AN ASSIGNMENT OF
PRINCIPLES OF FOOD PRESERVATION
AND PROCESSING
SUBMITTED BY –
ROLL NO. -
TYPICAL DESIGN-FOR LAYOUT
1. Cold Store Capacity & Typical Layout of A Four Chamber Design
Each chamber of 20 x 17 x 12.5
Capacity of each chamber - 1250 MT based on 3.4 m / MT
Each bag of 50kg
Ante room and other areas as marked on the layout.
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CONSTRUCTION FEATURES:-
The general norms for conventional construction are as follows:
Foundation: Conventional Foundation / Pile Foundation / Raft Foundation - to be
designed by qualified & licensed structural / civil engineer. The
design shall meet the relevant seismic zone norms for earthquake
proof designs.
Cold Chamber:
Walls 230 mm Brick walls / solid concrete blocks with sand- cement plaster
RCC slabs or Truss Roof with GI / Pre-coated GI Sheet cover. RCC
Roof
slab to have proper water proofing with reflective colour paint / China
mosaic finish. Slab to have proper slope for rain water drainage.
In case of truss roof, provision to be made for fixing insulated panels on
the ceiling & supporting of cooling units from the trusses
(alternatively cooling units can be supported on floor mounted frame
structure on top floor).
Provision for FRP sheets for natural lighting to be made in roof
sheeting at certain locations. For ventilation of attic, provision of
ridge monitor or turbo ventilators (which require no electric power)
can be made. Alternatively roof can also be designed by installing
insulated roof panels with proper slope & sealing of longitudinal
& lateral joints. The work to be handled by experienced agencies
to ensure a trouble free roof structure. The roof may be kept walkable
for maintenance.
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Floor The floor comprises of base concrete, in cold stores with suitably
lower levels in cold
chambers. The level difference between cold chambers and ante
room to be equal to
the thickness of floor insulation plus the layer of PCC or tremix finish.
Inter-floors The basic structure can be RCC columns & beams or steel columns &
steel beams
Grating Wooden batten grating or steel grating using flats / square tubes etc.
The interfloors
have to be designed for a product loading of 900 kg/m 2 min. Where
AC units are located on top floor, the structure has to be suitable for
the unit static & dynamic loads.
Ante Room This shall be designed to accommodate staircase, electrical hoist
cage and have wider
doors. Provision for fire escape stair & exits to be made as per local
norms. The
interfloors in ante room to have doors to each cold room on each
floor.
Rooms for machines, Electricals etc.
Dock Loading & unloading dock shall be designed with RCC slab roof or
sheet roofing. However the machine roof can have RCC slab-roof to
accommodate the evaporative
condensers, pump sets, water tank, water softener etc. The dock
area to accommodate suitably sized office & toilet for staff & labour.
Strip Curtains To be provided to reduce infiltration during loading/ unloading. Air
curtains can also used although they consume energy.
Ancillaries Underground fresh water storage, storage for fire fighting, water
supply & sanitary arrangements, compound wall / fencing, main
gate, security, small canteen / electrical sub-station & [Link]
platform, roads & parking place for vehicles etc. Green land scaping
with benches for labourers.
THERMAL INSULATION
Cold chambers have to be insulated on walls, ceilings / roofs & floors with proper insulating
material of adequate thickness, with provision for vapour barrier on outer side & proper cladding/
cover on inner side. The commonly insulation materials are:
a. Expanded polystyrene
b. Rigid Polyurethane foam
c. Rigid phenolic foam
d. Mineral wool / glass wool
e. Extruded polystyrene
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The ancillary materials to be used include:
a) Vapour barrier eg. aluminium foil, polyurethane sheet, with bitumen / cold mastic adhesives
b) Teakwood batten pegs, Tees etc.
c) G.S. sheet runners (avoid wooden batten runners)
d) Cladding of profiled / pre-coated G.S. sheets 0.5 / 0.6 mm thick / Fiber glass sheets of
suitable thickness
For Conventional Insulation
Walls & Ceiling
1. Primer Coat followed by two layers of bitumen
2. Fixing aluminums foil min. 50 microns
3. Fixing wooden pegs at suitable intervals
4. Fixing two layers of insulation with staggered joints
5. Fixing G.S sheet runners over the pegs in longitudinal & lateral directions
6. Fixing profiled & pre coated g.s. sheets, 0.5 / 0.6 mm thick over the runners with proper
finishing of joints. Alternatively FRP sheets can be used.
