1

UNIVERSITY OF SANTO TOMAS

FACULTY OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT

DESIGN REPORT
ON A
120 TONS CAPACITY REFRIGERATION PLANT

ACADEMIC YEAR 2015-2016

Date Submitted: May 20, 2016 NAMES: INSON, Jerome Richard

Grade: JUSTO, Lorenzo Gabriel
LEE, Renzo Nicholas
LEGASPI, Jude Airiz
LOBO, Kevin Lester

PROFESSOR: Engr. Mary Rose Cobar, Ph.D

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REMARK SHEET
 3

TABLE OF CONTENTS
Design Code Problem 4
Ice Making and Ice Storage 5
Ice Load Computations 5
Cans 6
Freezing Tank 6
Brine Calculations 6
Ice Making and Ice Storage Dimensions 7
Air Change 8
Workers 9
Lightings 9
Crane 10
Heat Load Tabulation 10

Cold Storage 11
Product Load Computations 11
Medicine Information 13
Air Change 14
Workers 15
Lightings 15
Crane 16
Heat Load Tabulation 16

Wall Gain 17

Medicine Packaging and Pallets 28

Machine Computations 33

Feasibility of the Plant 38

Socio-Economic Impact 39

Plant Site Selection 40

Wiring Diagram 42

Piping Diagram 44

Bill of Materials 45

Appendices 46

References 51
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DESIGN CODE PROBLEM

100 TONS ORDINARY BLOCK ICE and

100 TONS COLD STORAGE CAPACITY FOR LOCAL
AND IMPORTED MEDICINES
 5

ICE MAKING (100 TONS ORDINARY ICE BLOCK)

ICE MAKING LOAD, Qice:

Raw water temperature: 28°C Heat of fusion Lf: 335 KJ/Kg
kJ
Harvesting temperature: -10°C Specific heat of water: 4.187
kg K
kJ
Freezing temperature: 0°C Specific heat of ice: 2.094
kg K

𝑸𝒊𝒄𝒆 = (𝒎𝑪𝜟𝒕) + (𝒎𝑳𝒇) + (𝒎𝑪𝜟𝒕)

Q ice
1000kg kJ 1000kg 1000
100tons ( ) (4.187 ) (28 − 0) + (100tons) ( ) (335) + (100)( )(2.094)(0 − (−10))
1ton kg − K 1ton 1
=
3600sec
36hrs( )
hr

𝑇𝑅
= 365.105 𝐾𝑊 (3.52𝐾𝑊)

Qice = 103.72 TR

NUMBER OF ICE CANS, N:

Weight of ice to be pulled every 24 hrs: 100 tons

Freezing Time, H: 36 hours* (for ordinary ice block)
Weight of block ice: 165 lb (Actual) *
Brine Temperature: 18°F or -7.778°C*
Standard Ice Can Size: 8”x 16” x 42” *
*From Kent’s Handbook Power Volume, Table 1

𝑾𝑯
𝑵=
𝟐𝟒𝑪
2000 lb
100 tons ( ton )(36 hrs)
N=
lb
24 hrs (165 can)

N = 1818.18 ≈ 1819 cans

 6

FREEZING TANK DIMENSIONS: 30

Arrangement of 30 x 32 = 960 cans
Can size: 8”x 16” x 42”
Number of freezing tank: 2 tanks
Spacing in between cans and on top: 3”
Spacing at bottom: 5”
Space for brine agitator: 45” 32

Clearance, C = 3” + 45” for brine raceway

Length, L = (32 cans)(16”) + (32+1)(3”) + 45” = 656 in = 16.66 m
Width, W = (30 cans)(8”) + (30+1)(3”) = 333 in = 8.46 m
Height, H = 3” + 42” + 5” = 50 in = 1.27m

VOLUME OF TANK:
VT = (L)(W)(H)
= (16.66)(8.46m)(1.27m)
VT = 179 m3

VOLUME OF CAN:
Vc = (L)(W)(H)
= (8”)(16”)(42”)
= 5,376 in3 = 0.0881 m3/can
= (1819 cans)(0.0881 m3/can)
Vc = 160.25 m3
45.24”

VOLUME OF BRINE, VB
Vb = Vt - Vc
= 179 m3-166.29 m3
Vb = 12.71 m3

BRINE LEVELS: lb 165lb

57.5 3
= (12𝑖𝑛)3
ft (8 in)(16 in)(h)
Density of ice, ρice:
h = 38.74”
𝐥𝐛 𝐖
𝛒𝐢𝐜𝐞 = 𝟓𝟕. 𝟓 𝟑 =
𝐟𝐭 𝐯 Brine Level = h + floor spacing + brine
allowance
Brine level = h + 5” + 1.5 = 45.24in
 7

ICE MAKING AND ICE STORAGE INSIDE DIMENSIONS

Ice Making Ice Storage

Length: 20.9 meters
Width: 19.9 meters
Height: 5 meters
Wall Thickness: 0.44074 meters
Area: 415.91 meters
Length: 10.2 meters
Width: 6.3 meters
Height: 5 meters
Wall Thickness: 0.44074 meters
Area: 62.26 meters
 8

AIRCHANGE LOAD (ICE STORAGE)

Number of exchange: 4.63 air changes per 24 hours *
Inside Volume: 10.2 x 6.3 x 5m = 321.3 m3 = 11346.602 ft3
Air change factor: 2.56 BTU/ ft3
Outside Temperature: 30 C (50% RH)
Inside Temperature: -10 C
*Equations and constants taken from Principles of Refrigeration, R.J.Dossat. Table 10-8

𝟏
Qairchange = (number of exchange) (volume space) (air change factor) (𝟐𝟒 𝐡𝐨𝐮𝐫𝐬)
𝐚𝐢𝐫 𝐜𝐡𝐚𝐧𝐠𝐞𝐬 11346.602 ft3 BTU
Qairchange = (4.63 𝟐𝟒 𝐡𝐨𝐮𝐫𝐬
) ( 𝐚𝐢𝐫 𝐜𝐡𝐚𝐧𝐠𝐞𝐬 ) (2.56 𝑓𝑡 3 )
𝑇𝑅
Qairchange = 5603.71 BTU/hr. = 1.6422 KW (3.52𝐾𝑊)

Qairchange = 0.4665 TR
 9

ICE STORAGE MISCELLANEOUS LOAD

LABOR
People factor in Ice Storage: 1140 BTU/hr. *
Temperature: -10C or 14 F
Number of Workers for Ice Storage: 5
Working Hours: 8
*Equations and constants taken from Principles of Refrigeration, R.J.Dossat. Table 10-16

(𝒑𝒆𝒐𝒑𝒍𝒆 𝒇𝒂𝒄𝒕𝒐𝒓 𝒙 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒑𝒆𝒐𝒑𝒍𝒆 𝒙 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈 𝒉𝒐𝒖𝒓𝒔)

𝐐𝐰𝐨𝐫𝐤𝐞𝐫 =
𝟐𝟒𝒉𝒓
𝐵𝑡𝑢
1140 𝑥 5 𝑥 8 ℎ𝑟
ℎ𝑟
Qworkers (IceStorage) = 24 ℎ𝑟
𝐵𝑡𝑢 𝑇𝑅
Qworkers(IceStorage) = 1900 = 0.556KW(3.52𝐾𝑊)
ℎ𝑟

Qworkers(IceStorage) = 0.158 TR

LIGHTING
Ice Making area:
𝑙𝑢𝑥
(𝒍𝒖𝒙)(𝑨𝒓𝒆𝒂) (250 2 )(415.91𝑚2 )
𝑚
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒍𝒂𝒎𝒑𝒔, 𝒏 =
𝑳𝒖𝒎𝒆𝒏𝒔
= 6000𝑙𝑚
= 17.32 = 18 lamps

