Pack House SMART COLD WAREHOUSE

தமிழ்நாடு அரசு வேளாண்மம
ேிற்பமை ோரியம் பயிற்சி மமயம்
உத்தமவசாழபுரம்
சேலம்
நாள்: 22/08/2019
In Association with saiTech Salem
Our Topics Today
1. Cold Storage Management
2. Cold Storage Design
3. SMART Cold Storage
4. Storage Systems
5. Banana Ripening Chambers
Understanding Cold Storage
• Cold storage facility for a commodity under
controlled conditions
• A cold storage unit incorporates a refrigeration

system to maintain the desired room
environmental conditions
Choosing a Cold Storage
• Based on storage conditions
• Short term or temporary (7-10 days)
• Long term (6-8 months)
• Frozen storage (years)
Specifications
• Uniform temperatures
• Length of air blow and impingement on stored products
• Effect of relative humidity
• Effect of air movement
• Controlling ventilation systems, if necessary.
• Product entering temperature
• Expected duration of storage
• Required product outdoor temperature
• Transportation in and storage area
Basis for Design
1. Selection of site
2. Orientation and building form
3. Size
4. Space requirement
5. Design of building
6. Thermal insulation
7. Refrigeration system for cold store
8. Heat Load calculation
Cold storage design (Contd..)
1. Selection of site
2. Orientation and building form

• N-S direction
• W-E walls should have
good plantation
• Surface to volume ratio less
7
3. Size
•Volume of product to store

•Product containers (boxes, hampers, buckets)
•Volume required per container
•Space for mechanical or manual operation
•Lateral and head space
•Available site space
8
V = v(C+S)
Where,
→V is the total volume needs in cubic feet.

→v is the volume occupied by one product container in cubic feet.
→C is the maximum number of containers to be cooled at any one time.
→S is the maximum number of containers to be stored at any one time
9
• 4. Space requirement
Storage space 3.4 m 3 /ton suitable for
stacking and circulation of cold air
(EIRI 2003)
Chamber height -3 to 10 m
For loading and unloading distance between

Rack & rack - should not < 75cm
Rack & wall - least 20-25 cm
Ceiling & product shelf top - 30 cm
.
10
• 5. Design of building
• Roof
• Ceiling
11
Floor
Ground load 5500-8000 kg/m2
(FAO)
12
Doors 1
x 90mm.
3
13
Shelf
14
6. Insulation
15
Insulating materials
Polyisocyanurate Foam
16
Problems in cold store
17
Vapor Barrier
18
• Air diffusion
Air Chillers/freezers Cooling coils
19
Defrosting
• Refrigerant below -3°C , deposition of frost
20
Monitoring
CFD of cool room including droplet tracks of
humidification spray, temperature and humidity
(taken with permission from Delele et al., 2008).
21
Refrigeration system
Vapor Absorption System
• Comparatively costlier but economical in operation
• Cannot be used for temperature below 100C
Vapor Compression System

Comparitive chaper than VAS
Characteristics Diffusive VCS Fin coil VCS Bunker VCS
Height of storage room Low 5.4 11.5
Economic status costliest 5% costlier than Cheapest

Bunker Energy efficient
22
Refrigeration system VCS
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
23
Working
Apple Apple
Apple Apple
Apple Apple
Source: http://www.google.ca/search?hl=en&q=refrigeration+effect&meta
24
Refrigeration cycle
25
Refrigerants
PRIMARY
Group I -nontoxic and nonflammable
CFC
Group II -slightly toxic and flammable

Inorganic R-717(NH3), CO2, Azeotropes
Group III - highly toxic and flammable

Hydrocarbons
SECONDARY
Brine solutions, alklyene gycols
26
Selection of refrigerant
• Thermodynamic & thermophysical
• Suction pressure
Clausius Clapeyron Eq.
• Discharge pressure
• Pressure ratio
• Latent heat of vaporization

• Environmental & safety properties
• Economics
27
Refrigeration equipment
National codes of practice, insurance companies, as well as

international recommendations
• (ISO R1662)
• (BS4434 1989/).
28
Flooded type evaporator
Where,
f.m = recirculation factor & mass flow rate in
the evaporator tubes
m = mass flow rate through the

expansion valve and to the compressor.
X4 = quality of mixture after the expansion
valve
x = be the quality of mixture after boiling in
the tubes
29
Heat load calculation
• Field heat: heat required to reduce the product temperature at harvest down to the
safe storage level.
• Heat of respiration : energy released by the product during the respiration process.
• Conductive heat gain : is heat gained/lost through the building floor, walls and ceiling by
conduction.
• Convective heat gain :is heat that is transferred by convection, the mixing of outside air
with the cold inside air.
• Equipment heat load : is the energy gained from equipment operating in the room.
• Human energy load
30
• Visual basic 6.0
• Heat transfer through wall ceiling & floor
kJ/s
Q  U A (T0  Ti )
• Field heat mC p (Tj  Tz)

