/TL NaturalLightingforgeneralareas VFDforfans/compressors RefrigerantControlsand Automation AirPurgermanual/automatic PowerFactorController Renewable/SolarEnergye.g. PVlighting PLCControl,&DataAcquisition Anyotherfeaturese.g.water recycling,rainwaterharvesting

I.Operation&Maintenance
Description ProposedstaffforOperation&Maintenance ProposedAnnualMaintenanceContracts (ifany) Training&PreventiveMaintenance Nos./Details

procedures Sanitation&Hygienepractice PollutionControl

J. EstimatedPerformanceParametersofProposedColdStore

Parameters

Peak/loading Period

HoldingPeriod

LeanPeriod

CoefficientOfPerformance (COP) b) ForFreezerUnit c) ForFrozenFoodStore PowerConsumption (KWH/Day) b) ForFreezerUnit c) ForFrozenFoodStore TotalElectricityCost(Rs/Day) b) ForFreezerUnit c) ForFrozenFoodStore ElectricityConsumption a) ForFreezerperMT/Day b) ForFrozenFoodStore perMT/Day

K. OtherInformation Place Dated

DATASHEETFORAIRBLASTFREEZING/IQFSYSTEM TypeofFreezer Refrigerantused

InsulationoftheCabinet

Material

Internal&Externalcladdingmaterial &finish Thickness(mm) Wall/Ceiling/Floor

SizeoftheCabinetL,B,H,mm Nooffreezingstations Noofbelts/beltwidth,mm Belttensionsensor Productheightlimitcontrol Interlinkingwithfeedingdevices& automaticpackagingmachinery A.C.Unitcapacity,KW Nooffan

Airflowcapacitycmh&externalsp. mmmg. Initialproducttemperature0C Finalproducttemperature 0 C(core) EstimatedFreezingtimeperbatchin minutes Expectedfreezingcapacityperday, MT Refrigerationcapacityrequired,KW Evap.Temp.()
0

Refrigerantfeedsystem Gravity/Pumpcirculation/DX Provisionfordigitalthermometer& other controls DefrostingType Hotgas/water/offcycle CabinetDimensions,mm FreezerMake&ModelNo ElectricalControlPanel Refrigerationsystemtobeofferedas package/tobeprocuredseparately Anyotherrelatedinformation

DATASHEETFORPLATEFREEZINGSYSTEM TypeofFreezer Horizontal/Vertical Refrigerantused InsulationoftheCabinet

Material Internal&Externalcladdingmaterial &finish Thickness(mm) Wall/Ceiling/Floor

SizeoftheCabinetL,B,H,mm Nooffreezingstations PlateDimensions,mm MaterialofPlates Maximumopeningbetweenplates, mm Initialproducttemperature0C Finalproducttemperature 0 C(core) EstimatedFreezingtimeperbatchin minutes EstimatedFreezingcapacityper batch,Kg

Expectedfreezingcapacityperday, MT Refrigerationcapacityrequired,KW Evap.Temp.()0C Refrigerantfeedsystem Gravity/Pumpcirculation/DX Provisionfordigitalthermometer DefrostingType Hotgas/water/offcycle FreezerMake&ModelNo Refrigerationsystemtobeofferedas package/tobeprocuredseparately ElectricalControlPanel Anyotherrelatedinformation

SECTION4(CommonforPartI&II) PROTOCOLFORIMPLEMENTATIONOFTECHNICALSTANDARDS Subject to provisions of Variation Clause, only those cold storage projects that are in conformity with the prescribed technical standards will be eligible for Central Government Subsidy.Inordertoverifythis,followingmechanismneedstobeputinplace A. SystemofLetterofIntent(LOI)LOItobeobtainedbythepromoterpriortoundertaking constructionofcoldstorageneedstobeintroduced.AnapplicationforLetterofIntentmust beaccompaniedbyfollowingdocuments,inadditiontoanyotherdocumentsprescribed ii. Acopyofthedetailedprojectreport iii. InformationinprescribedBasicDataSheetaccompaniedbyrequisitedocuments Technicalscrutinyoftheabovedocumentswillbeundertakentoensurethattheprojectisin conformitywiththeprescribedtechnicalstandardsoranyvariationisfullyjustifiedkeepingin view the product to be stored, prescribed storage conditions, energy efficiency and environmentalandsafetyconcerns. B. Civil Structure Following documents must be submitted by the promoter in respect of civilconstruction ii. iii. iv. Certificateofapprovalofthebuildingplanbylocalplanningauthority, Certificateissuedbyregisteredcivildesignengineeraboutconformity withrelevantBIS Standardsandprescribedstandardsandsafetyconcerns, Certificatebysiteengineer/architecttotheeffectofconstructionofthecivilstructureas per approved building plan and design and completion of the civil components accordinglyinallrespectsasperprescribedplanandstandards, ThermalInsulation&RefrigerationSystem,ControlandSafetyDevises

