ncrac 2011 inv 09 presentation

8/3/2019 NCRAC 2011 Inv 09 Presentation

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COLD CHAIN DEVELOPMENT IN INDIA -MODERNIZATION OF THE INFRASTRUCTURE OF

COLD STORAGE OF PERISHABLES

by

ARVIND SURANGE

ACR PROJECT CONSULTANTSPune, India

www.acrconsultants.net

PRESENTATION AT NCRAC 2011


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INDIAS DEMOGRAPHY

Largest democracy in the world

Second largest in population withapprox 1.16 billion people

Area 3,287,263 sq km

(land: 2,973,193 sq km & water: 314,070 sq km)

28 states and 7 Union Territories


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INDIAS DEMOGRAPHY

India's Position in World's Production

Largest producer of milk in the world -105 million MT per annum

Largest livestock population estimated meat production 485 MMT)

Second largest producer of fruits & vegetables - 210 MMT

Third largest producer of fisheries products - 6.4 MMT

52% cultivable land compared to 11% world average

20 agri-climatic regions


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COLD CHAIN DEVELOPMENT IN INDIA Development of Cold Store Industry in India started after 1950

The number of units grew from 83 in 1955 to an estimated 6000units in 2009

The capacity of these units grew from 43000 MT in 1955 to an estimated25.5 million MT in 2009

Till 1970, majority of these units stored only potatoes & they were mainlyconcentrated in UP, West Bengal, Bihar & Punjab

The units were based on older technology of Construction, Insulation &Refrigeration & Handling systems

After 1970, a new trend of multipurpose, multiproduct cold stores wasobserved, mainly in Maharahtra, especially in Navi Mumbai, Pune &other parts of Maharashtra and this was followed in Gujarat, MP,Karnataka & Delhi


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Year

No.of Units(in Nos.)

Capacity(in '000 MT)

1955 83 431960 359 306

1965 600 682

1970 1218 1638

1975 1615 1994

1979 2266 3348

1986 2607 5402

1995 3253 10000

2004 4748 19552

2006 5101 21694

2007 5316 23334

2009 6000 25500

GROWTH PATTERN OF COLD STORAGE CAPACITY IN INDIA


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1955

1960

1965

1970

1975

1979

1986

1995

2004

2006

2007

0

5000

10000

15000

20000

25000

30000

0

1000

2000

3000

4000

5000

6000

7000

1 2 3 4 5 6 7 8 9 10 11

Capac

cityin'000MT

N

umbers

Year

Growth of Cold Storage Industry in India

No.of CS Installed Capacity in '000 MT

1955 19651960 1970 1975 1979 1986 2004 2006 20092007


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North50%

East

30%

Central7%

South6%

West

7%

Zonewise distribution of Cold Stores Capacity(base 2009)


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Zonewise growth of Cold Storage Capacity in India(in 000 MT)

2004 2006 2007 2009

CENTRAL 1367 1341 1369 1496

EAST 5759 6633 7784 8506

NORTH 10070 10861 10968 11986

SOUTH 1029 1367 1566 1712

WEST 1329 1492 1647 1800

Zonewise growth of Cold Storages in India (in Nos.)

2004 2006 2007 2009

CENTRAL 328 340 352 397

EAST 783 861 947 1069

NORTH 2163 2365 2386 2693

SOUTH 674 741 778 878

WEST 800 839 853 963

0

2000

4000

6000

8000

10000

12000

14000

1 2 3 4

Zonewise growth of Cold Storage Capacity(in 000 MT)

CENTRAL EAST NORTH SOUTH WEST

2004 2006 2007 2009

0

500

1000

1500

2000

2500

3000

1 2 3 4

Zonewise growth of Cold Storages in India (in Nos.)

CENTRAL EAST NORTH SOUTH WEST

2004 2006 2007 2009


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TRENDS IN COLD CHAIN DEVELOPMENT

From the old bulk single commodity storage concept, today theindustry has grown to wide areas of application in the cold chain

sector

These can be classified as follows:

Bulk Cold Stores mainly for single commodity like potato, apples, redchillies & raisins. Units mainly concentrated in areas like

UP, Punjab, Haryana, Delhi, West Bengal, Bihar, MP & Andhra

Multipurpose Cold Stores for storing variety of items likefruits, vegetables, dry fruits, spices, pulses, milk products etc. Unitsmainly located in Maharashtra, Gujarat, Karnataka. Many units havefrozen food stores as a part of the cold store complex.

Sorting, Grading, Packing, Pre-cooling & Cold Storage for items suchas grapes, mangoes, pomegranates, papaya etc. inMaharashta, Karnataka, Gujarat etc

continued


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classification continued

Processing, Freezing & Storage of Frozen foods for commodities like

fruits & vegetables, ice cream, butter, meat, fish & poultry products.This development happened mainly after 1970.

Sorting, Grading & Packing & Controlled Atmosphere (CA) Storagefor

extending life of perishable / seasonal fruits like Apples, Pears, Plumsetc. A few units have come up mainly in the Northern sector total

capacity only 40,000 MT. Development mainly in the last 10 years.