Q
t
• Heat produced from lightning
Q = Number of bulbs * W * (UF) * (AF) kJ/s
31
• Heat produced due to human occupancy
Q= n .Sensible heat gain
• Heat given by power equipment

Q= Power range of motor in hp x 746 x 3.41 kJ/s
Motor efficiency
• Total refrigeration required

Total heat removed
3.5
1 Ton of refrigeration = 3.5 kJ /s
32
Working with software
33
Working with software
34
Software results
35
SMART COLD CHAIN
SMART
Cold Chain
Application of RFID in Cold Chain

Content
1. Introduction
2. Process Analysis of RFID-based Cold Chain
Content 3. Basic RFID Technology
4. Application of RFID in Cold chain
5. Conclusion
Group 11 ECLT 5710 Distributed and Mobile Systems

A True Story
French people like

drinking grape wine shipping grape wine
Australia is famous for

grape wine
Group 11 ECLT 5710 Distributed and Mobile Systems 39

A True Story
In 2005, an accident happened
Oh, it’s
tooooooooo acid！
No！There is no
problem！

A True Story
+ RFID tag
Exceeding
30 oC！
It’s a temperature problem！

What is Cold Chain?
 Cold Chain: temperature—controlled supply

chain
 Temperature-sensitive products need to be

kept in low-temperature environment

Content
1. Introduction
5. Conclusion

Process Analysis of RFID-based Cold Chain
Production & Shipping

Company A  Breeding process before slaughter
 Temperature monitoring during shipping
shipping
Storage & Distribution
Distribution
Centre B  Storage and distribution stage
Distribution
the Marketing Process
Retailer C
Group 11 44
1). Breeding process before slaughter in A
Animal’s Information
RFID ear mark
Real-time monitoring
unqualified
RFID System disposed
qualified
Slaughter
Group 11 45
2). Temperature monitoring during shipping to B
RFID Temperature Tag
Temperature
Sensor
Information
data
input
Company A
RFID Chip
Real-time temperature
GPRS system
MIS
Group 11 46
3). The Storage and distribution stage in B
RFID Temperature
Monitoring Inventory
Update RFID Inventory Replenishment

Inventory Management
Information System System
RFID Reader
Outbound Unqualified
System
Qualified
Outbound
RFID Temperature
Monitoring Refrigerated Trucks
Distribution
Group 11 47
4). The Marketing Process base on RFID in Retailer C
Refrigerated Trucks Retailer C
RFID Reader
Unqualified
Sales System
Qualified
On Shelve RFID Reader
Update Buying Auto-

Replenishment
system
Total Price
Order
Distribution
Payment Centre B
Group 11 48
Content
1. Introduction
5. Conclusion

3. Basic technology of RFID
• What is RFID?
• Actually RFID is using radio waves to exchange data. It

is used in different industry.
• used as code bar For identification
• In mobile phones Mobile Wallet
• Other industries such as logistics and supply chain

• 1 What is RFID?
Use of RFID indifferent countries
Taiwan, Others,
2.00%3.50%
China, 9.60%
Japan, 3.90%
USA, 42.50%
Italy, 2.30%
Use of RFID in different industries of China
Russia, 2.70% Others, Storage,
Packages 15.20% transportation
printing, , materials,
Nordics, 4.50% 19.30%
3.90%
France, 5.90% Vehicle, Check on work
5.30% attendance,
Animal 13.10%
Germany, Canada, identification,
10.40% UK, 10.30%
3.10% 5.80%
Costume,
Fixed assets
5.80%
Airport management,
National
baggage Train/Vehicle 8.70%
defense,
security, identification,
6.30%
7.30% 8.70%

• What are the categories?
According to different frequency
• Low frequency(LF): below 135KHz
• High frequency(HF): 13.56MHz
E.g.: entrance guard, book management
• Ultra high frequency(UHF):860-960MHz
• Microware frequency(MF):2.4G-5.8G
E.g.: China mobile and Chain Telecom

• What are the categories?
According to energy supply
• Passive RFID (no battery)
• Active RFID (has battery)
• Semi-active RFID (energy for maintaining the data)
According to readers position
• Fixed RFID (readers can not move )
• Mobile RFID (readers are mobile )

• What are the components?