C.

ii.The components of insulation and refrigeration system should be certified in form of a technical datasheetby the manufacturerconfirmingthe ratingand performanceas per prescribedstandards. iii. Further, site inspection at appropriate stages of construction / erection and commissioning may be undertaken by an inspection team constituted by competent authorityforthispurpose. iv. Finally, the manufacturer/refrigeration contracting agency will issue a certificate of satisfactory commissioning of the cooling system in conformance to the performance indicatorsasperprescribedstandards. v. The manufacturer/refrigeration contracting agency will also provide as built drawings, includingcoldstorelayout, P&I andelectrical drawing and anoperation & maintenance manualalongwithalistofessentialspareparts. vi. A set of above documents alongwith the refrigeration system performance certificate issued by therefrigerationcompany / contracting agency, duly signed by anauthorized graduateengineerofthecompany/agency,mustbesubmittedtocompetentauthorityfor recordandacopyofthesamemustbeissuedtothepromoter/owneroftheproject.

Annexure I ListofRelevantBISandOtherStandards

The Codes and Standards listed in this annexure represent practices and methods published by Bureau of Indian Standards (BIS) and other International Organizations applying to design and construction of Cold Stores, Pack House, Ripening Chambers, andFoodProcessingFacilitiesetc.Theyarevaluableguidesforthepracticingengineer in determining test methods, rating, performance requirement and limits applying to designconstructionandequipmentsused. Thecodesandstandardslistedareintendedtoserveasminimumrequirement,andare nottobeconstruedaslimitinggoodpractice.WhereverISCodeisnotavailable,relevant standard codes of ASME / ASHRAE / IIAR or other International Codes are to be followed.Latestrevisionswillbefollowedinallcases. Theresponsibilityfordecidingwhetherotherrequirementsadditionaltotheoneslistedin this document are necessary to ensure system integrity, efficiency and overall safety, including operation, maintenance andservicing and/or the necessity to adopt additional requirements in the system design and construction to guarantee the overall performance, still rests with the supplier / manufacturer. The suppliers / manufacturers shall furnish to the owner copies of instruction manual which shall include operation & maintenance instruction, as built drawings, wiring diagrams, recommended spare parts andreplacementpartlist. Thesuppliers/manufacturersshallprovidetrainingfortheplantandmachineryinstalled including safety and emergency procedures. The supplier /manufacturer will follow all practices set forth by good manufacturing practices by various applicable Codes and Standards listed in this document and shall fully certify the equipment, plant and machinerysupplied/installedincompliancetotherelevantcodesandstandards. Where there is a requirement for deviation, the difference(s) must be brought to the intentionoftheregularitybodyandthecustomerinwriting. All exceptions/deviations to the codes and standards for the plant and machinery including civil works and design shall be identified and detailed in the proposal / bid documents to the customers /owner and his specific approval in writing will be taken beforecommencementofsupply/work. The supplier / manufacturer/contractor should be fully aware of all details in his scope etc,anditisimperativethatallworkperformedshallbedonebypersonneltrainedand skilledintheinstallationofplantandmachinery.

CODESANDSTANDARDS

A. Electrical BureauofIndianStandards(BIS)

S.No. 1.

Title

Reference

PVC Insulated cables (light duty) for working IS6941977 voltageupto1100volts PartI&II PVC Insulated cables (heavy duty) for working IS15541976 voltageupto1100volts PartI PVCInsulatedcablesforvoltage3.3KVto11KV IS15541976 PartII

2.

3.

4.