Floor
1. Laying of polythene sheet, min. 250 microns, as vapour barrier
2. Fixing insulation slabs in two layers with bitumen as adhesive for the first layer
3. Covering with tarfelt
4. Laying PCC / tremix of 75 mm / 100 mm thickness
For Insulated Panel Structure
Walls & Ceiling
1. Perimeter of the plinth to be in level for panel installation
2. Panels to have cam lock or tongue / grove joints
3. Sheet metal flashing to be provided on all concrete / wall ceiling joints internally &
externally. PVC coving or concrete curbing to be provided on wall - floor joints.
4. Horizontal Tie bracings to be provided between vertical wall panels & external columns, to
take care of wind loads.
5. Adequate numbers of Pressure relief ports to be provided on all chambers with electrical
Connection.
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6. Insulated doors shall be suitable for panel mounting
Minimum insulation thickness for various insulation materials
Ceiling/ roof U
Floor U value
Material Wall value = 0.24 2
W/m2K =0.29W/m K
Type of insulation
o
P Density K (at 10 C) Thickness Thickness
Kg/M3 Thickness mm Thickness mm
W/mK mm mm
EPS 15 0.036 150 72 150 125
PUF 32 0.023 100 50 100 100
XPS# 30-35 0.025# 100 50 100 100
Notes
K values from IS661:2000 at 10 °C for all insulation materials except XPS
K value# in case of XPS is as per ISO/FDIS 4898:2008(E) at 10°C mean/28days
minimum
U values are the recommended heat transmission coefficients for cold
storage temperature range -4 to 2°C by IS661:2000
All values rounded off in multiples of inch (25 mm)
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Cooling Load Calculations
Chamber size: 20x17x12.5
Basic Assumptions:
Ambient Conditions : 0.4% annual for Delhi - 42°C/ 22.1°
(ASHRAE data) : 0.4% for March in Delhi (for loading period only) - 34.9°C/
19.9°C
Loading period : 20 days
Specific heat of the potato : 3.433kJ/kg
Ventilation air : 4 air changes/ day
Heat of respiration at 3° : 0.018W/kg (Ref. - Ashrae Refrigeration handbook 2006)
(California potato) at 15° : 0.027W/kg.
Occupancy : 4 people working for 12 hours during loading
Lighting load : 1.85 kW for 12 hours during loading period for 4chambers
Enthalpy wheel for ventilation : 70% energy recovery
Fan load : Estimated based on refrigeration capacity of each chamber,
(Ref. W.F .Stoecker, Industrial refrigeration handbook) Front
face(40x12.5) orientation of the building assumed to be 60
degree west of south
Insulation U values as per : 2000
IS
661
Transmission load calculated on the basis of ASHRAE RTS method.
Pull down period : 24 hrs
TYPICAL SPECIFICATIONS OF REFRIGERATION SYSTEM
Products that can be stored: Potatoes, Apples, pears for storage above 1 oC.
Estimated refrigeration capacity : 340 - 370 kW
Refrigerant : Anhydrous Ammonia / Freon
Gravity feed system
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Refrigeration Compressors & Motors
Quantity 3 Nos each of 50% capacity(One standby)
Reciprocating, multi cylinder complete with water
cooled head / jackets, with accessories like oil
Type separators, capacity control & unloaded start.