• How does it work?
Reader Antenna Tag Antenna
RF-generator Variable
Loader
Mixer
ID-encoder
Filter
ID-decoder
Oscillator
Monitor
RFID Reader RFID Tag

Content
1. Introduction
5. Conclusion

4. RFID for cold-chain
• 1) Cold chain life cycle
refrigeration processing
refrigeration storage
refrigeration distribution and

transportation
refrigeration sales and checkout

counter

• 2) Principles
Scanning
GPRS/wireless
net
Shipping
Tag
Reader

• 3) Advantages
provides an effective
way of products
tracking
Simplify the processes
Reduce the handling

cost of enterprises

Limitations
• Reliability
• Lack of uniformity in global standards
• Troubleshooting and data-driven decision-making
• Accuracy
• Difficulty of establishing a return on investment(ROI)
• Lack of collaboration in the supply chain
• Customer adoption of RFID

• 5) Future Prospect
Combination of RFID and TTI
Wireless technology in RFID
Multi-sensing RFID nanosensors
Battery-free RFID tags for continuous

temperature monitoring

Content
1. Introduction
5. Recommendations

• Recommendations:
• Use RFID technologies and similar wireless monitoring
systems to guarantee high quality
• Focus on cost reduction
• set methodology for the calculation of ROI
• Develop the global RFID standard
• Use TTI to facilitate collaboration between the relevant
• supply chain partners

Banana
Ripening Chambers
Best bunch management practices:
“quality control from the field to the shelf”
Packing house practices:
Field practices:  Good packing house hygiene
 Leaf removal (diseased leaves, sanitation)  Hang bunches in shade over night to
 Deflowering (of individual fingers) cool
 Bunch spray (to reduce insect and mold)  Careful de-handing (clean cuts)
 Bagging and Tagging  Washing
 On-time harvest  Drying
 Careful handling & transport to packing  Packing
house  Storage (refrigerated), shipping (prompt)
Bunch of bananas
Banana Bunch management in the FIELD:
 Leaf removal: minimizes fruit injury Remove leaves that rub against bunches
Remove severely diseased leaves (de-trashing)
 Deflowering: reduces incidence of fungus and insect attack; reduces abrasion injury on fruit skin.
 Bunch spray (diazinon, insecticidal soap, BT, copper hydroxide): reduces pest and disease damage
(moth, thrips, sooty mold, etc.)
 Field sanitation: reduces insect and pathogen populations
 Bagging and Tagging: protects bunch; ensures on-time harvest of cohorts

 Good cultural practices (weed, pest, disease management, drainage, fertility, pruning, plant spacing, etc):
ensures healthy, consistent fruit
 Careful harvesting, handling & transport to packing house: minimizes fruit injury and bruising.
Bagging and Tagging
Bagging is done once per week
Perforated polyethylene sleeves
Tied at top and bottom
Tagged with bi-colored ribbon
Bagging minimizes sooty mold,

insect damage and abrasion injury
to fruits.
Identify plants at critical stage of development and mark the pseudostem
with the date
A simple alternative to Bagging and Tagging

Hanging on hooks on Hanging on pieces of PVC pipe
rollers and runners
on greased steel pipe
Hang bunches overnight under cover in a packing house to cool down the
banana pulp temperature. Wash and pack them the following day.
Commercial Ripening
 Assures good shelf life
 Provides excellent fruit appearance
 Provides optimum eating quality
 Fruit is available when and where required

Commercial Ripening: four major factors
 Ethylene gas
 Temperature control
 Relative humidity control
 Adequate air circulation
Because each batch of fruit varies, it is necessary to

Continuously monitor ripening.
Ethylene Gas
Naturally occurring plant hormone
 Produced in all plant tissues
 Governs many physiological functions, including senescence and ripening
 Produced in greater amounts as plant organs (fruits) mature.
 Also ethylene is produced in response to plant stress:
wounding, sunburn
infection and disease
drought
Factors which can contribute to uneven

ripening in banana fields.
 Ethylene gas is produced by decaying plant material

1. Ethylene gas
Colorless gas, slightly sweet odor, soluble in

water Normally produced during banana fruit r.
ripening
If applied to bananas, it initiates ripening and assures even ripening
Only 1 ppm is required to initiate ripening,

but up to 1000 ppm are frequently used.
Banana fruits are exposed to the gas for about 24 hours.
Note: a concentration of ethylene gas higher than 2.7% (27,000 ppm)