(𝒏)(𝑾𝒂𝒕𝒕𝒂𝒈𝒆)(𝟑. 𝟒𝟐
𝑩𝒕𝒖
𝑸𝒍𝒊𝒈𝒉𝒕 = 𝒘𝒂𝒕𝒕)(𝟖𝒉𝒐𝒖𝒓𝒔) ∗ 𝟏𝒌𝑾
𝟐𝟒 𝒉𝒐𝒖𝒓𝒔 𝑩𝒕𝒖
𝟑𝟒𝟏𝟐. 𝟏𝟒𝟐
𝒉𝒓
(18)(60)(3.42
𝐵𝑡𝑢
𝑄𝑙𝑖𝑔ℎ𝑡 = 𝑤𝑎𝑡𝑡)(8ℎ𝑜𝑢𝑟𝑠) ∗ 1𝑘𝑊
24 ℎ𝑜𝑢𝑟𝑠 𝐵𝑡𝑢
3412.142
ℎ𝑟
𝑸𝒍𝒊𝒈𝒉𝒕 = 𝟎. 𝟑𝟔𝟎𝟖𝒌𝑾
Ice Storage
𝑙𝑢𝑥
(250 )(62.26𝑚2 )
𝑛= 𝑚2 = 𝟐. 𝟓𝟗 = 𝟑 𝒍𝒂𝒎𝒑𝒔
6000𝑙𝑚

𝐵𝑡𝑢
(3)(60)(3.42
𝑄𝑙𝑖𝑔ℎ𝑡 = 𝑤𝑎𝑡𝑡)(8ℎ𝑜𝑢𝑟𝑠) ∗ 1𝑘𝑊
24 ℎ𝑜𝑢𝑟𝑠 𝐵𝑡𝑢
3412.142
ℎ𝑟
𝑸𝒍𝒊𝒈𝒉𝒕 = 𝟎. 𝟎𝟔𝟎𝟏𝒌𝑾

𝑇𝑅
Total Qlights = (0.3608 KW + 0.0601 KW )( )
3.52𝐾𝑊

𝐐𝐥𝐢𝐠𝐡𝐭 = 𝟎. 𝟏𝟏𝟗𝟔𝐓𝐑
 10

CRANE
No of crane: 2
Number of operating hours: 8
Motor Factor
*Equations and constants taken from Principles of Refrigeration, R.J.Dossat. Table 10-16

(𝐡𝐨𝐫𝐬𝐞 𝐩𝐨𝐰𝐞𝐫) 𝐱( 𝐦𝐨𝐭𝐨𝐫 𝐟𝐚𝐜𝐭𝐨𝐫) 𝐱 (𝐧𝐨. 𝐨𝐟 𝐜𝐫𝐚𝐧𝐞) 𝐱 𝟖 𝐡𝐫

𝐐𝐜𝐫𝐚𝐧𝐞 =
𝟐𝟒𝐡𝐫𝐬
Driving motor:
𝐵𝑡𝑢
1hp x 3700 x 2x8 hr 1𝑘𝑊 𝑇𝑅
ℎ𝑝−ℎ𝑟
𝑄𝐷𝑟𝑖𝑣𝑖𝑛𝑔 𝑚𝑜𝑡𝑜𝑟 = ∗ 𝐵𝑡𝑢 (3.52𝐾𝑊)
24ℎ𝑟𝑠 3412.142
ℎ𝑟

𝑸𝑫𝒓𝒊𝒗𝒊𝒏𝒈 𝒎𝒐𝒕𝒐𝒓 = 0.3615kW

Crane motor:
𝐵𝑡𝑢
3hp x 2945 x 2x 8 hr 1𝑘𝑊 𝑇𝑅
ℎ𝑝−ℎ𝑟
𝑄𝐶𝑟𝑎𝑛𝑒 𝑚𝑜𝑡𝑜𝑟 = ∗ 𝐵𝑡𝑢 (3.52𝐾𝑊)
24ℎ𝑟𝑠 3412.142
ℎ𝑟

𝑸𝑪𝒓𝒂𝒏𝒆 𝒎𝒐𝒕𝒐𝒓 = 0.8631kW

𝑇𝑅
Total Qlights = (0.3615 KW + 0.8631 KW )( )
3.52𝐾𝑊

𝐐𝐜𝐫𝐚𝐧𝐞 = 𝟎. 𝟑𝟒𝟕𝟗 𝐓𝐑

HEAT LOAD TABULATION (FOR ICE STORAGE)

Product Load 103.72 TR
Air Change 0.4665 TR
Labor 0.158 TR
Lighting 0.1196TR
Crane 0.3479 TR
TOTAL HEAT LOAD 104.812 TR
 11

PRODUCT LOAD (100 TONS OF LOCAL/IMPORTED MEDICINES)

a) 20 Tons of Paracetamol

Unloading temperature: 20°C kJ

Specific heat of tablet: 0.89 kg K
Storage temperature: 12°C
(if blister packs and cardbox are neglected due to weight)

𝑚𝐶𝛥𝑡
𝑸𝒑𝒂𝒓𝒂𝒄𝒆𝒕𝒂𝒎𝒐𝒍 = ( )
𝑇 𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙
𝑘𝑔 𝑘𝐽
(20 𝑡𝑜𝑛𝑠) (1000
𝑡𝑜𝑛) (0.89 𝑘𝑔 − °𝐾 ) (20 − 12)°𝐶
𝑸𝒑𝒂𝒓𝒂𝒄𝒆𝒕𝒂𝒎𝒐𝒍 = 𝑠𝑒𝑐
24ℎ𝑟𝑠 (3600 )
ℎ𝑟
Qparacetamol = 1.6481 KW

b) 20 Tons of Ethyl Alcohol

Unloading temperature: 20°C kJ

Specific heat of ethyl alcohol: 2.46 kg K
Storage temperature: 12°C

𝑚𝐶𝛥𝑡
𝑸𝒆𝒕𝒉𝒂𝒏𝒐𝒍 = ( )
𝑇 𝑒𝑡ℎ𝑎𝑛𝑜𝑙
𝑘𝑔 𝑘𝐽
(20 𝑡𝑜𝑛𝑠) (1000
𝑡𝑜𝑛) (2.46 𝑘𝑔 − °𝐾 ) (20 − 12)°𝐶
𝑸𝒆𝒕𝒉𝒂𝒏𝒐𝒍 = 𝑠𝑒𝑐
24ℎ𝑟𝑠 (3600 )
ℎ𝑟
Qethanol = 4.5556KW

c) 20 Tons of Melphalan

Unloading temperature: 20°C kJ

Specific heat of ethyl alcohol: 0.89 kg K
Storage temperature: 5°C

𝑚𝐶𝛥𝑡
𝑸𝒎𝒆𝒍𝒑𝒉𝒂𝒍𝒂𝒏 = ( )
𝑇 𝑚𝑒𝑙𝑝ℎ𝑎𝑙𝑎𝑛
𝑘𝑔 𝑘𝐽
(20 𝑡𝑜𝑛𝑠) (1000
𝑡𝑜𝑛) (0.89 𝑘𝑔 − °𝐾 ) (20 − 5)°𝐶
𝑸𝒎𝒆𝒍𝒑𝒉𝒂𝒍𝒂𝒏 = 𝑠𝑒𝑐
24ℎ𝑟𝑠 (3600 )
ℎ𝑟

Qmelphalan = 3.0903 KW
 12

d) 20 Tons of 5% Dextrose

Unloading temperature: 20°C kJ

Specific heat of 5% dextrose:
kg K
Storage temperature: 5°C

𝑚𝐶𝛥𝑡
𝑸𝒅𝒆𝒙𝒕𝒓𝒐𝒔𝒆 = ( )
𝑇 𝑑𝑒𝑥𝑡𝑟𝑜𝑠𝑒
𝑘𝑔 𝑘𝐽
(20 𝑡𝑜𝑛𝑠) (1000
𝑡𝑜𝑛) (4.04 𝑘𝑔 − °𝐾 ) (20 − 5)°𝐶
𝑸𝒅𝒆𝒙𝒕𝒓𝒐𝒔𝒆 = 𝑠𝑒𝑐
24ℎ𝑟𝑠 (3600 )
ℎ𝑟
Qdextrose = 14.0278 KW

e) 20 Tons of Measles, Mumps, and Rubella Virus Vaccine

Unloading temperature: 10°C kJ

Specific heat of MMR: 1.325 kg K
Storage temperature: 5°C

𝑚𝐶𝛥𝑡
𝑸𝑴𝑴𝑹 = ( )
𝑇 𝑀𝑀𝑅
𝑘𝑔 𝑘𝐽
(20 𝑡𝑜𝑛𝑠) (1000
𝑡𝑜𝑛) (1.325 𝑘𝑔 − °𝐾 ) (10 − 5)°𝐶
𝑸𝑴𝑴𝑹 = 𝑠𝑒𝑐
24ℎ𝑟𝑠 (3600 )
ℎ𝑟
Qdextrose = 1.5336KW