Ripening facilities mainly for Bananas, Mangoes, Papaya etc. development is catching up now.

Distribution centers - an important part of cold chain logistics the firstlarge unit has come up in Navi Mumbai & many smaller unit in the retailsector development in the last 6 to 7 years.



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classification continued

Super markets, Malls & other Retail Units with Walk-in cold stores, MiniUnits, AC & Ventilated stores. A big development is on for the last 5years

Refrigerated Transport a variety of refrigerated vehicles developed for

Indian handling practices and for exports / imports.



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BULK COLD STORE


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MULTIPURPOSE COLD STORE


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PRECOOLING FACILITY WITH COLD STORE


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PROCESSING FACILITIES


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CONTROLLED ATMOSPHERE STORE


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FOOD DISTRIBUTION CENTER


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Old Units with Bunker type coils

Old units with Diffuser type coils

Multipurpose units with conventional construction andceiling suspended ACUs

Multipurpose units with Sandwich Panel construction

Single floor with Mechanised handling facilitiesMulti-floor with Manual handling facilities

TRENDS IN TECHNOLOGICAL FEATURES OF COLD STORES


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TYPICAL OLD DESIGN OF COLD STORE WITH SHEET

ROOFING & LARGE BUNKER TYPE COOLING COIL (SECTION)

OLD UNITS WITH BUNKER TYPE COILS

OLD UNITS WITH DIFFUSER TYPE COILS


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TYPICAL COLD STORE WITH R.C.C.SLAB ROOF

& FLOOR MOUNTED AC UNIT WITH DUCTING

ACU

OLD UNITS WITH DIFFUSER TYPE COILS

MULTIPURPOSE UNITS WITH CONVENTIONAL CONSTRUCTION


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TYPICAL COLD STORE WITH CEILING

SUSPENDED AC UNIT

MULTIPURPOSE UNITS WITH CONVENTIONAL CONSTRUCTIONAND CEILING SUSPENDED ACUS

MULTIPURPOSE UNITS WITH SANDWICH PANEL CONSTRUCTION


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REF.UNIT

RACKS

LOADING / UNLOADING

C.S. C.S. C.S. C.S.

ANTE ROOM

OFFICE

C.S.

TYPICAL COLD STORE WITH INSULATED PANEL STRUCTURE& MODULAR REF. UNIT WITH MECHANISED HANDLING - PLAN

MULTIPURPOSE UNITS WITH SANDWICH PANEL CONSTRUCTION


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1. Conventional buildings with RCC frames, brick wallswith

a) Truss type sheet roofs

b) RCC slab type roof

Internal floor structure of RCC or Steel Floor grating of wood or steel

2. Pre-engineered building structures designed with cold

chambers constructed from sandwich insulated panels.

a) Internal floors with steel structure

b) Single floor with racks for mechanised loading

TRENDS IN CONSTRUCTION PRACTICES


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CONVENTIONAL CONSTRUCTION 1


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CONVENTIONAL CONSTRUCTION 2


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CHAMBER WITH INSULATED PANELAND STEEL STRUCTURE


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A well stacked Cold chamber


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TRENDS IN THERMAL INSULATION PRACTICES

Old Units Rice husk used as Thermal Insulation Cheap but necessitated large thickness

Lot of maintenance problems Walls and Ceiling finished with AC sheets- Many units had cork as insulation

Last Three decades Expanded Polystyrene, Fiber glass on walls

and ceilings with sand and cement plaster orSheet metal cladding using Al. sheet or PrecoatedG.S. sheet. Floor with EPS-HD

- Development of On-site Panel system /One side panel system

Latest Prefab Insulated Panel Structure

(also called Sandwich Panel) EPS Panels with EPS bonded to sheet metal skins

using special glue

PUF Panels using Polyurethane as insulationmaterial foamed between two metal skins

INSULATED PANELS


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Application right from small walk-ins to very large Cold Stores

Gone beyond cold store construction used for

processing plants, prefabricated houses, ware houses etc. Also for doors for cold stores light and simple construction

Highlights

Greater flexibility and faster construction

Better isolation and better thermal insulation Brick Walls eliminated and therefore C.S. volume increases on a given

floor area

Modular construction feasible and offers advantage of addition /expansion as per requirement

Some what more expensive and hence application was limited to small

Cold Rooms , Walk-ins , Blast Freeze and Frozen Food Stores

Now being used in many cold chain projects.