Alternatively screw compressor, open type with
Accessories
Capacity at (-) 3 deg C Evaporating & 38deg C
185 to 190 kW
Condensing
55 kW x 1450 RPM, TEFC Sq. cage, class F
Estimated Motor rating insulation, suitable for 415 V, 3 ph, 50 c/s. AC
supply
Image of Compressor
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Evaporative Condenser
Hot dip galvanized M.S. pipes CDW Boiler
Coil Section
quality tubes or S.S.304 tubes
With 2 / 3 Axial Flow Fans with Cast Aluminium
Fan Section OR S. impellers, complete with TEFC Sq. cage
motors, Class F insulation & IP-55 protection
S.S.304 or M.S. Epoxy coated with necessary
Water sump tank
connections
Water spray arrangement, air inlet grilles,
Other provisions
eliminators of suitable design
with removable G.S sheet panels & inspection
Unit casing
windows etc.
Estimated Heat rejection capacity at 38 deg C 480 to 500 kW
condensing & and applicable WB temp
Atmospheric Condenser
Evaporative
Condenser
H.P. Receiver
With necessary connections, reflex type level
Horizontal Ammonia receiver complete
gauge etc.
Capacity 1500 liters (min)
Material of construction Boiler quality steel plates
2 Nos. (Two nos are suggested since some
Quantity states regulations call for Pressure testing of
high pressure vessels on a periodic basis)
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Air Cooling Units
Coil design to be suitable for gravity feed / pump circulation as
a) Finned Cooling coil
per design
Hot dip galvanised M.S. pipes CDW Boiler quality tubes or
M.O.C
S.S.304 tubes & Aluminium fins with proper bonding system
Fin spacing 6.25 to 8.5 mm (3-4 FPI)
With cast aluminium / S.S. / FRP impellers, with variable pitch,
b) Axial Flow fans TEFC Squirrel cage motors with class F insulation, IP-55
protection
Vertical / horizontal with necessary connections (in case of
c) Accumulator
gravity feed units)
G.S. sheet duly painted, drain pan of G.S / M.S with epoxy
d) Unit casing
paint
e) Defrosting arrangement Water
Unit capacities 3 nos per chamber
Estimated capacity each at (-) 3 deg
C Evaporating & 5 deg C T.D
34.5 to 38.3 kW
(between evap temp & air entering
temp)
Estimated coil surface area 270 to 330m2
Estimated air flow capacity 9 to 10 m3/ s
each
For fruits & Vegetables requiring higher humidities, lower delta T, higher flow rates of air and higher coil
surface areas need to be used.
For 1 no. F & V cold store 3 nos
Estimated capacity each at (-) 2 deg C 38.3 kW
Evaporating & 4 deg CT.D
Estimated coil surface area 300 to 380 m2
Estimated air flow capacity each 10 to 12 m3/s
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Refrigerant Piping, Fittings & Valves
Piping
M.S. black piping conforming to IS-1239 and
Interconnecting piping between compressor, other relevant Indian standards
condenser, receiver and cooling units
Water Piping, Fitting & Valves
Piping shall be used for
Piping to be G.I class B for sizes up to 65 NB
a) Condenser water circulation
& M.S. black pipe conforming to IS-1239.
b) Compressor cooling
Valves up to 40 NB to be Gate / Globe type.
c) Defrosting
Valves 50 NB / larger to be butterfly type.
d) Drain lines
Water Pump sets
Water flow capacity to take care of condenser
2 nos. (one standby)
water flow & compressor head / jacket cooling
Capacity 13 to 14 lps
Thermal insulation for refrigerant piping etc.
a) EPS pipe section
b) PUF pipe section with 0.6 mm
Aluminium or 0.5 mm GI pre coated
Material for insulation for refrigerant suction sheet cladding
line, accumulators etc c) Nitrile Rubber / EPDM / pipe section /
other acceptable materials with woven
glass cloth with UV treated pigmented
epoxy Coating.
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Duct Mouth pieces
To be provided on each fan outlet for uniform
GI sheet ducting as per IS 655
distribution of air at the topmost level
Ventilation for cold chambers
Axial flow / Inline duct fans with cleanable inlet
filters, GI sheets / Aluminium / PVC ducting
upto cold chambers and ducting for exhaust
System to be designed for providing adequate from cold chambers to outside Heat exchanger
air changes / day with energy recovery wheel or heat pipe can
be used for cooling the incoming air from the
exhaust air. Typical efficiencies of heat
exchangers are 70% or higher.