TOTAL PRODUCT LOAD

Qproduct = Qparacetamol + Qethanol + Qmelphalan + Qdextrose + Qdextrose
= 1.6481 KW + 4.5556 KW + 3.0903 KW + 14.0278 KW + 1.53356 KW
Qproduct = 24.8553 KW = 7.0612 TR
 13

MEDICINE INFORMATION
Generic Name: Paracetamol
Brand Name: Biogesic
Manufacturer: Unilab (local)
Dosage Form: Tablet
Storage Temperature: <25°C
Core ingredient: Microcyrstalline
cellulose
Specific heat: 0.89 KJ/kgK
Brand Name: M-M-R® II
Manufacturer: Merck and Co., Inc.
Dosage Form: Solution for injection
Storage Temperature: 2°C - 8°C
Core excipient: Sorbitol
Specific heat: 1.325 KJ/kgK
Mass per Empty Vial: 17 grams

Generic Name: Ethyl Alcohol (C2H6O) Generic Name: Glucose Anhydrous

Brand Name: Cleene
Manufacturer: TELSTAR Manufacturing
Corp (local)
Form: Liquid
Freezing point: -144C
Storage Temperature: 20°C - 25°C
Core ingredient: Ethanol 70%
Specific heat: 2.46 KJ/kgK
Brand Name: 5% Dextrose Injection, USP
Manufacturer: DEMO SA
Dosage Form: Solution for Infusion
Storage Temperature: 4°C - 25°C
Core ingredient: d-glucose at 5%
Specific heat: 4.04 KJ/kgK

Generic Name: Melphalan

Brand Name: Alkeran
Manufacturer: GlaxoSmithKline
Dosage Form: Tablet
Storage Temperature: 2°C - 8°C
Core excipient: Microcyrstalline cellulose
Specific heat: 0.89 KJ/kgK

Generic Name: Measles, Mumps, and

Rubella Virus Vaccine, Live
 14

AIR CHANGE LOAD

(5°C STORAGE ROOM)
Number of exchange: 1.1 air changes per 24 hours *
Inside Volume: 21.8 x 27 x 8.875m = 5223.825m3 = 184477.636 ft3
Air change factor: 1.652 BTU/ ft3
Outside Temperature: 30°C (50% RH)
Inside Temperature: 5°C
*Equations and constants taken from Principles of Refrigeration, R.J.Dossat. Table 10-8 and 10-9.

𝟏
Qairchange = (number of exchange) (volume space) (air change factor) (𝟐𝟒 𝐡𝐨𝐮𝐫𝐬)
𝐚𝐢𝐫 𝐜𝐡𝐚𝐧𝐠𝐞𝐬 184477.636 ft3 BTU
Qairchange = (1.1 𝟐𝟒 𝐡𝐨𝐮𝐫𝐬
) ( 𝐚𝐢𝐫 𝐜𝐡𝐚𝐧𝐠𝐞𝐬 ) (1.652 𝑓𝑡 3
)
𝑇𝑅
Qairchange = 13,968.03 BTU/hr = 4.0936(3.52𝐾𝑊)

Qairchange(5C) = 1.162 TR

(12°C STORAGE ROOM)

Number of exchange: 1.6 air changes per 24 hours *
Inside Volume: 17.1 x 14.7 x 8.875m = 2230.9 m3 = 78783.4889 ft3
Air change factor: 1.176 BTU/ ft3
Outside Temperature: 30°C (50% RH)
Inside Temperature: 12°C

𝐚𝐢𝐫 𝐜𝐡𝐚𝐧𝐠𝐞𝐬 78783.4889 ft3 BTU

Qairchange = (1.6 )( ) (1.176 )
𝟐𝟒 𝐡𝐨𝐮𝐫𝐬 𝐚𝐢𝐫 𝐜𝐡𝐚𝐧𝐠𝐞𝐬 𝑓𝑡 3
𝑇𝑅
Qairchange = 6176.625 BTU/hr = 1.81KW (3.52𝐾𝑊)

Qairchange(12C) = 0.514 TR
 15

COLD STORAGE MISCELLANEOUS LOAD

FORKLIFT:
Motor Factor: 2950 BTU/hp-hr *
Number Forklifts: 4
Working Hours: 8
(𝐡𝐨𝐫𝐬𝐞 𝐩𝐨𝐰𝐞𝐫) 𝐱( 𝐦𝐨𝐭𝐨𝐫 𝐟𝐚𝐜𝐭𝐨𝐫) 𝐱 (𝐧𝐨. 𝐨𝐟 𝐟𝐨𝐫𝐤𝐥𝐢𝐟𝐭𝐬) 𝐱 𝟖 𝐡𝐫
𝑸𝒇𝒐𝒓𝒌𝒍𝒊𝒇𝒕 =
𝟐𝟒𝒉𝒓𝒔
𝐵𝑡𝑢
5.36 ℎ𝑝 𝑥 2950 𝑥 4 𝑓𝑜𝑟𝑘𝑙𝑖𝑓𝑡𝑠 𝑥 8 ℎ𝑟 1𝑘𝑊
ℎ𝑝 − ℎ𝑟 𝑇𝑅
𝑄𝑓𝑜𝑟𝑘𝑙𝑖𝑓𝑡 = ∗ ( )
24 ℎ𝑟 𝐵𝑡𝑢 3.52𝐾𝑊
3412.142
ℎ𝑟
𝑄𝑓𝑜𝑟𝑘𝑙𝑖𝑓𝑡 = 1.7553 TR

LABOR:

People factor in Ice Storage: 720 BTU/hr *

Number of Workers for 12°C Storage: 3
Working Hours: 8

(𝑝𝑒𝑜𝑝𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 x number of people x 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 ℎ𝑜𝑢𝑟𝑠)

𝑄𝑝𝑒𝑟𝑠𝑜𝑛 =
24hr
𝐵𝑡𝑢
720 x 3 person x 8 hr 1𝑘𝑊 𝑇𝑅
𝐻𝑟
𝑄𝑝𝑒𝑟𝑠𝑜𝑛 = ∗ 𝐵𝑡𝑢 ( )
24 ℎ𝑟𝑠 3412.142 3.52𝐾𝑊
ℎ𝑟

𝑸𝒑𝒆𝒓𝒔𝒐𝒏(𝟏𝟐𝑪) = 0.06 TR

People factor in Ice Storage: 840 BTU/hr *

Number of Workers for 5°C Storage: 3
Working Hours: 8
𝐵𝑡𝑢
840 x 3 person x 8 hr 1𝑘𝑊 𝑇𝑅
𝐻𝑟
𝑄𝑝𝑒𝑟𝑠𝑜𝑛 = ∗ 𝐵𝑡𝑢 ( )
24 ℎ𝑟𝑠 3412.142 3.52𝐾𝑊
ℎ𝑟

𝑸𝒑𝒆𝒓𝒔𝒐𝒏(𝟓𝑪) = 0.0699 TR
 16

LIGHTING:

Cold Storage 1: 5°C

𝑙𝑢𝑥 2
(𝑙𝑢𝑥)(𝐴𝑟𝑒𝑎) (250 𝑚2 )(588.6𝑚 )
𝑛= = = 𝟐𝟒. 𝟓𝟐𝟓 = 𝟐𝟓 𝒍𝒂𝒎𝒑𝒔
𝐿𝑢𝑚𝑒𝑛𝑠 6000𝑙𝑚

𝑩𝒕𝒖
(𝒏)(𝑾𝒂𝒕𝒕𝒂𝒈𝒆)(𝟑. 𝟒𝟐
𝑸𝒍𝒊𝒈𝒉𝒕 = 𝒘𝒂𝒕𝒕)(𝟖𝒉𝒐𝒖𝒓𝒔) ∗ 𝟏𝒌𝑾
𝟐𝟒 𝒉𝒐𝒖𝒓𝒔 𝑩𝒕𝒖
𝟑𝟒𝟏𝟐. 𝟏𝟒𝟐
𝒉𝒓
(25)(60)(3.42
𝐵𝑡𝑢
𝑄𝑙𝑖𝑔ℎ𝑡 = 𝑤𝑎𝑡𝑡)(8ℎ𝑜𝑢𝑟𝑠) ∗ 1𝑘𝑊
(
𝑇𝑅
)
24 ℎ𝑜𝑢𝑟𝑠 𝐵𝑡𝑢 3.52𝐾𝑊
3412.142
ℎ𝑟
𝑸𝒍𝒊𝒈𝒉𝒕 = 𝟎. 𝟏𝟒𝟐𝟒 𝑻𝑹

