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LLOYD INSULATIONS (INDIA) LIMITED

MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY

INDIAS FOOD ECONOMY

India is one of the largest producers of fruits and vegetables in the world. Inadequate handling infrastructure and methods result in a value-loss of over 30% of all fresh produce. There is no proper Cold Chain for any Agricultural/Horticultural Products

THE COLD CHAIN


Harvest Cooling (pre-cooling) Cold Storage Transport to market Handling at Destination Handling at home or food service

MAINTAINING THE COLD CHAIN FOR PERISHABLES


Harvest
Protect the product from the sun Transport quickly to the packinghouse

Cooling

Minimize delays before cooling


Cool the product thoroughly as soon as possible

Temporary Storage

Keep the product at optimum temperature Ship to market as soon as possible

SHADING TO PROTECT PRODUCE FROM SUN

COLD STORAGE FACILITIES

WHOLESALE MARKET

DISTRIBUTION CENTER

RETAIL DISPLAYS

MODERN COLD STORES FOR TODAYS COLD CHAIN INDUSTRY

Cold Stores Plays an Important Role in the Cold Chain

DEFINITION OF A COLD STORE


A Cold Store IS A BUILDING OR A GROUP OF BUILDINGS WITH THERMAL INSULATION AND A REFRIGERATION SYSTEM, IN WHICH PERISHABLE FOODSTUFFS CAN BE STORED FOR VARIOUS LENGTHS OF TIMES IN SET CONDITIONS OF TEMPERATURE, HUMIDITY AND APPROPRIATE ENVIRONMENT TO SLOW DOWN DETERIORATION AND SPOILAGE, WHICH WOULD OCCUR IN A NATURAL ENVIRONMENT.

DEFINITION OF A COLD STORE


A Cold Store may also be defined as a sealed structure the internal volume of which is maintained at a temperature generally below ambient & and other conditions and used for the storage of goods of all types, mainly foods.

DESIGN ASPECTS OF A COLD STORE


The design of Cold Stores Stores follows what is known as a Cold Store LOGIC. The starting point is Product to be stored. Once the Product is identified, it defines the Optimum Storage Conditions (Temperature, Humidity and Environment). The Packaging of the product both as received and as required at delivery (Handling) determines the type of Racking. The Quantum to be handled and Held in Storage outlines the size of the store. The Location and its Ambient conditions then ensure the proper selection of the Five Elements of a Cold Storage.

ELEMENTS OF A COLD STORAGE


The five important elements of a Cold Storage are: Land &Civil Building Thermal Insulation (of Structure and Piping) Refrigeration

Material Storage System (Racks)


Product Handling Techniques Services (Electricity, Water )

COLD STORE-SPECIFICATIONS THE CONDITIONS OF STORAGE


Normal temperatures of storage Differential of controls Duration of storage, by product or category of product Method of handling the loads (hand truck, pallet truck, fork-lift truck, rail) Method of stacking ( height of stacks, size of load units) the produce which may if necessary, be stored together

COLD STORE - SPECIFICATIONS


The Store Whether it is to be set up in an existing building or a new building is to be constructed Number of Refrigerated rooms and their configurations Layout of the store and the machine room Means of access Characteristics of pre-existing equipment Constraints if any Extensions and future expansions

COLD STORE - SPECIFICATIONS


The Environment Climate: External temperatures during 6 hour period ( from 9.00 to 15.00) Maximum Minimum Annual mean Relative humidity : Extreme values Rainfall : Frequency, Degree of precipitation

COLD STORE - SPECIFICATIONS


The Resources Available Energy resources: nature, power, method of supply Water resources: origin ( river, well, sea ) temperature and flow chemical composition presence or absence of mud or sand Labor resources: local availability of labor technical operating and control personnel handling and general maintenance personnel

COLD STORE - SPECIFICATIONS


Other Specifications:

Maximum allowable heat ingress via the walls (5 to 6 W/m2 in frozen and 8 to 10 W/m2 in chill storage as per IIR guidelines) Special requirements of construction (e.g. resistance of the insulation to fire and insects, toxicity of the refrigerant fluid etc.)

NEED FOR EFFECTIVE LOW TEMPERATURE COLD STORAGE IN INDIA.


India is a large producer of all kinds of Foods, of both Plant (living) and Animal Origin. India is also classified as having a Warm Tropical type climate for most of the year. With high ambient Temperatures (+35C) and high humidity conditions, preservation techniques involving low temperature storage are mandatory for slower aging, for extending the Shelf Life and less loss of weight, inhibiting the growth of spoilage organisms, and restricting the development of Toxins.