can be explosive
RIPENING OVERVIEW
Green bananas in cartons are loaded into the ripening room.
 The room is closed and refrigerated for 12 to 16 hours until the pulp temperature reaches 15 to 17°C. Relative humidity is 90%
 Ethylene is discharged into the room at a concentration of around 0.1%. The room is then kept closed for 24 hours. The
ethylene acts as a catalyst initiating the hormonal process of ripening. Relative humidity is 90%
 At the end of this time the room is ventilated to clear the ethylene.
 The room is then closed again and the atmosphere controlled at a temperature of 15 to 17°C for three to four days. The fruit
pulp may reach a temperature of 32°C during this process and gases, including carbon dioxide, are evolved in substantial
quantities. Relative humidity is about 75%.
 The room is finally ventilated and the ripe fruit removed. A common way of ventilating involves opening the doors for at least 5,
usually 15 minutes before entry is made. Extractor fans may also be used.
 The amount of ethylene gas required for a ripening room is normally calculated on the free air space after the bananas have
been loaded (i.e., if bananas take up to 35% of the room size, calculate the amount of ethylene required for remaining 65% free air
space).
 Temperature control (pulp temperature)
Without adequate temperature control, bananas can have very short shelf life (as short as 4 days at >73 F)
Fruits ripened at high temperature have poor appearance (dull grey-green) And poor flavor.
Low temperature (less than 55 F) delays banana ripening. Optimum ripening temperatures are
58 F – 64 F.
Actual temperature used depends on when you want the fruit ready, with higher temperature (64 F)
producing ripe fruits most rapidly.
 Relative Humidity (RH) control
Without adequate relative humidity control, bananas can affect skin color,
freshness and may cause splitting, weak necks, breaking, weight loss
and may cause existing blemishes to become enhanced.
Ripening RH levels:
90% RH (use automatic humidifiers with humistat control)

reduce RH to 75%
Begin ripening:
Color break:
 Air circulation
Assures uniformity of ripening and prevents buildup of CO 2
Air circulations fans operate continuously while ripening fruit
Fruit boxes are stacked to allow air circulation. Many stacking patterns
are available, but a 4-inch air channel is ideal.
Rule of thumb: the discharge from the centrifugal blower in cubic feet
per minute should equal the cubic capacity of the ripening room.
A RIPENING SCHEDULE FOR BANANAS
Ripening time is from hard green to Color Stage 4 ( green-yellow with dark green tips)
Fruit Temperature (pulp) in °F

Number Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7
of Days
to Ripen
4 64 64 62 60 - - -
5 62 62 62 62 60 - -
6 62 62 60 60 60 58 -
7 60 60 60 60 60 58 58
 Air temperatures in ripening room will usually be lower than banana pulp temperatures.
 Do not start ripening with ethylene until pulp temperatures stable at desired temperature.
 Seal ripening room and gas with 1000 ppm ethylene for 12 to 24 hours.
 After initial gassing thoroughly ventilate ripening room with fresh air for 20 to 30 minutes every 12 hours.
 Inspect fruit regularly and adjust air temperatures to control pulp temperature in desired range.
 Always use a proper pulp thermometer.
Commercial, large-scale
ripening rooms require
forklifts and computerized
automation and control.
METHODS OF INTRODUCING ETHYLENE GAS
Catalytic Generators (e.g., 'Ethy-Gen‘)

A method by which a liquid concentrate 'Ethy-Gen' is decomposed in an electrically powered catalytic generator, to
produce ethylene gas. The 'Ethy-Gen' concentrate is supplied in containers which produce about 12 ft3 (0.33 m3 )
of ethylene gas. The amount of liquid put in the generator depends on size of ripening room.
Ethylene Cartridges
Each ethylene cartridge contains approximately 51g of pure ethylene and the ethylene concentration in the
room may be controlled simply and accurately by using the appropriate number of cartridges. Ethylene is
released by piercing the cartridge with a tool which is supplied.
Ethylene and Ethylene/Nitrogen Cylinders

The explosion risk from ethylene can be eliminated by the use of a mixture of gas consisting of 5% ethylene in
nitrogen. Pure ethylene and the mixture can be obtained from British Oxygen Company Limited and Air Products
Limited.
Pure Ethylene Cylinders