Cold Storage 2: 12°C

𝑙𝑢𝑥
(250 )(257.25𝑚2 )
𝑛= 𝑚2 = 𝟏𝟎. 𝟕𝟐 = 𝟏𝟐 𝒍𝒂𝒎𝒑𝒔
6000𝑙𝑚

(12)(60)(3.42
𝐵𝑡𝑢
𝑄𝑙𝑖𝑔ℎ𝑡 = 𝑤𝑎𝑡𝑡)(8ℎ𝑜𝑢𝑟𝑠) ∗ 1𝑘𝑊
(
𝑇𝑅
)
24 ℎ𝑜𝑢𝑟𝑠 𝐵𝑡𝑢 3.52𝐾𝑊
3412.142
ℎ𝑟
𝑸𝒍𝒊𝒈𝒉𝒕 = 𝟎. 𝟎𝟔𝟖𝟒 𝑻𝑹

HEAT LOAD TABULATION (FOR COLD STORAGE)

Product Load 7.0612 TR
Air Change (5°C) 1.162 TR

Air Change (12°C) 0.514 TR

Forklift 1.7553 TR

Labor (5°C) 0.06 TR

Labor (12°C) 0.0699 TR
Lighting (5°C) 0.1424 TR
Lighting (12°C) 0.0684 TR
TOTAL HEAT LOAD 10.3706 TR
 17

WALL GAIN COMPUTATION

Different temperatures:
Outside temperature = 40°C
Inside temperature of ice storage = -10°C
Inside temperature of the ice plant = 21°C
Cold Storage 1 temperature = 12°C
Cold Storage 2 temperature = 5°C
Floor temperature = 30°C
Correction factor for solar radiation = 4

 Wall Compositions
 18

a) Paint: (Inside and outside)

Thickness: 0.26 mm
𝑊
Thermal conductivity = 0.17𝑚∗𝐾

b) Cement: (Inside and outside)

Thickness: 17.78 mm
𝑊
Thermal conductivity = 0.29𝑚∗𝐾

c) Hollow Blocks: (Inside and

outside)
Thickness: 0.1016 m
𝑊
Thermal conductivity = 1.4𝑚∗𝐾

d) Polyurethane foam:
Thickness: 0.1016 m
𝑊
Thermal conductivity = 0.03𝑚∗𝐾
 19

2∗26 2∗17.78
Total wall thickness = 1000 + + 2 ∗ 0.1016 + 0.15
1000

Total wall thickness = 0.44076m

Thermal resistance of the wall

0.00026 ∗ 2 0.01728 ∗ 2 0.1016 ∗ 2 0.15
𝑅𝑠𝑒𝑟𝑖𝑒𝑠 = + + +
0.17 0.29 1.4 0.03
𝐊 ∗ 𝐦𝟐
𝐑 𝐬𝐞𝐫𝐢𝐞𝐬 = 𝟓. 𝟐𝟔𝟕𝟒
𝐖

For Ice storage walls facing the outside

40°𝐶 − (−10°𝐶)
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟗. 𝟒𝟗𝟐𝟑
𝐦𝟐

For Ice storage walls facing the inside of the facility

21°𝐶 − (−10°𝐶)
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟓. 𝟖𝟖𝟓𝟑
𝐦𝟐

For Ice storage walls facing the 5°C Cold Storage

5°𝐶 − (−10°𝐶)
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟐. 𝟖𝟒𝟕𝟕
𝐦𝟐
 20

For Ice storage walls facing the 12°C Cold Storage

12°𝐶 − (−10°𝐶)
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟒. 𝟏𝟕𝟔𝟔
𝐦𝟐

For the 12°C Cold Storage room facing the outside

40°𝐶 − 12°𝐶
𝑞= ∗4
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟓. 𝟑𝟏𝟓𝟕
𝐦𝟐

For the 12°C Cold Storage room facing the inside of the facility
21°𝐶 − 12°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟏. 𝟕𝟎𝟖𝟔
𝐦𝟐

For the 5°C Cold Storage room facing the outside

40°𝐶 − 5°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟔. 𝟔𝟒𝟓
𝐦𝟐
For the 5°C Cold Storage room facing the inside of the facility
21°𝐶 − 5°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟑. 𝟎𝟑𝟕𝟓
𝐦𝟐
 21

For the 5°C Cold Storage room facing 12°C Cold storage room
12°𝐶 − 5°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.2674 𝑊

𝐖
𝐪 = 𝟏. 𝟑𝟐𝟖𝟗
𝐦𝟐

 Floors

Floor Material = Concrete

𝑊
Thermal conductivity of concrete = 1.4𝑚∗𝐾
Thickness of concrete = 0.15m
Floor Material = Steel Plate
𝑊
Thermal conductivity of concrete = 45𝑚∗𝐾
Thickness of concrete = 0.05m
Insulation = Polyurethane
𝑊
Thermal conductivity of insulation = 0.03𝑚∗𝐾
Thickness of insulation = 0.15m

Thermal resistance of the floor

0.15 0.15 0.05
𝑅𝑠𝑒𝑟𝑖𝑒𝑠 = + +
1.4 0.03 45
𝐊 ∗ 𝐦𝟐
𝐑 𝐬𝐞𝐫𝐢𝐞𝐬 = 𝟓. 𝟏𝟎𝟖𝟑
𝐖
For floors in 5°C cold storage
20°𝐶 − 5°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.1083 𝑊

𝐖
𝐪 = 𝟐. 𝟗𝟑𝟔
𝐦𝟐
For floors in 12°C cold storage
20°𝐶 − 12°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.1083 𝑊

𝐖
𝐪 = 𝟏. 𝟓𝟔𝟔
𝐦𝟐
 22

For floors in Ice Storage

20°𝐶 − (−10°𝐶)
𝑞=
𝐾 ∗ 𝑚2
5.1083 𝑊

𝐖
𝐪 = 𝟓. 𝟖𝟕𝟑
𝐦𝟐
 Ceiling

Ceiling Material = Aluminum

𝑊
Thermal conductivity of concrete = 205
𝑚∗𝐾

Thickness of concrete = 0.002m

Insulation = Polyisocyanurate
𝑊
Thermal conductivity of insulation = 0.023𝑚∗𝐾

Thickness of insulation = 0.1524m

Thermal resistance of the ceiling

0.002 0.1524
𝑅𝑠𝑒𝑟𝑖𝑒𝑠 = +
205 0.023
𝐊 ∗ 𝐦𝟐
𝐑 𝐬𝐞𝐫𝐢𝐞𝐬 = 𝟔. 𝟔𝟐𝟔
𝐖
For ceiling in 5°C ice storage
40°𝐶 − 5°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.282
𝑊
𝐖
𝐪 = 𝟔. 𝟔𝟐𝟔
𝐦𝟐

For ceiling in 12°C cold storage

40°𝐶 − 12°𝐶
𝑞=
𝐾 ∗ 𝑚2
5.282 𝑊

𝐖
𝐪 = 𝟓. 𝟑𝟎𝟏
𝐦𝟐
 23

For ceiling in Ice Storage

40°𝐶 − (−10°𝐶)
𝑞=
𝐾 ∗ 𝑚2
5.282 𝑊

𝐖
𝐪 = 𝟗. 𝟒𝟔𝟔
𝐦𝟐
 Doors (Ice storage)