Humidification
Fogger type external humidification system
with 2 to 10 micron particles with automatic
External humidification for 90 to 95 % RH regulation
Controls
Temp Indicators cum controllers for individual
chambers. Temperature scanners and a
Temperature control centralized temperature indication in machine
room
RH control RH indicator & controller
CO 2 sensors for regulation of ventilation
CO2control system
Refrigerant flow controls Liquid level controls, solenoid valves etc.
PLC control systems For overall control of various parameters
Installation, Testing & Commissioning
The plant shall be installed, tested &
Installation commissioned as per IS 660.
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Liquid Overfeed System:
The above design recommendations are for gravity feed for air cooling units. It is also possible to
use pump circulation system (overfeed system) requiring following components:
a. Centralized ammonia L.P receiver
b. Ammonia pumps - 2 nos
c. Refrigerant flow & safety controls
d. Interconnecting piping - both supply & return lines shall be insulated
In this case the individual accumulators for AC units & level controls etc. are not required. The coil surface
area may be 5 - 10% lower.
ELECTRICAL INSTALLATION
Substation
a. Step down transformer suitable
for incoming H.T. voltage / 433 V as
per IS- 2026 / other applicable
standards
b. Two pole / four pole structure as per
Substation with a rating of about 200kW local requirements
c. Outdoor type metering cubicle with
approved meter, CTs / PTs etc.
d. Earthing station as per requirement
e. Switchyard fencing with gates as per
Electrical Board requirements
[Link] for standby power
[Link] complete with accessories and with
Estimated Rating : 160kW for single
weather-proof and noise-proof canopy as per
One big and one small can also be used
local pollution control norms
Main power distribution panel with changeover facility for normal electric supply & D.G. set supply. With
ongoing feeders for various electrical panels
Electric panels
a. Refrigeration
b. Lighting, Electric hoist, Fans
Electric panels for c. APFC (Automatic Power Factor
Correction) panel
d. Water supply, fire fighting etc.
Power & Control cabling etc.
Aluminium armoured conductors for main
Power and Control cabling, Earthing etc for
power lines & equipment lines & copper
various electrical circuits
conductors for lighting, control wiring etc.
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Lighting
Lighting in
The light fittings should be energy efficient eg.
a. cold stores, ante room
CFL fittings for cold chambers. A central switch
b. other areas
may be provided
c. outside areas
Electrical hoist
With wire ropes, steel fabricated cage with
Electric hoist guides & openable doors for material
movement, product lifting
Capacity 2 MT of product
SAFETY PROVISIONS
Ammonia sensors in cold chambers near ACUs
& machine room
Emergency ventilation for machine room
Provision for handling accidental leakage of
Safety release of refrigerant to water sump
ammonia
Ammonia masks
First aid kit
Instructions for handling emergencies
Fire sensors in cold chambers & machine room.
Dry & water based fire fighting systems as per
Fire protection
specs below. Sprinklers for high pressure
receivers
Emergency lighting system May be solar PV cells with batteries & controller
To be provided with switches near all cold store
Emergency alarm system doors and alarms located in common public
areas
Lightning arrestors for the building as per local regulations
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Fire Fighting
(Dry Type )
a) Dry chemical powder type 5.0 Kg
Cap with ISI Mark Fire Extinguisher
complete with wall mounting
bracket.
Fire fighting equipment necessary for b) Carbon Di-Oxide (CO 2 ) type 4.5
extinguishing liquid, solid and electrical fire : Kg. capacity Fire Extinguisher
complete with wall mounting
bracket.
c) G.I. Fire Buckets
d) M.S. Stand for Fire Buckets
Water based
i) 2 sets of Water supply pumps.
ii) 2 sets Fire fighting pumps
iii) G.I. piping, class C with
necessary fittings & valves
System shall comprise of iv) Rubber Hose reel
v) Canvas Hose pipe
vi) M.S. Fabricated hose box with
key
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