NEED FOR LOW TEMPERATURE STORAGE (CONTD.)


Fresh fruits and vegetables, being living items, are affected by the conditions under which they are stored and handled. They continuously influence their storage environment by heat of respiration, by gases exchanged (O2, CO2, C2H2), and the effect of Humidity. Correctly Designed and Operated Refrigerated Storage and proper handling Techniques as envisaged in a Cold Chain have a direct influence on quality at point of Sale and therefore the returns from the produce.

CONVENTIONAL COLD STORE


Brick wall
The basic rules for insulation system are :

Bitumen

Using good insulating material having a high insulating value, characterized by a low thermal conductivity
Protection to the insulant against vapour ingress, by providing a Vapour Retarder applied directly to the wall to restrict migration of ambient atmospheric moisture into the cold room interior.

Thermal insulation

Final finish

Vapor barrier Metal mesh

Use an interior lining on insulation essentially to prevent mechanical damage


Plaster+Brick+Plaster+VB+Insulation+Finish Approx. 360mm wall

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CONVENTIONAL COLD STORES


EXISTING SITUATION Insulation Material Expanded Polystyrene, PUF in 100 150mm on walls, fixed between wooden framework, Polythene sheet vapour barrier.
Floor Insulation with EPS /PUFslabs 50-100mm.

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EXISTING COLD STORE - PROBLEMS


Ineffective insulation

Moisture ingress thru porous plaster into insulation resulting into cold spots, Algae formation

Improper Storage
Product decay Unhygienic conditions More energy consumption due to more compressor running time
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EXISTING COLD STORE PROBLEMS, CONVENTIONAL PRACTICE


Brick wall
Sequential application of vapor barrier, insulation & plaster finish
Thermal insulation

Bitumen

Final finish

What about moisture ingress from inside & life of plaster finish

Basic Thermal & Civil Engg. Design problem


Vapor barrier
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Metal mesh
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EXISTING COLD STORE PROBLEMS


CAUSES OF THERMAL INSULATION SYSTEM FAILURE Continuous moisture ingress through plaster Insulation becoming wet & resistivity decreases Plaster chipping off Vapour barrier becomes weak Formation of cold spots Deterioration & failure of Thermal Insulation System

1 % OF MOISTURE INGRESS = 5 % REDUCTION IN R VALUE

DOUBLE MOISTURE ATTACK


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INSULATION LIFE
Insulation needs to be properly fixed to surface
Insulation needs to be covered & protected Cold Insulation needs vapour barrier on warm

side
Cold storage Insulation needs vapour barrier on

both sides to counter moisture attack on both sides.


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ELEMENTS OF A MODERN COLD STORE


The MODULAR Cold Stores requires the following: a) Pre-fabricated Steel Building (Single/Multi Level of storage) b) Pre insulated factory finished sandwich panels c) Energy Efficient Refrigeration systems d) Insulated Doors, e) Loading docks f) Racking system g) Energy Efficient Lighting and Controls h) Forklift Trucks

PRE - ENGINEERED BUILDINGS

PRE-ENGINEERED BUILDING

Pre-Engineered Building is a systematic arrangement of manufactured Engineered components at site.

ADVANTAGES OF PEB
Low construction time Reduced cost

Large clear spans


Low maintenance cost Ease of future expansion

COMPONENTS OF PEB

TYPICAL PEB FRAME

TYPES OF FRAMES

PEB DETAILS

GREEN FOOD PARK LTD., BHAGALKOT

M/s. EASTERN CONDIMENTS, THENI

PRE-FAB PUF/POLYISO PANELS

SALIENT FEATURES OF PUF/POLYISO PANELS


High Strength to weight Ratio with Significant saving

in Steel works and Load Bearing Foundation resulting in Large Spans High Thermal Efficiency ensures low Heat Transmission and Low Refrigeration Cost No Deterioration in Thermal Efficiency with Time Vertually Maintenance Free Dimensionally Very Stable 12 m length Panels ensure less no of Joints and Fast Construction

LLOYD PRE-FAB PANELS


LLOYD PRE-FAB PolyIso Panels Have been Tested at FM Approvals Lab at Rhode Island USA and are awarded FM Approvals 4880 Class I Certification. This is an Unique Achievement for an Indian Manufacturer

LLOYD PANEL SYSTEM- FOAM PROPERTIES - THERMAL


Thermal Conductivity @ +10 C -0.023 W/mK or 0.0198 Kcal/hr m deg C Temperature Range- -