Door Material:
Thickness 𝑾
𝒌( )
𝒎∗𝑲
Expanded Polyurethane 0.2541 m 0.17

Similar Hardwood 0.0508 m 0.16

Total Thickness 0.3049 m

Thermal resistance of the door

0.2541 0.0508
𝑅𝑠𝑒𝑟𝑖𝑒𝑠 = +
0.17 0.16
𝐊 ∗ 𝐦𝟐
𝐑 𝐬𝐞𝐫𝐢𝐞𝐬 = 𝟏. 𝟖𝟏𝟐𝟐
𝐖

(ADD 5°C to ∆T for allowance to solar radiation)

[40°𝐶 − (−10°𝐶)] + 5
𝑞= ∗4
𝐾 ∗ 𝑚2
1.8122 𝑊

𝐖
𝐪 = 𝟑𝟎. 𝟑𝟒𝟗𝟖
𝐦𝟐
 24

ACTUAL WALL GAIN HEAT LOAD

For the 5°C Cold Storage
North wall (21.8m)
𝐖
𝐐 = 𝟔. 𝟔𝟒𝟓 ∗ (𝟐𝟏. 𝟖𝒎 ∗ 𝟖. 𝟖𝟕𝟓𝒎)
𝐦𝟐
𝐐 = 𝟏𝟐𝟖𝟓. 𝟔𝟒𝟏 𝐖
East wall (27m)
𝐖
𝐐 = 𝟏𝟓𝟗𝟐. 𝟑𝟎𝟖 ∗ (𝟐𝟕𝒎 ∗ 𝟖. 𝟖𝟕𝟓𝒎)
𝐦𝟐
𝐐 = 𝟔𝟖𝟐. 𝟑𝟖 𝐖
South wall (21.8m) (facing ice making)
𝐖 𝐖
𝐐 = 𝟑. 𝟎𝟑𝟕𝟓 𝟐 ∗ (𝟐𝟏. 𝟖𝒎 ∗ 𝟓𝒎) + 𝟔. 𝟔𝟒𝟓 𝟐 ∗ (𝟐𝟏. 𝟖𝒎 ∗ 𝟑. 𝟖𝟕𝟓𝒎)
𝐦 𝐦
𝐐 = 𝟖𝟗𝟐. 𝟒𝟐𝟒 𝐖
West wall (21.8m) (facing 12°Cold Storage and Loading bay)
𝐖 𝐖
𝐐 = 𝟏. 𝟑𝟐𝟖𝟗 ∗ (𝟏𝟒. 𝟕𝒎 ∗ 𝟖. 𝟖𝟕𝟓𝒎) + 𝟑. 𝟎𝟑𝟕𝟓 ∗ (𝟏𝟐. 𝟑𝒎 ∗ 𝟓𝒎)
𝐦𝟐 𝐦𝟐
𝐐 = 𝟑𝟔𝟎. 𝟏𝟕𝟖𝐖

Floor
𝐖
𝐐 = 𝟐. 𝟗𝟑𝟔 ∗ (𝟐𝟏. 𝟖𝒎 ∗ 𝟐𝟕𝒎)
𝐦𝟐
𝐐 = 𝟏𝟕𝟐𝟖. 𝟏𝟑𝐖
Ceiling
𝐖
𝐐 = 𝟔. 𝟔𝟐𝟔 ∗ (𝟐𝟏. 𝟖𝒎 ∗ 𝟐𝟕𝒎)
𝐦𝟐
𝐐 = 𝟑𝟗𝟎𝟎. 𝟎𝟔𝟒𝐖
Door
𝐖
𝐐 = 𝟑𝟎. 𝟑𝟒𝟗𝟖 ∗ (𝟑𝒎 ∗ 𝟓𝒎)
𝐦𝟐
𝐐 = 𝟒𝟓𝟓. 𝟐𝟒𝟕𝐖
 25

Total wall gain for the 5°C Cold Storage

𝑸𝟓° 𝑪𝑺 = 𝟏𝟐𝟖𝟓. 𝟔𝟒𝟏 𝐖 + 𝟔𝟖𝟐. 𝟑𝟖 𝐖 + 𝟖𝟗𝟐. 𝟒𝟐𝟒 𝐖 + 𝟑𝟔𝟎. 𝟏𝟕𝟖𝐖 + 𝟏𝟕𝟐𝟖. 𝟏𝟑𝐖
+ 𝟑𝟗𝟎𝟎. 𝟎𝟔𝟒𝐖 + 𝟒𝟓𝟓. 𝟐𝟒𝟕𝐖

𝑸𝟓° 𝑪𝑺 = 𝟗𝟑𝟎𝟒. 𝟐𝟒𝟒𝐖

For the 12°C Cold Storage

North wall (17.7m)
𝐖
𝐐 = 𝟓. 𝟑𝟏𝟓𝟕 ∗ (𝟏𝟕. 𝟏𝒎 ∗ 𝟖. 𝟖𝟕𝟓𝒎)
𝐦𝟐
𝐐 = 𝟖𝟎𝟔. 𝟕𝟐𝟒 𝐖
West wall (14.7m)
𝐖
𝐐 = 𝟓. 𝟑𝟏𝟓𝟕 ∗ (𝟏𝟒. 𝟕𝒎 ∗ 𝟖. 𝟖𝟕𝟓𝒎)
𝐦𝟐
𝐐 = 𝟔𝟗𝟑. 𝟓 𝐖

South wall (17.1m) (facing Loading bay)

𝐖 𝐖
𝐐 = 𝟏. 𝟕𝟎𝟖𝟔 ∗ (𝟏𝟒. 𝟕𝒎 ∗ 𝟓𝒎) + 𝟓. 𝟑𝟏𝟓𝟕 ∗ (𝟏𝟐. 𝟑𝒎 ∗ 𝟑. 𝟖𝟕𝟓𝒎)
𝐦𝟐 𝐦𝟐
𝐐 = 𝟒𝟐𝟖. 𝟑𝟕𝟖𝐖

Floor
𝐖
𝐐 = 𝟏. 𝟓𝟔𝟔 ∗ (𝟏𝟒. 𝟕𝒎 ∗ 𝟏𝟕. 𝟏𝒎)
𝐦𝟐
𝐐 = 𝟑𝟗𝟑. 𝟔𝟒𝟓𝐖

Ceiling
𝐖
𝐐 = 𝟓. 𝟑𝟎𝟏 ∗ (𝟏𝟒. 𝟕𝒎 ∗ 𝟏𝟕. 𝟏𝒎)
𝐦𝟐
𝐐 = 𝟏𝟑𝟑𝟐. 𝟓𝟏𝟐𝐖
 26

Door
𝐖
𝐐 = 𝟑𝟎. 𝟑𝟒𝟗𝟖 ∗ (𝟑𝒎 ∗ 𝟓𝒎)
𝐦𝟐
𝐐 = 𝟒𝟓𝟓. 𝟐𝟒𝟕𝐖

Total wall gain for the 5°C Cold Storage

𝑸𝟏𝟐° 𝑪𝑺 = 𝟖𝟎𝟔. 𝟕𝟐𝟒 𝐖 + 𝟔𝟗𝟑. 𝟓 𝐖 + 𝟒𝟐𝟖. 𝟑𝟕𝟖𝐖 + 𝟑𝟗𝟑. 𝟔𝟒𝟓𝐖 + 𝟏𝟑𝟑𝟐. 𝟓𝟏𝟐𝐖
+ 𝟒𝟓𝟓. 𝟐𝟒𝟕𝐖

𝑸𝟏𝟐° 𝑪𝑺 = 𝟒𝟏𝟏𝟎. 𝟎𝟏𝐖

For the Ice Storage

South wall (10.2m)
𝐖
𝐐 = 𝟗. 𝟒𝟗𝟐𝟑 ∗ (𝟏𝟎. 𝟐𝒎 ∗ 𝟓𝒎)
𝐦𝟐
𝐐 = 𝟒𝟖𝟒. 𝟏𝟎𝟕𝐖

West wall (6.3m) (facing control room)

𝐖
𝐐 = 𝟓. 𝟖𝟖𝟓𝟑 ∗ (𝟔. 𝟑𝒎 ∗ 𝟓𝒎)
𝐦𝟐
𝐐 = 𝟏𝟖𝟓. 𝟑𝟖𝟕 𝐖

East wall (6.3m) (facing machine room)