Specification of Polyurethane insulated PVC IS59591970 sheeted heavy duty electrical cables, voltage not PartI exceeding1100V Specification of Polyurethane insulated PVC IS59591970 sheeted heavy duty electrical cables, voltage 3.3 PartII KVto11KV Guideformakingofinsulatedconductors IS55781970

5.

6. 7.

Codeofpracticeforinstallationandmaintenanceof IS12551967 paperinsulatedpowercables Codeofpracticeforearthling IS30431966

8. 9.

Guideofpracticeforinstallationandmaintenanceof IS52161969 inductionmotors Codeofpracticeforinstallationandmaintenanceof IS52141969 ACinductionmotorstarters Codeofpracticeforinstallationandmaintenanceof IS9001965 ACinductionmotors Codeofpracticeforinstallationandmaintenanceof IS3721975 switchgears

10.

11.

12.

13.

Codeofpracticeforinstallationandmaintenanceof IS18861967 transformers Code of practice for electrical wiring installation, IS7321963 voltagenotexceeding650V Code of practice for electrical wiring installation IS22741963 (systemvoltageexceeding650V) GuidefortestingthreephaseinductionMotor ThreePhaseinductionMotors Electrical measuring accessories Currenttransformers Dimensionsofsliderailsofelectricmotors FlexibleSteelconduitsforelectricwiring AirBreakSwitches instruments and IS40291967 IS325 there IS248

14.

15.

16. 17. 18.

19. 20 21. 22. 23. 24. 25.

IS2705 IS2968 IS3480 IS4064

MotorStartersforvoltagenotexceeding1000Volts IS8544 Conduitsforelectricalinstallation Selection,installation&maintenanceof Transformers IS9537 IS10028

26.

Selection,installation&maintenanceofswitchgear IS10118 andcontrolgear NationalElectricalCodes Selfblastedlampsforgenerallightingservice SP:30 IS 15111 Part 1 and2

27. 28.

B. Mechanical BureauofIndianStandards(BIS)

S.No. 1. 2.

Title SafetycodesforMechanicalRefrigeration

Reference IS660

Code of practice for thermal insulation of cold IS661 storages Code of practice for application of polyurethane IS13205 insulationbyinsitupouringmethod Rigidphenolicfoamsforthermalinsulation IS13204

3.

4. 5.

Application for spray applied insulation code of IS12432 practicePolyurethane/Polyisocyanurate PartIII Specifications for preformed rigid polyurethane IS12436 (Pur)andpolyisocyanurate(Pir) foams for thermal insulation Expandedpolystyreneforthermalinsulation IS4671

6.

7. 8.

Code for practice for fire safety of industrial IS3594 buildings: General Storage and warehousing includingcoldstorage Anhydrousammonia IndustrialBitumen IS662 IS702

9. 10. 11.

Gunmetal gate, globe and check valve for general IS778 purpose Ball Valves including floats for water supply IS1703 purposes Mild Steel Tubes, tubular and other wrought steel IS1239 pipesfittings SteelPlatesforpressurevesselsusedatmoderate IS2041 andlowtemperature

12.

13.

14.

15. 16. 17. 18. 19. 20 21.

Colorcodeforidentificationofpipelines Vbeltsforindustrialpurposes Hotdipgalvanizingofironandsteel Codeforunfiredpressurevessels Glossaryoftermsforsafetyandreliefvalves Steelforpressurevesselsandweldedstructures

IS2379 IS2494 IS2629 IS2825 IS3233 IS3503

Steeltubesformechanicalandgeneralengineering IS3601 purposes Steelforgeneralstructuralpurposes Steeltubesforstructuralpurposes IS2062 IS1161

22. 23. 24.

Specifications for steel doors, windows and IS1038 ventilators Code of practice for design loads (other than IS875 earthquake)forbuildingandstructures PartItoV Criteria for earthquake resistant design of IS1893 Structures Specificationsforcoldformedlightgaugestructural IS811 steelsections Code of practice for use of Steel Tubes in general IS806 buildingconstruction Code of practice for use of cold form light gauge IS801 steel structural members in general building construction Codeofpracticeforgeneralconstructioninsteel IS800

25.

26.

27.

28.

29.

30. 31.

Glossary of terms used in refrigeration and air IS3615 conditioning Pressureandvacuumgauges SafetyCodesforscaffoldsandladders Formedendsfortanksandpressurevessels IS3624 IS3696 IS4049

32. 33. 34.

