COLD STORAGE, PACK HOUSE,

E-TRADING, KISAN CALL CENTRE

Presented by: Agri-Business Manager


Part -1


Agricultural Scene in India
W
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Fruits & Vegetables, Livestock, Chicken meat, Fish, Dairy
1st
Milk
2nd
Fruits & Vegs.
3rd
Fish
5th
Livestock
6th
Meat
Why We Need Cold Storage & Pack Houses ?
Opportunities

Fruit production of 11% of global output.
Vegetable production of 14% of global output
The worlds leading producer of bananas (29%),


mango (54%),

Cauliflower (33%).

Paradox
We are among the top few
producers of many
agricultural commodities in
the world

The post-harvest losses of
fruits and vegetables are
estimated to be 25 to 40 %

We have a middle class of
250-300 million people
with adequate purchasing
power to buy
manufactured goods

Yet our share in the world food
trade is only 1.6 %

Yet less than 2 % is processed

Yet value addition to agricultural
products is less than 7%


Gap
Supply driven, rather than demand led.
Wastage levels are High - estimates put this at 25% of
production.
Innumerable intermediaries in the system.
Lack of pre & post harvest facilities.
Absence of a cold chain.
Inadequate grading & sorting infrastructure.
No transparency in pricing.


Cold Storage
A Cold Store is a Refrigerated Ware House for preservation of perishables.

Cold storages are meant to preserve the perishable commodities

cold storages are used for high value items

or when prices crash down due to bumper crop or for such items
which are grown during the season but there is a demand round the year
Key Target Markets for cold storages facilities:
The envisaged facility would especially cater
to the following industries:
Milk and Milk Products
Fruits and Vegetables
Meat and Meat Products
Packed Foods
Beverages
Biologicals

Cold storage facilities
India has 5101 Cold Storage units with
a total expected capacity of 22 L MT
5101 units
22 L MT
Second highest fruit and vegetable producer in the world with a cold
storage facility available only for 10 per cent of produce
5101 units
22 L MT
Current Scenario
80% of this is used for potatoes
Current Scenario
Huge wastage occurs due to
inadequacies in technology
Poor energy efficiency
Jammed packing restricting air circulation
Ineffective refrigeration systems
Current Storage conditions
Improvised bunker coils inadequate heat transfer area
Ceiling fans for air circulation in bunker coil systems
Industrial humidifiers make the cold store and produce wet
Typical interconnecting stairway between mezzanines
Repacking in bags crude methods employed
Typical machine room arrangement
design and safety issues not considered
Electrical control and automation exhibiting ignorance
and lackadaisical approach
Typical drying, grading and sorting process
Poor sorting, grading, material handling
No focus on energy-efficiency
Non-compliance to international standards
Lack of operational practice
Huge gaps in processes:
Necessity for Perfect Cold chain & Technology

Storage losses
- Weight loss 5-8 %
- Rotting exceeds 5%
- 10% off-graded in local markets
Processing and export losses
- Unpredictable variation in quality
- Does not follow international standards
- Just 20% passes quality for processing

Consequences
Higher utilization
Design based on - Current & Future Needs

Maximum Space Utilization
Usage of Racks
Technology Status and Application Rack
System
Lower Power Consumption
Provides accurate temperatures
Greater plant flexibility through multiple
compressors
Racks are favoured to integrate multiple product
rooms with variable temp conditions
Demaraction Despatch & receiving
- To avoid Congestion
Usage of Pallets

Air circulation
Air circulation Over Product , not the room.

Cooling the centre of the boxes, not only the side walls.

Efficient cooling with proper air Circulation.

Flexibility to select the blocks (rows) that need to be
cooled.

Cold Air Circulation
Air mixing
chamber
IDU
Air
circulation
fan
Potatoes
stored in
wooden
Boxes
Dampers
With Hood
Air
Flows
through
Boxes
Highest Leakage Point.
The Door glides up under
the roof when opened,
allowing free space around
the door opening and leaving
the door opening completely
free

Pictures of Automatic Sliding Doors

Air Tight Doors
Material Handling
Storage & Material Handling System
Palletized Stacking facilitates not only better air circulation around the
products, but also better handling and more storage in lesser area
with increased height

Automation
Min therm Ext block Ext Fail Hatch closed
Outside temp Fan High
Outisde AH
Outside RH Fan Low
Duct temp Hatches
Product temp Refrigeration
Product AH
Product RH Defrost
Duct RH Heater
Room temp Circul vent
Product CO2 Dose pump
CIPC treat Door outlet
Timers Alarm
Heater mod Fan mod Refrig mod
Sensor position
Automation
Better controls can lead to substantial energy savings
Controls can play an important role :
- avoid overcooling
- monitor the temperature and humidity levels
- Reduce large fluctuations in temperature
Controls can help reduce energy consumption in the
tune of up to 15 20%