𝐖
𝐐 = 𝟗. 𝟒𝟗𝟐𝟑 ∗ (𝟔. 𝟑𝒎 ∗ 𝟓𝒎)
𝐦𝟐
𝐐 = 𝟐𝟗𝟗. 𝟎𝟏 𝐖

North wall (10.2m) (facing Ice Making)

𝐖
𝐐 = 𝟓. 𝟖𝟖𝟓𝟑 ∗ (𝟏𝟎. 𝟐𝒎 ∗ 𝟓𝒎)
𝐦𝟐
𝐐 = 𝟑𝟎𝟎. 𝟏𝟓𝐖
 27

Floor
𝐖
𝐐 = 𝟓. 𝟖𝟕𝟑 ∗ (𝟏𝟎. 𝟐𝒎 ∗ 𝟔. 𝟑𝒎)
𝐦𝟐
𝐐 = 𝟑𝟕𝟕. 𝟒𝐖

Ceiling
𝐖
𝐐 = 𝟗. 𝟒𝟔𝟔 ∗ (𝟏𝟎. 𝟐𝒎 ∗ 𝟔. 𝟑𝒎)
𝐦𝟐
𝐐 = 𝟔𝟎𝟖. 𝟐𝟗𝐖

Door
𝐖
𝐐 = 𝟑𝟎. 𝟑𝟒𝟗𝟖 ∗ (𝟑𝒎 ∗ 𝟓𝒎)
𝐦𝟐
𝐐 = 𝟒𝟓𝟓. 𝟐𝟒𝟕𝐖

Total wall gain for the 5°C Cold Storage

𝑸𝒊𝒄𝒆 𝒔𝒕𝒓 = 𝟒𝟖𝟒. 𝟏𝟎𝟕𝐖 + 𝟏𝟖𝟓. 𝟑𝟖𝟕 𝐖 + 𝟐𝟗𝟗. 𝟎𝟏 + 𝟑𝟎𝟎. 𝟏𝟓𝐖 + 𝟑𝟕𝟕. 𝟒𝐖 + 𝟔𝟎𝟖. 𝟐𝟗𝐖
+ 𝟒𝟓𝟓. 𝟐𝟒𝟕𝐖
𝑸𝒊𝒄𝒆 𝒔𝒕𝒓 = 𝟐𝟕𝟎𝟗. 𝟓𝟗𝟏𝐖

OVERALL WALL GAIN

𝑸𝑾𝒂𝒍𝒍 𝑮𝒂𝒊𝒏 = 𝟗𝟑𝟎𝟒. 𝟐𝟒𝟒𝐖 + 𝟒𝟏𝟏𝟎. 𝟎𝟏𝐖 + 𝟐𝟕𝟎𝟗. 𝟓𝟗𝟏𝐖
𝑸𝑾𝒂𝒍𝒍 𝑮𝒂𝒊𝒏 = 𝟏𝟔, 𝟏𝟐𝟑. 𝟖𝟒𝟓𝐖

𝑸𝑾𝒂𝒍𝒍 𝑮𝒂𝒊𝒏 = 𝟒. 𝟓𝟖𝟏𝐓𝐑

 28

PRODUCT PACKAGING AND PALLETS

PARACETAMOL

20 Tablets per Blister pack

500 Tablets per paracetamol box

500 𝑡𝑎𝑏𝑙𝑒𝑡𝑠 1 𝑏𝑙𝑖𝑠𝑡𝑒𝑟 25 𝐵𝑙𝑖𝑠𝑡𝑒𝑟

( ) = 𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙 𝑏𝑜𝑥
𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙 𝑏𝑜𝑥 20 𝑇𝑎𝑏𝑙𝑒𝑡𝑠

500 𝑚𝑔 500 𝑡𝑎𝑏𝑙𝑒𝑡 0.25 𝑘𝑔

( ) = 2,5000mg =
𝑡𝑎𝑏𝑙𝑒𝑡 𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙 𝑏𝑜𝑥 𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙 𝑏𝑜𝑥

1,000 𝑔 1,000 𝑚𝑔 1 𝑡𝑎𝑏𝑙𝑒𝑡 1 𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙 𝑏𝑜𝑥

20 ton ( )( )( )( ) = 80,000 paracetamol boxes
𝑘𝑔 𝑔 500 𝑚𝑔 500 𝑡𝑎𝑏𝑙𝑒𝑡𝑠

500 𝑡𝑎𝑏𝑙𝑒𝑡𝑠
80,000 paracetamol boxes (𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙 𝑏𝑜𝑥) = 40,000,000 tablets

1𝑏𝑙𝑖𝑠𝑡𝑒𝑟
40,000,000 tablets (20𝑡𝑎𝑏𝑙𝑒𝑡𝑠) = 2,000,000 blister packs

1 packaging box = 48 boxes

1 𝑝𝑎𝑐𝑘𝑎𝑔𝑖𝑛𝑔 𝑏𝑜𝑥
(80,000 paracetamol boxes) = 1,666.67 = 1,667 packaging box
48 𝑝𝑎𝑟𝑎𝑐𝑒𝑡𝑎𝑚𝑜𝑙 𝑏𝑜𝑥𝑒𝑠

1 𝑝𝑎𝑙𝑙𝑒𝑡
1,667 packaging boxes (20 𝑝𝑎𝑐𝑘𝑎𝑔𝑖𝑛𝑔 𝑏𝑜𝑥𝑒𝑠) = 83.35 = 84 pallets

Total Height = 30 cm (5 layers) + 15 cm (thickness of pallet) = 1.65 m

 29

VACCINES
1 𝑟𝑎𝑐𝑘
444,445 vials (50 𝑣𝑖𝑎𝑙𝑠) = 8,889 racks

0.045 𝑘𝑔 2.25 𝑘𝑔
( 𝑣𝑎𝑐𝑐𝑖𝑛𝑒 ) (50 vials) = 𝑟𝑎𝑐𝑘

50 𝑣𝑖𝑎𝑙𝑠 10 𝑟𝑎𝑐𝑘𝑠 500 𝑣𝑖𝑎𝑙𝑠

( )=
𝑟𝑎𝑐𝑘 𝑏𝑜𝑥 𝑏𝑜𝑥

2.25 𝑘𝑔 10 𝑟𝑎𝑐𝑘 22.5 𝑘𝑔

( )=
𝑟𝑎𝑐𝑘 𝑏𝑜𝑥 𝑏𝑜𝑥

22.5 𝑘𝑔 15 𝑏𝑜𝑥 337.5 𝑘𝑔

( 𝑙𝑎𝑦𝑒𝑟 ) =
𝑏𝑜𝑥 𝑙𝑎𝑦𝑒𝑟

15 𝑏𝑜𝑥𝑒𝑠 45 𝑏𝑜𝑥𝑒𝑠
(3 𝑙𝑎𝑦𝑒𝑟𝑠) =
𝑙𝑎𝑦𝑒𝑟 𝑝𝑎𝑙𝑙𝑒𝑡

1 𝑏𝑜𝑥
8,889 rack (10𝑟𝑎𝑐𝑘) = 889 boxes

1 𝑝𝑎𝑙𝑙𝑒𝑡
889 boxes (45 𝑏𝑜𝑥𝑒𝑠) = 19.76 = 20 boxes

337.5 𝑘𝑔
(3 layers) = 1,012.5 kg
𝑙𝑎𝑦𝑒𝑟

1,012.5 kg + 15 kg (pallet) = 1,027.5 kg (total weight per pallet)

Total Height = 30 cm (3 layers) + 15 cm (thickness of pallets) = 1.05 m

 30

ETHYL ALCOHOL

1 box = 288 bottles

1 layer = 6 boxes = 1728 bottles

4 layers = 24 boxes = 1 pallet = 6,912 bottles

422,833 bottles (1box/288bottles) = 1,468.17 = 1469 boxes

1469 boxes (1pallet/24boxes) = 61.21 = 62 pallets

𝑚
= 𝑣

789𝑘𝑔 𝑚
= 0.00006𝑚3
𝑚3

m = 0.04734 kg
0.04734 𝑘𝑔 6912 𝑏𝑜𝑡𝑡𝑙𝑒𝑠
( ) = 327.21 kg
𝑏𝑜𝑡𝑡𝑙𝑒 𝑝𝑎𝑙𝑙𝑒𝑡

Total Weight = 327.21 kg + 15 kg (pallet) = 342.21 kg

0.3𝑚
Total Height = (4 boxes) + 0.15 m (thickness of pallet) = 1.35 m
𝑏𝑜𝑥
 31

DEXTROSE (12,500 bottles)