35. 36. 37.

Shellantubetypeheatexchangers Codeofsafetyforammonia

IS4503 IS4544

Expanded polystyrene for thermal insulation IS4671 purposes HotdipZinccoatingonsteeltubes Unitsandsymbolforrefrigeration IS4736 IS4831

38. 39. 40.

HDPEpipesforpotablewatersupplies,sewageand IS4984 industrialeffluents Gaugeglasses IS5428

41. 42.

Specificationforsprayedaluminumandzinccoating IS5905 onironandsteelsurfaces SteelPipeflanges IS6392

43. 44.

Injection molded HDPE fittings for portable water IS8008 supplies Verticalsteelladders Treatmentofwaterforindustrialcoolingsystems Nominalsizesofvalves IS8172 IS8188 IS9520

45. 46. 47. 48.

Selection, use and maintenance of respiratory IS9623 protectivedevices Polythenefloatsforballvalves Generalpurposeballvalves SIunits Recommendationsforgeneralpipelinewelding Ammoniavalves IS9762 IS9890 IS10005 IS10234 IS11132

49. 50. 51. 52. 53. 54. 55. 56. 57.

Finnedtypeheatexchangerforroomairconditioner IS11329 Refrigerationoilseparators MStubesforverticalcondenser Specificationformetalairduct IS11330 BS3059 IS655

58. 59.

Specificationforgalvanizedsteelsheet Specificationsfor Performed RigidPolyurethane

IS227 IS124361988

60.

Glossary of Terms used in Refrigeration& Air IS3615:2007 conditioning Code of Practice for Fire Safety of Ware housing Asper elevant includingcoldstorages ISspecification Food Hygiene General Principle Code of IS24911998 Practice

61.

62.

C. Publication by International Societies and Associations Pre Engineered Building S.no. 1. 2. 3. 4. 5. 6. BuildingCode DesignCode ToleranceCode PurlinCode WeldingCode Wind Load& Seismic Load Title Reference IBC2006 AISC2005 MBMA2002 AISI2001 ANS2006 IS 875 & IS A893 2002& Relevant Codes

D. EuropeanOrganizationforTechnicalApprovals(EOTA) S.no. Title Reference 1. ExternalThermalInsulationCompositeSystems ETAG004 withRendering Cold Storage Premises Kits Part1: Cold ETAG21 StorageRoomKits Cold Storage Premises Kits Part2: Cold ETAG021 StorageBuildingEnvelopeandbuildingits

2.

3.

American Society of Heating, Refrigeration and Air Condition Engineers, Inc ASHRAE RefertoREFRIGERATIONSystemsandApplications,Handbook Chapter51CodesandStandards. OTHERSTANDARDSANDREFERENCES There is sufficient data available on design of energy efficient cold stores and commercial storage practices of fresh fruits and vegetables and other perishable commoditiesfromvariouspublicationsbyorganizationssuchas: 1. International Association of Refrigerated Warehouses (IARW) and World Food LogisticsOrganizations, b) CommodityStorageManual c) CrisisManagementManual d) GuidetoEffectiveWareHouseOperations e) MaintenanceandModernizationManual 2. American Society of Heating, Refrigeration and Air Condition Engineers, Inc ASHRAEHandbooks b) c) d) e) 3. 4. 5. 6. REFRIGERATIONSystems&Applications FUNDAMENTALS HVACSystemsandEquipment HVACApplications

TheInternationalInstituteofRefrigeration(IIR), InternationalInstituteofAmmoniaRefrigeration(IIAR), UnitedStatesDepartmentofAgriculture(USDA), PostharvestTechnologyResearch&InformationCenterUCDAVIC

Annexure II
FLOWCHARTVEGETABLES&FRUITS processasperproductrequirement RAWMATERIAL (CHOICEOF CULTIVATOR)

MATURITYASSEMENT

HARVESTING&TRANSPORTATION

FACTORYGATE INSPECTION

PREPARATION a b c d e f g h i j k l m WASHING/INSPECTION CUTTING/DEPODDING/SNIPPING/PEELING CLEANING/AIRCLEANING/VIBRATINGSEIVING WASHING SLICING/DICING/SHREDDING/WHOLE WASHING BLANCING COOLING INSPECTION DEWATERING FREEZING SEIVING METALDETECTION/XRAYINSPECTION CCP5 CCP4 (VEGETABLESONLY) CCP2 CCP3 CCP1

n o p q

PACKING COLDSTORAGE@BELOW 18DEGC TRANSPORTATION@18DEGC CITYOULETSTORES@18DEGC CCP6 CCP7 CCP8

CUSTOMERTOSTOREINHOUSE FREEZER CCP9 (homefreezer2degCformax8days&18degCforlongtime aspermfgdate)

