Cold Storage & Pack House Presentation 1

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Haryana State Agricultural Marketing Board

Transcript of Cold Storage & Pack House Presentation 1

  • COLD STORAGE, PACK HOUSE, E-TRADING, KISAN CALL CENTREPresented by: Agri-Business Manager

    Part -1

  • Agricultural Scene in India MilkFruits & Vegs.FishLivestockMeatWhy 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%).

  • ParadoxWe 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 StorageA 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 ProductsFruits and VegetablesMeat and Meat ProductsPacked FoodsBeveragesBiologicals

  • Cold storage facilities India has 5101 Cold Storage units with a total expected capacity of 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

  • Current Scenario 80% of this is used for potatoes Current Scenario Huge wastage occurs due to inadequacies in technologyPoor energy efficiency

  • Jammed packing restricting air circulationIneffective refrigeration systemsCurrent 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 processPoor sorting, grading, material handling

  • No focus on energy-efficiency Non-compliance to international standards Lack of operational practiceHuge 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 utilizationDesign based on - Current & Future Needs

  • Maximum Space Utilization

  • Usage of Racks

  • Technology Status and Application Rack SystemLower Power ConsumptionProvides accurate temperaturesGreater plant flexibility through multiple compressorsRacks are favoured to integrate multiple product rooms with variable temp conditions

  • Demaraction Despatch & receiving - To avoid Congestion

  • Usage of Pallets

  • Air circulationAir 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.

  • 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 HandlingStorage & Material Handling SystemPalletized Stacking facilitates not only better air circulation around the products, but also better handling and more storage in lesser areawith increased height

  • Automation

  • Sensor position

  • AutomationBetter 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 designsPotato cold storage in the USA

  • Pre-engineered Cold Store facilityModern technology

  • Bulk Storage Systems in EuropeGlobal trends

  • Civil Structural

  • Civil Structural

  • Electricals

  • Refrigeration

  • Cold storage

  • Seeds Storage

  • Flower Storage

  • Vapur Heat Treatment plant CoolingPack house

  • Other treatmentsPre-coolingDryingSelection,cleaning and disinfectionReception

    Grading Packing and packagingStorage

    Transport

    Harvesting

  • Typical Cold ChainCollection CentreIntegratedPack HouseTerminalMarketMulti CommodityCold StorageExportsRetailFood Processing

  • Components of a Cold ChainCollection CentreLocated close to farmhousesPlace of source for farmersFacilities available Pre cooling, F&V sortingIntegrated Pack House (IPH)Cold Chain facility at farm end to maintain temperature, humidity and atmospheric conditions as suited for various produceFacilities available Short term & long term cold storages, ripening,

  • Components of Cold ChainTerminal MarketsForward linkagesExport housesFood processing unitsBackward linkagesFarmers / Growers / AssociationsTrader community - Electronic Trading facility

    Multi Commodity StorageWide variety of climatic conditions for various products

  • Integrated Pack HouseWhat 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 chamberWhat 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 CoolingPre Cooling

  • Pallet pre-cooling and transition to CA rooms

  • Packing, Grading

  • Simple on-Farm Washing of FruitWashingPotato Washing

  • Grading

  • Grading of Onions

  • Waxing and Grading of fruits

  • Conveyor System

  • Air in the internal CavityWax layer restricts the gases interchange.

  • Packaging

  • Packaging

  • Short / Long term Cold StoragesWhat 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.

    BenefitsLonger storage lifeImproved product quality Less chemical inputResultsExtended marketing seasonBetter pricesGreater volumeMore distant markets

  • Cold storageT = +1CLife = 18 weeksN2=79%O2=16%CO2 = 5%Air

  • C.A. StoreT = +1CLife = 40 weeksN2=97%O2= 2%CO2 = 1%AirCO2 Scrub

  • Ripening RoomsWhat 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 StoragesControlled Atmosphere StoragesValue added Services by Cold storage Companies.Packing ,DistributionControl 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 LevelerBridging 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,inspectionInitial coolingCold storageBin dumppresizeWash / scrubSpecialoperationsDryWaxfungicideHand sortCull and byproductAutomatic Sorting & sizinglabelingHand sortHand sortBoxFillBoxFillpalletizeCooling & storageSchematic of the typical unit operations in a mechanized packinghousePACKINGHOUSE OPERATIONS

  • HSAMB Cold Storage & Pack House

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