1𝐿 1𝑚3
1,000mL (1,000𝑚𝐿)(1,000𝐿) = 0.001𝑚3

Hbottle = 0.19 m = 190 mm

𝜋𝑑2
0.001 𝑚3 = (0.19 m)
4

dbottle = 0.082 m = 82mm

𝑚
=
𝑣

1.6 𝑔 𝑚
𝑐𝑚3
= 0.001𝑚3

m = 1,600g = 1.6 kg
7 𝑏𝑜𝑡𝑡𝑙𝑒𝑠 6 𝑏𝑜𝑥𝑒𝑠 8 𝑙𝑎𝑦𝑒𝑟𝑠 336 𝑏𝑜𝑥𝑒𝑠
( 𝑙𝑎𝑦𝑒𝑟𝑠 ) ( )=
𝑏𝑜𝑥 𝑝𝑎𝑙𝑙𝑒𝑡 𝑝𝑎𝑙𝑙𝑒𝑡

336 𝑏𝑜𝑡𝑡𝑙𝑒𝑠 1.6 𝑘𝑔 537.6 𝑘𝑔

(𝑏𝑜𝑡𝑡𝑙𝑒) =
𝑝𝑎𝑙𝑙𝑒𝑡 𝑝𝑎𝑙𝑙𝑒𝑡

336 𝑏𝑜𝑡𝑡𝑙𝑒𝑠
12500 bottles ( ) = 37.2 = 38 pallets
𝑝𝑎𝑙𝑙𝑒𝑡

Total Weight = 537.6 kg + 15 kg (pallet) = 552.6 kg

Total Height = 0.19 m (8 layers) + 0.15 m (thickness of pallet) = 1.67 m

 32

MELPHALAN
2 𝑚𝑔
(25tablets) = 0.05 g
𝑡𝑎𝑏𝑙𝑒𝑡

Weight of bottle + Medicine box = 6 g

Total weight of medicine box = 0.05 g + 6 g = 6.05 g

Medicine box per packaging box = 10(6)(3) = 180 medicine boxes

Weight of packaging box = 120 g

Total weight of medicine box = 180(6.05 g) = 1089 g

Total weight of packaging box = 1089 g + 120 g = 1209 g

48 𝑝𝑎𝑐𝑘𝑎𝑔𝑖𝑛𝑔𝑏𝑜𝑥
2(4)(6) = 𝑝𝑎𝑙𝑙𝑒𝑡

1 𝑏𝑜𝑥𝑒𝑑 𝑏𝑜𝑡𝑡𝑙𝑒
20,000kg ( ) = 3,305785 boxed bottles
0.00605𝑘𝑔

1 𝑝𝑎𝑙𝑙𝑒𝑡
3,305,785 boxed bottles (8,640 𝑏𝑜𝑥𝑒𝑑𝑏𝑜𝑡𝑡𝑙𝑒𝑠) = 382.61 = 383 pallets
 33

MACHINE COMPUTATIONS
Refrigerant: R-717
Compressor: MYCOM Reciprocating Compressor
Safety Factor: (1.5 x Heatload)

Medicine Storage (12 OC):

Heat load with Safety Factor = (1.6481+4.556)(1.5) = 9.3055 kW
From MYCOM Compressor Specification Performance Table:
COMPRESSOR MODEL: N2WA
Refrigeration Capacity = 49.5 kW
Compressor Capacity = 11.3 kW
Evaporating Temperature: -5OC
Condensing Temperature: 35OC

Medicine Storage (5 OC):

Heat load with Safety factor = (3.0903+14.0278+1.5336)(1.5)
= 27.9776 kW
From MYCOM Compressor Specification Performance Table:
COMPRESSOR MODEL: N2WA
Refrigeration Capacity = 61.3 kW
Compressor Capacity = 11.6 kW
Evaporating Temperature: 0OC
Condensing Temperature: 35OC

Ice Making:
Heat load with Safety factor = (103.72)(1.5) = 155.58 kW
From MYCOM Compressor Specification Performance Table:
COMPRESSOR MODEL: N8WA
 34

Refrigeration Capacity = 161.7 kW

Compressor Capacity = 52.6 kW
Evaporating Temperature: -15OC
Condensing Temperature: 35OC

Ice Storage:
Heat load with Safety factor = (29.4659)(1.5) = 44.1989 kW
From MYCOM Compressor Specification Performance Table:
COMPRESSOR MODEL: N4WA
Refrigeration Capacity = 61.6 kW
Compressor Capacity = 23.9 kW
Evaporating Temperature: -20OC
Condensing Temperature: 35OC

Condenser: EVAPCO Evaporative Condensers

Medicine Storage (12 OC) (1 Set of Compressor):

Condenser Load = (Evaporator Load + Compressor Load)

Condenser Load = (49.5 kW + 11.3 kW)

Condenser Load = 60.8 kW

Medicine Storage (5 OC) (1 Set of Compressor):

Condenser Load = (Evaporator Load + Compressor Load)

Condenser Load = (61.3 kW + 11.6 kW)

Condenser Load = 72.9 kW

 35

Ice Making (1 Set of Compressor):

Condenser Load = (Evaporator Load + Compressor Load)

Condenser Load = (161.7 kW + 52.6 kW)

Condenser Load = 214.3 kW

Ice Storage (1 Set of Compressor):

Condenser Load = (Evaporator Load + Compressor Load)

Condenser Load = (61.6 kW + 23.9 kW)

Condenser Load = 85.5 kW

Total Condenser Load = 60.8 kW + 72.9 kW + 214.3 kW + 85.5 kW

Total Condenser Load = 433.5 kW

Heat Rejection Factor (HRF)

Heat Rejection Factor from Table 1 of EVAPCO Evaporative Condenser

HRF = HRF @ 35° Condensing Temp. and 29°C Wet Bulb Temp. in the Phil.
HRF = 2.12

Condensing Load Correction:

Corrected Condenser Load = Total Condenser Load x Heat Rejection Factor (HRF)
Corrected Condenser Load = 433.5 kW x 2.12

Corrected Condenser Load = 919.02 kW

From Table 3, Unit Heat Rejection of EVAPCO Evaporative Condensers :

For medicine (12°C and 5°C) and ice storage that has less than 155 kW condenser load,
we will use EVAPCO Evaporative Condenser LSC Model LSC-36E-1g.
 36

Ice making that has less than 233 kW condenser load, we will use EVAPCO Evaporative
Condenser LSC Model LSC-54E-1g.

Evaporator:
For medicine (12°C and 5°C) and ice storage, Super Radiator Coils Evaporators which
has maximum of 100 kW cooling capacity will be used.

For ice making, Evapco SSTXB evaporator which have 120 to 200 kW cooling capacity
will be used.

Liquid Receiver: Heldon Quality Products, Liquid Receiver

Insulation: DYD insulated door by DYD Refrigeration Systems Inc.

TOTAL REFRIGERATION LOAD

ICE MAKING LOAD 104.812 TR

COLD STORAGE LOAD 10.3706 TR
WALL GAIN 4.581 TR
TOTAL REFRIGERATION
119.7656 TR
LOAD
 37

PROCESS DIAGRAM

•Medicines are manufactured by Pharmaceutical Companies.

1

•They are packed and stacked according to the brand and generic name of each medicine.
2

•Transporting medicines is complicated strict rules and standards are to be followed.