AnnexureIII

AnnexureIV

TechnicalStandardsCoreCommitteeExperts 1. Sh.BijayKumar, ManagingDirector,NationalHorticultureBoard, MinistryofAgriculture,Govt. of India,PlotNo.85,InstitutionalArea,Sector18,Gurgaon(Haryana) 2. Dr.S.K.Malhotra,PrincipalSecretary(Hort),ICAR,NewDelhi 3. Mr.SushilKumarSingla,Director,DAC,NewDelhi 4. Mr. Gokul Patnaik, Managing Director, Global Agri System Pvt. Ltd., K13A, Hauz Khas Enclave, NewDelhi 5. Mr.P.K.Chakraborty,Director,FSSAI,NewDelhi. 6. Mr. A. K. Lal, Sc. D, Bureau of Indian Standards, Manak Bhawan' 9, Bahadur Shah Zafar Marg, NewDelhi 7. Sh. Chinmay Dwivedi , Scientist 'C', Food and Agriculture , Bureau of Indian Standards, Manak Bhawan'9,BahadurShahZafarMarg,NewDelhi 8. Mr.RajinderSingh,SeniorFaculty,GBPantPolytechniq,Okhla,NewDelhi 9. Mr.AbhayAnand,AmitFinishers,Pune 10. Dr.R.K.Sharma,Director,NationalHorticultureBoard,MinistryofAgriculture,Govt.ofIndia,Plot No.85,InstitutionalArea,Sector18,Gurgaon122015(Haryana) 11. Mr.DavishiVerma,IL&FS,NewDelhi 12. Mr.SandeepKtiyan,IL&FSClasters,NewDelhi 13. Mr.GurmitSingh,ManagingDirector,M/sWalcoEngineeringLtd.,7/15,KirtiNagar,IndustrialArea, NewDelhi110015(andChairmanofCII,TechnicalStandardsCommittee). 14. Mr.M.S.Manjunath,IngersollRand,Bangalore 15. Mr.DilipWagh,6SigmaFoodtech,Pune 16. Mr.MenonVenugopal,RACGlobal/CabinPlantA/sDenmark 17. Mr.Allan MollerHansen,CabinPlantA/sDenmark 18. Mr.NitinShilaskar,Urschel,Pune 19. Mr.ArvindSurange,Consultant,H.O.VijayApts.,39/35Erandavana,Pune411004(Maharashtra) 20. Mr.HarshalSurange,Consultant,H.O.VijayApts.,39/35Erandavana,Pune411004(Maharashtra) 21. Mr.R.M.Iyengar,ConsultantCII,Chennai 22. Mr.N.S.Brar,MD,PAGROFoods 23. Mr.MukeshPuri,ISHRAE 24. Mr.V.K.Seth,ISHRAE 25. Mr.SupriyoSaha,ManagementConsultant,M/sFinancialEscortPvt.Ltd,WestBengal 26. Mr.R.Shivakumar,VoltasLtd 27. Mr.M.Verma,ICL 28. Mr.AtulGarg,KPMG 29. Mr.J.M.Gupta,APCPolycoat(P)Ltd 30. Sh.S.S.Malik,Interko 31. Col.Deswal,SunshinePvt.Ltd 32. Mr.AjayMahendirata,ISHRAE 33. Mr.PankajMehta,Carrier 34. Mr.SanjayGupta,Infracol 35. Mr.TarunMalhotra,CarrierTrans 36. Mr.AsishGoswami,CarrierRefrigeration 37. Mr.ParvinderSingh,VertriebIndienSalesIndia 38. Mr.UmeshAgarwal,ISOPAN 39. Mr.MaheshShastri,StarfrostAsia 40. Mr.NavneetS.Pruthi,GoblinFoodsPvt.Ltd,Mumbai 41. Mr.SanjeevSaini,BayerMaterial