Latest designs
Potato cold storage in the USA
Pre-engineered Cold Store facility
Modern technology
Bulk Storage Systems in Europe
Global trends
Civil Structural
Civil Structural
Electricals
Refrigeration
Cold storage
Seeds Storage
Flower Storage
Vapur Heat Treatment plant Cooling
Pack house
Other
treatments
Pre-cooling
Drying
Selection,
cleaning and
disinfection
Reception

Grading
Packing and
packaging
Storage

Transport

Harvesting

Typical Cold Chain
Collection
Centre
Integrated
Pack House
Terminal
Market
Multi Commodity
Cold Storage
Exports
Retail
Food Processing
Components of a Cold Chain
Collection Centre
Located close to farmhouses
Place of source for farmers
Facilities available Pre cooling, F&V sorting
Integrated Pack House (IPH)
Cold Chain facility at farm end to maintain
temperature, humidity and atmospheric
conditions as suited for various produce
Facilities available Short term & long term
cold storages, ripening,


Components of Cold Chain
Terminal Markets
Forward linkages
Export houses
Food processing units
Backward linkages
Farmers / Growers / Associations
Trader community
- Electronic Trading facility

Multi Commodity Storage
- Wide variety of climatic conditions for various products


Integrated Pack House
What is an IPH?

Cold Chain facility at the farm end
for storage of agricultural produce
to maintain temperature, humidity
and atmospheric conditions as
suited for various produce
Components of an IPH
Pre Cooling Chamber
Short term / long term
cold storages
Ripening rooms
Grading & sorting Lines
Other components
-Weighing Machines
-Conveyers
-Pallets, Crates
-Dock Levelers, Dock Seals
-Pallet Trucks, Trolleys.
-Stores - Packing material
-Facilities - Employees.
-Offices

Pre-cooling chamber
What is Pre-cooling?

A process of rapid removal of
heat from freshly harvest
produce to minimise enzymatic
and other process which cause
deterioration

Because 1 hour lost in pre-
cooling may result in 8 to 24
hour loss in shelf life

Pre-Cooling Chamber

Movement of the caloric
energy from the product to the
cooling substance.
Objective: to remove the field heat.
Vacuum Cooling
Pre Cooling
Pallet pre-cooling and transition to CA rooms
Packing, Grading
Simple on-Farm Washing of Fruit
Washing
Potato Washing
Grading
Grading of Onions
Waxing and Grading of fruits
Conveyor System
Air in the internal
Cavity
Wax layer restricts
the gases interchange.
Packaging
Packaging
Short / Long term
Cold Storages
What are Cold Storages?

Cubic rooms made with pre-fab.
PUF insulated panels with
Refrigeration Units to maintain
desired temperature and humidity
conditions
Controlled Atmosphere
Altering, Controlling
and Maintaining the
atmospheric
composition in a air
tight cell to extend
the storage life of
perishable produce.

Benefits
Longer storage life
Improved product quality
Less chemical input
Results
Extended marketing season
Better prices
Greater volume
More distant markets
Cold storage
T = +1C
Life = 18 weeks
N
2
= 79%
O
2
= 16%
CO
2
= 5%
Air
C.A. Store
T = +1C
Life = 40 weeks
N
2
= 97%
O
2
= 2%
CO
2
= 1%
Air
CO
2

Scrub
Ripening Rooms
What are Ripening Rooms?

Rooms with regulated ingress
of ethylene to promote
ripening, with controlled gas
levels and safety mechanisms to
prevent accidents
Ripening Chamber
Ripening is a process in fruits that causes them to become
more edible
It is a bio-chemical process of converting starch into sugar
Fruit Ripening Process
When fruits approach maturity they
release ethylene
Ethylene promotes ripening process
Ethylene gas is odourless,
colourless and normally exists in nature

CALCIUM CARBIDE RIPENING IS
HARMFUL CAN CAUSE CANCER

Equipment layout of Ripening Room
The design & selection of equipments
should ensure a smooth operation and
uninterrupted product flow from
arrivals to Cold room or Ripening
room with in least possible time
Important Feature-IPH
Necessity of Modernization

Multi Commodity Storages
Controlled Atmosphere Storages
Value added Services by Cold storage Companies.
Packing ,
Distribution
Control of Stocks
Transportation .
Divergent Needs More Efficiency
Material Handling
Dock Leveler
Dock leveler is intended to bridge the gap between
dispatch area and transport vehicle
Material Handling - Dock Leveler
Bridging the Gap for quicker loading & unloading
movements

Handling - Dock Shelter

Seals between
Vehicle & Building - reducing the
Ambient temp ingression
in the Cold Storage Area.

Receiving,
inspection
Initial cooling
Cold storage
Bin dump presize
Wash / scrub
Special
operations
Dry
Wax
fungicide
Hand sort
Cull and byproduct
Automatic
Sorting & sizing
labeling
Hand sort
Hand sort
Box
Fill
Box
Fill
palletize
Cooling &
storage
Schematic of the typical unit operations in a mechanized packinghouse
PACKINGHOUSE OPERATIONS
HSAMB Cold Storage & Pack House