ncrac 2011 inv 09 presentation
TRANSCRIPT
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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.
TRENDS IN COLD CHAIN DEVELOPMENT
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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.
TRENDS IN COLD CHAIN DEVELOPMENT
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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
TRENDS IN REFRIGERATION SYSTEMS
TRENDS IN REFRIGERATION SYSTEMS
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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
TRENDS IN REFRIGERATION SYSTEMS
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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
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
FEATURES OF GREEN COLD STORES
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