3

•Medicines are transported using carriers with a cold storage since they must always be kept
at a certain temperature after manufacturing.
4

•Medicines are kept in Cold Storage facilities for safe keeping and ensuring that drugstores
and hospitals in the area can be supplied immediately when they are needed.
5
 38

FEASIBILITY STUDY

Cavite is known as the “Historical Capital of the Philippines” because it is where Emilio

Aguinaldo declared the first independence of the Philippines from Spain. Cavite is a progressive

province because of its nearness to Metro Manila. It is also the most populated province in the

country. It is still a province that consists of many vacant lands. Most of the lands are used for

agriculture, residences and open areas. Different rivers such as Bacoor River, Imus River and

San Juan River also surround it.

Locations are usually a major problem when it comes to storages, warehouses, plants and

factories. People can rarely see these at urban areas. Most of it can be found in rural areas like

provinces. Cavite is a great location to start investing and building warehouses and plant storage

because of its accessibility to consumers, customers, and producers. Easy transportation like

riding a bus, taxi, jeepneys and even ferry services are available.

Isolated vacant land is much better for pharmaceutical plants/ storages because of risks

and contamination. Contamination can easily be transmitted thru air, water, animals and even a

human being. Isolated places can reduce the number of casualties during fire or an earthquake.

Electricity and water will not be a problem because electricity is supplied by Manila Electric

Company (Meralco) while the water is supplied by Maynilad Water Services.

Cavite can be almost being compared to Metro Manila because of its industrialization and

rapid growth. Industrialize means more people. Populations of 3.09 million were recorded as of

May 2010. More people means more demand. When a person gets sick, first thing in mind is to

buy and drink appropriate medicine for faster healing. When a disease spreads or an outbreak

occurs, demand on medicine will surely rise and soon a certain or specific medicine will be out of

stock and no longer available at that time. Warehouses and storages are needed to preserve and

stock bulk medicines for future use.

 39

SOCIO-ECONOMIC IMPACT
The significance of our plant is that aside from ice making, it is providing medicine
refrigeration service which these times are very important. Also, we are locating it to a
site that is capable enough to provide the plant requirement, especially the land area, and
at the same time the plant location provides good accessibility to the urban area in terms
of travel distance and travel time. The location, also, is near the commercial area of the
municipality, making the hospitals and medical centers within the area to be the plant’s
primary target customers.
 40

PLANT SITE SELECTION

Topography
The site of the plant construction is an empty grass land located at Silang Rd., General Mariano
Alvarez, Paliparan, Dasmarinas Cavite.

Environmental Impact
The chosen location is empty grassland which means tree cutting is not needed to be
implemented when the constructing the plant.

Accessibility (Transportation)
The location of the plant is very accessible; the travel time from Metro Manila to the plant is
approximately 45 minutes. It is also located few kilometers away from the commercial area in
the locale.

Proximity (Target Customer)

Although the plant is in Cavite, the location is not far from Metro Manila hence, hospitals and
medical centers near the Southern Metro Manila area are the target customers. There are also
several medical centers in the local area that can be the primary target customers (San Jose
Hospital & Medical Center and Dra. Vida G. Rubio Memorial Medical Clinic).
 41

Land Cover and Land Area

The location chosen is empty grassland wide
enough to provide the land area that the plant
requires. To have a safe distance from the
road, the plant is located few meters away from
the main road. The area covered also has
allowance to provide free space for delivery
vehicles. The total area covered by the plant is
approximately 2500 square meter.

Resources (water/electricity)
Since the location is near the commercial area,
the electricity and water supply is very
accessible.
 42

WIRING / SINGLE LINE DIAGRAM OF THE PLANT

43
 44

PIPING AND DUCTING DIAGRAM OF THE PLANT

 45

BILL OF MATERIALS

Machineries/Materials Quanity Price Total

Compressor
MYCOM N2WA 2 P43000 P86000
MYCOM N8WA 1 P258000 P258000
MYCOM N4WA 1 P210000 P210000
Condenser
LSC Model LSC-36E-1g 1 P1827500 P1827500
LSC Model LSC-54E-1g 1 P2000000 P2000000
Evaporators
UNITED METAL PRODUCTS D251500 1 P161250 P161250
Evaporative
Evapco Evaporator 1 P86000 P86000
Liquid Receiver
Heldon Quality Products 1 P4300 P4300
Insulation
DYD Insulated door - - Made to order
(price may vary
according to size)
Total P4632550
 46

APPENDICES

Forklift

Container Electric Forklift CPD1000 Specification:

Model No. CPD1000

Rated load 1000kg
Lifting height 3000mm
Turning radius 1650mm
Lifting Speed 480mm/460mm
Descending/falling Speed 400mm
Running/Driving speed 15km/h
Loading centre distance 400mm
L x W x H (Without fork) 1780 x 960 x 2050mm
Fork, W x L 93 mm x 1070mm
Machine weight 1400kg
Lifting motor power 2.0kW
Driving motor power 2.0kW
Ground clearance 100mm
Wheel base 1080mm
Rear wheels specification 15 × 4½-8
Wheel thread (front &back) 780/730mm
Front wheels specification 16 × 6-8
Battery (V/AH) 12V/170Ah
Number of batteries 5
Charging time 8hrs
Working time per full charge Up to 10hrs (dependent on load)
Input voltage 220v
 47

Overhead Crane

Quick Details
Feature: Bride Crane, Over head
Rated Load Capacity: 2ton
Max. Lifting Height: 24m
Brand Name: Keliyuan
Lifting Mechanism: Electric hoist
Drive motor: 1 hp
Crane motor: 3 hp
Lifting Speed: 1-8m/min
Rated Lifting moment: 20kN
 48

Compressor
 49

Lighting

VTV LED VAPOR TIGHT SPREAD BEAM FOR WET / IP67 & COLD STORAGE

Voltage ratings: 120 – 270V (dimmable)

Wattage: 60W

Lumens: 6000lm

Operating Temperature: -40°C – 50°C

https://cdn.shopify.com/s/files/1/0366/7997/files/AEI-VTV-VaporTight-LED-032216-
withDLC.pdf?15001682466620361508
 50

Condenser
 51

REFERENCES

 https://en.wikipedia.org/wiki/Pharmaceutical_packaging
 https://www.um.edu.mt/__data/assets/pdf_file/0016/153160/Storage_of_Medicin
es_and_Medical_devices.pdf
 http://www.fao.org/docrep/003/p3407e/p3407e05.htm
 http://www.pharmacopeia.cn/v29240/usp29nf24s0_c1079.html
 https://en.wikipedia.org/wiki/Glucose
 http://www.ncbi.nlm.nih.gov/pmc/articles/PMC3547732
 https://en.wikisource.org/wiki/Popular_Science_Monthly/Volume_39/May_1891/Ic
e-Making_and_Machine_Refrigeration
 http://www.icelings.net/block_ice_plant.php
 http://www.icemakingplant.com/industrial-ice-plants/
 http://www.fao.org/wairdocs/tan/x5940e/x5940e01.htm
 52

SOURCES OF EQUATIONS:

Number of Ice Cans

Carmichael, C. (1950). Kent’s Kent's Mechanical Engineers' Handbook 12th Edition:
Design and Production Volume: John Wiley & Sons, pp. 11-48

Wall Gain Load

Dossat, R. (1997). Principles of Refrigeration (4th Ed.). Upper Saddle River (New
Jersey): Prentice-Hall, Inc. pp. 154-155; 167-168

U Factor
Dossat, R. (1997). Principles of Refrigeration (4th Ed.). Upper Saddle River (New
Jersey): Prentice-Hall, Inc. pp. 155-157

Product Load
Dossat, R. (1997). Principles of Refrigeration (4th Ed.). Upper Saddle River (New
Jersey): Prentice-Hall, Inc. p. 170

Air Change Load

Dossat, R. (1991). Principles of Refrigeration (3rd Ed.). Englewood Cliffs (New
Jersey): Prentice-Hall, Inc. pp. 180-183

Miscellaneous Load

Persons
Dossat, R. (1997). Principles of Refrigeration (4th Ed.). Upper Saddle River (New
Jersey): Prentice-Hall, Inc. p. 171

Lights
Dossat, R. (1997). Principles of Refrigeration (4th Ed.). Upper Saddle River (New
Jersey): Prentice-Hall, Inc. p. 171

Forklift
Dossat, R. (1997). Principles of Refrigeration (4th Ed.). Upper Saddle River (New
Jersey): Prentice-Hall, Inc. p. 171