Pure ethylene can be obtained in cylinders.
CATALYTIC GENERATORS
Pour one or two quarts of Ethy-Gen® II and ethylene

production begins.
Provides pressureless ethylene on a continuous basis for

uniform ripening.
Ethylene output is adjustable for multiple room sizes.
Can work with a computerized ripening room control system. Available in a wall-mounted
version.
Large 2½ quart reservoir.
1,500 cubic foot (43 cubic meters) minimum room size.
Electrical specifications:
120 VAC / 160 W / 60 Hz / 1.2 Amps OR
230 VAC / 160 W / 50 - 60 Hz / 0.65 Amp
Conversion Rate Settings and approximate room size*:

# 1: 1 Quart of Ethy-Gen® II every 48 hours; 1,500 to 2,499 ft3 (43 - 70 m3)
Fan used while ethylene
is being generated
Simple banana ripening in a refrigerated
Matson container in Hilo, Hawaii. Capacity:
Catalytic generator
320 boxes of bananas. for ethylene
Ethylene gas
from compressed gas cylinders:
two methods
Single shot of gas, Continuous slow trickle of gas

given at one time. into the room for 24 hrs.
A method to monitor ethylene concentration should be available.

Alternate ripening methods
ETHEPHON (Ethrel-Union Carbide) is a compound that breaks down to

form ethylene. However, this is not currently approved for post-harvest use
on bananas. Work done at the University of Hawaii found a 0.33%
ethephon spray to be effective in ripening bananas.
CALCIUM CARBIDE breaks down to form acetylene, which at high

concentrations produces the same effect as ethylene. This method is
widely used in markets in Southeast Asia. About ½ ounces of calcium
carbide is wrapped in newspaper. These packets are placed through the
banana pile. The bananas are covered with a tarpaulin and the high
humidity generated activates the carbide.
Thank you all
Questions!

Pack House SMART COLD WAREHOUSE

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தமிழ்நாடு அரசு வேளாண்மம

ேிற்பமை ோரியம் பயிற்சி மமயம்

• A cold storage unit incorporates a refrigeration

2. Orientation and building form

•Volume of product to store

→V is the total volume needs in cubic feet.

For loading and unloading distance between

Air Chillers/freezers Cooling coils

Vapor Compression System

Height of storage room Low 5.4 11.5

Economic status costliest 5% costlier than Cheapest

Group II -slightly toxic and flammable

Group III - highly toxic and flammable

• Latent heat of vaporization

National codes of practice, insurance companies, as well as

m = mass flow rate through the

• Field heat mC p (Tj  Tz)

• Heat given by power equipment

• Total refrigeration required

Application of RFID in Cold Chain

2. Process Analysis of RFID-based Cold Chain

Content 3. Basic RFID Technology

4. Application of RFID in Cold chain

Group 11 ECLT 5710 Distributed and Mobile Systems

French people like

Australia is famous for

Group 11 ECLT 5710 Distributed and Mobile Systems 39

Group 11 ECLT 5710 Distributed and Mobile Systems 40

Group 11 ECLT 5710 Distributed and Mobile Systems 41

 Cold Chain: temperature—controlled supply

 Temperature-sensitive products need to be

Group 11 ECLT 5710 Distributed and Mobile Systems 42

2. Process Analysis of RFID-based Cold Chain

Content 3. Basic RFID Technology

4. Application of RFID in Cold chain

Group 11 ECLT 5710 Distributed and Mobile Systems 43

Production & Shipping

RFID ear mark

Update RFID Inventory Replenishment

On Shelve RFID Reader

Update Buying Auto-

2. Process Analysis of RFID-based Cold Chain

Content 3. Basic RFID Technology

4. Application of RFID in Cold chain

Group 11 ECLT 5710 Distributed and Mobile Systems 49

• Actually RFID is using radio waves to exchange data. It

• In mobile phones Mobile Wallet

• Other industries such as logistics and supply chain

Group 11 ECLT 5710 Distributed and Mobile Systems 50

Group 11 ECLT 5710 Distributed and Mobile Systems 51

Group 11 ECLT 5710 Distributed and Mobile Systems 52

• Mobile RFID (readers are mobile )

Group 11 ECLT 5710 Distributed and Mobile Systems 53

Group 11 ECLT 5710 Distributed and Mobile Systems 54

RFID Reader RFID Tag

Group 11 ECLT 5710 Distributed and Mobile Systems 55

2. Process Analysis of RFID-based Cold Chain

Content 3. Basic RFID Technology

4. Application of RFID in Cold chain

Group 11 ECLT 5710 Distributed and Mobile Systems 56

refrigeration distribution and

refrigeration sales and checkout

Group 11 ECLT 5710 Distributed and Mobile Systems 57