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A Modern Cold Store with Sandwich Panel Construction


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Inside view of Sandwich Panel Construction

TRENDS IN REFRIGERATION SYSTEMS


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Old System

Use of slow speed ammonia refrigerationcompressors

No capacity control

Atmospheric condensers

Bunker type evaporator coils / floor mountedair cooling units




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Recent Trends Energy efficient designs of equipments both

Ammonia & HFC

Use of Reciprocating / Screw compressors withcapacity controls / Scroll compressors on HFC units

Evaporative condensers with M.S / S.S coils onAmmonia, S & T and Air cooled condensers on HFC

Ceiling suspended finned air cooling units using M.S(galvanised) / S.S coils with Aluminium fins /

Aluminium coils with Alu fins for Ammonia



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Recent Trends

S.S / Aluminium / FRP fans

Pump circulation (overfeed) systems for largeAmmonia units

Appropriate automation and control systems

G O S S


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REFRIGERATION SYSTEM

Systems currently being used can be classified as follows:

- Modular units using HFC / HCFC refrigerant

- Central Plants using HFC / HCFC refrigerants with

air cooled / water cooled machines

- Central Plants using Ammonia refrigerant single stage & two stage

- Vapour absorption system using ammonia &water combination


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Ammonia Central Plant with Recip Compressors


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Ammonia Central Plant with Screw Compressors


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Liquid Refrigerant recirculation system

IMPORTANT FEATURES RELATED TORECENT DEVELOPMENT


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RECENT DEVELOPMENT

Fire Protection - An essential feature- some units destroyed in fire in recent

years

- Wet & Dry systems as per local codes

Standards - Various standards are applicable for coldstorage construction

- Refrigeration plants to be designed as perrelevant ASHRAE / BIS / NHB standards

- Older units hardly followed any standardsbut now there is better awareness aboutstandards

continued

IMPORTANT FEATURES RELATED TORECENT DEVELOPMENT


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continued

Standards for Equipment design & installation

Standards for Piping

Standards for Safety Criteria

Guideline ammonia machine room ventilation Standards for Thermal Insulation

Fire protection codes

Building Codes NBC

ECBC guidelines

RECENT DEVELOPMENT


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ELECTRICALS

D.G.Set - standby power supply very important

Power Factor Correction

Efficient Lighting fixtures

MATERIAL HANDLING


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Conventional Handling Practices

Manual loading & unloading

Recent Development Use of electrical hoists / lifts / fork lift trucks

/conveyors Rack structures in chambers for storing Use of Pallets & Bins

Use of computers for maintaining record ofloading / unloading & stocks

MATERIAL HANDLING


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Refrigeration - an expensive process, both interms of first cost & energy cost

Lack of adequate energy supply & rising

energy cost - serious concerns

Need for employing various energy savingmeasures

Promotion of GREEN COLD CHAIN concept first mooted in India!

ENERGY SAVING


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Eco-friendly Plant Layout Efficient Building Design

Effective Thermal Insulation

Eco-friendly & Energy EfficientRefrigeration system

Waste Heat Recovery System

Effective Control Systems

Energy Efficient Lighting

continued

FEATURES OF GREEN COLD STORES



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continued

Ventilation Noise Control Fire Safety

Water Consumption and Recycling Rain Water Harvesting Strip / Air Curtains Operational Practices

(*) This is a recent concept and is expected togain significance in the years to come


Water Storage

/ Treatment

R li

Rain water

Harvest Tank


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Tall Trees Tall Trees

Main Gate

Solar PV Light

Reflective Coating

on Roof

FRP Sheets for

Natural Light

Over Attic

Dock Door

Solar PV Cells

Office

Below

Flyash

Brick

Wall

Insulated

PanelStructure

Machine

Room

TURBO VENTILATORS

OVER ATTIC

ACR PROJECT CONSULTANTS

39/35, ERANDAVANA, PUNE 411 004

TEL - (020) 25432764 / 25439209

E-MAIL : [email protected]

Cold

Chamber

Below

Loading / Unloading Platform

Below

LAYOUT SHOWING POSSIBLE PROVISIONS FOR A "GREEN COLD STORE"

Electrical

Room

Defrost water return line from

AC Units to condensers

RecyclingHarvest Tank

Flyash Brick Wall


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MULTIPURPOSE COLD STORE WITH INSULATED PANEL

GOVERNMENT INITIATIVES


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For the first time NHB (National Horticulture Board) has takenlead to create technical standards for Cold Chain projects.

Three standards already formalised Cold Storages without pre-cooling

Multi-commodity Storages with pre-cooling

Controlled Atmosphere Storages

Two more recently introduced

For Ripening chambers

For Refrigerated Transport

Besides NHB, National Horticultural Mission (NHM) & Ministry of

Food Processing Industries (MoFPI) are offering higher financialincentives for new projects as well as expansion of existingunits, subject to their being based on modern & efficienttechnology


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These standards are

available at

http://nhb.gov.in

CONCLUSION


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Good potential exists for the development of modern &energy efficient cold chain facilities. Currently the F&V

processing is only for 6% of the production and the targetover next 5 to 6 years is upto 20%

It is imperative to have a system of registration of theexisting and the new cold storage units

The Govt. offers good financial incentives for cold chain

projects.

Excise concession available for some components of plantand machinery.

The concept of GREEN Cold Storages should be promoted

Rating system for evaluation of the GREEN projects shouldbe formalized

Special incentives should be considered for the GREEN ColdStorage projects


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THANK YOU

ncrac 2011 inv 09 presentation

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