180 C - +95 C Water vapor permeability - 0.12 ng/pasm

LLOYD PANEL SYSTEM- FOAM PROPERTIES - MECHANICAL


CFC/HCFC FREE material Bending Strength - 3.0

blowing agent Pentane kgf/cm2 DENSITY - 40 +/- 2 Kg/m3 Dimensional Stability (48 hours)- -25 C - 2.0% PIR -45+/-2 Kg/m3 +70 C - 2% Compressive Strength @ 10% deformation- 2.1 kgf/cm2 Tensile Strength- 2.5Kg/cm2

LLOYD PANEL SYSTEM FACINGS AVAILABLE


SS 304 with - 0.5 /0.6 PLASTISOL

mm thickness with Strippable Plastic Film STELVATITE special Foodsafe coating of British Steel UK - 0.6 mm , 275 GMS/m2 , 15 0 microns film

COATING HP 200 PVC coated steel 0.6 mm hot dip zinc coated steel to BS EN 10 142: 1991 in Fe PO2 G (Galvatite) with 275 GMS/m2 Galvanizing, SMP Coated 175 GMS/m2 Galvanized, 240 MPA steel

LLOYD PANEL SYSTEM


FOAM PROPERTIES - FIRE RESISTANCE
-

Horizontal Extent of burn as per BS 4735- < 125 mm (PUF)

< 25 mm (PIR) Fire retarded Foam giving a self- extinguishing Character on removal of ignition source

LLOYD PANEL SYSTEMPANEL DETAILS


DIMENSIONS

Length
Width Thickness JOINING

: upto 12 m long (no joint) : 1000 mm : 40/50 60/80/100/120/150/200 mm

a)Tongue & Groove b) Labyrinth Joint

from a continuous line

LLOYD PANEL SYSTEMDOOR DETAILS


FREEZER & CHILL DOORS HINGED Dimensions : 900 mm x 1800 mm 1200 mm x 2000 mm SLIDING Dimensions : 1500 mm x 2500 mm 2000 mm x 2500 mm Doors from BG Doors Holland, Metaflex India

LLOYD PANEL SYSTEM ACCESSORIES DETAILS


Insulated Beam

Foam Tape & Silicon Sealant


Butyl Sealant One Component Foam

Pressure Relief Valve


Aluminum Extrusions with PVC profiles PVC Bump rails Inner & Outer Flashing

CONSTRUCTION OF COLD STORAGE WITH LLOYD PANEL SYSTEM

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COLD ROOM FIXING DETAILS

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COLD ROOM FIXING DETAILS

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COLD ROOM FIXING DETAILS

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COLD ROOM FIXING DETAILS

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FIXING DETAILS WITH PANELS

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FIXING DETAILS OF PANELS

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METAL ROOFING & CLADDING SAFAL - BANGALORE

LLOYD PANEL SYSTEM- SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM - SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM -SAFAL

LLOYD PANEL SYSTEM AT BALAJI BIO-TECH, NELLORE.

LLOYD PANEL SYSTEM- RADHA KRISHNA FOOD LANDS

LLOYD PANEL SYSTEM- RADHA KRISHNA FOOD LANDS

M/s. EASTERN CONDIMENTS, THENI

M/s. EASTERN CONDIMENTS, THENI

M/s. EASTERN CONDIMENTS, THENI

M/s. SNOWMAN

M/s. SNOWMAN

M/s. SNOWMAN

PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI, A/c. RADHAKRISHNA FOODLANDS PVT. LTD.

PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI, A/c. RADHAKRISHNA FOODLANDS PVT. LTD.

PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI, A/c. RADHAKRISHNA FOODLANDS PVT. LTD.

PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI, A/c. RADHAKRISHNA FOODLANDS PVT. LTD.

PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI, A/c. RADHAKRISHNA FOODLANDS PVT. LTD.

PU PANEL SYSTEM For FOOD PROJECT at KALAMBOLI, A/c. RADHAKRISHNA FOODLANDS PVT. LTD.

SAVLA FOODS & COLD STORAGES PVT. LTD., NAVI MUMBAI

SAVLA FOODS & COLD STORAGES PVT. LTD., NAVI MUMBAI

SAVLA FOODS & COLD STORAGES PVT. LTD., NAVI MUMBAI

SAVLA FOODS & COLD STORAGES PVT. LTD., NAVI MUMBAI

Thank You
For any further Queries please mail to bjk@lloydinsulations.in