1.

INTRODUCTION

A cold storage is essentially consists of a number of refrigerated chambers which are able

to chill, freeze and store any perishable product. Certain general substructural conditions must be

fulfilled to construct a cold store successfully: site selection for easy access by road and train;

terrain of good mechanical resistance and without problems of surface water; good supply of

potable and industrial water and electricity; drainage facilities. As well, the local availability of

labor (technical personnel, skilled labor for maintenance and general laborers) should be

investigated. (Planning of Cold Storage, 2005)

Chilling can be defined as the fundamental operation in applying cold to meat to reduce

its temperature quickly. This is done in a cold chamber with intensive air draught or movement.

Rapid cooling of the meat surface not only slows and nearly stops the development of surface

micro-organisms but also reduces weight loss and discoloration of the surface owing to

haemoglobin oxidation. Different systems of primary chilling are in use but air chilling is the

most commonly used system of cooling. (Cold Preservation of Meat Products, 2006)

The design of a cold storage for the preservation of meat requires utmost care. When the

meat is refrigerated near 7℃, the mesophilic organisms and most pathogens will not grow, but

still the psychrophilic will continue to grow, favoring the spoilage conditions. The color of the

meat is also influenced by the rate of cooling. Slower cooling rate will result in lighter colored

meat. Slower cooling rate also avoids the problem of cold shortening while rapid chilling

increases the shell life, reduces the bacterial growth, retains color and weight and also produces

smaller crystals preventing tissue damage. Most meat products experience longer storage life

with decrease in the freezing temperatures. The lower the freezing temperature, higher will be
the life of

meat. (Meat Handling and Storage Procedures, 2007)

2. PARAMETERS CONSIDERED FOR THE DESIGN

Parameters have to be specified in cold storage. The overall volume calculation for

storage comprises of the floor tub, walls, and roof. The gross volume is the total volume into

which you store the items. Inside cold storage temperature control can be simplified by

constructing a square container instead of a rectangular one. Rectangular structures have more air

room per square meter of storage volume, and more heat is spread out over the walls, making the

square form style more cost-effective.

2.1 SITE SELECTION

The cold storage should be place in a shady areas that have a good wind flow. It should

better be built inside of building. It should also have a good drainage conditions around. The

underground water level should be low. It is better to have interlayer below and it is best to keep

it well ventilated because dryness is important for cold storage. Before construction, the room

should be set up with corresponding three-phase electric capacity according to the machinery

power. If the room adopts water cooling methods, water pipes should be laid and cooling tower

should be assembles as well.

2.3 STORAGE TEMPERATURE

Temperature is the most important parameter for the meat storage purpose. Life of all

frozen foods is dependent on temperature of storage. In many meat types greater the frozen

temperature higher is the life of meat. There is a clear effect of temperature of storage on storage
life, but considerable scatter between results at some temperatures are also observed. The

following table below shows data for meat at different storage temperatures [Practical storage

life in months].

As per the

table the temperature for refrigeration should be -18℃ to -24℃. Therefore, this parameter is

crucial for the design.

2.4 RATE OF FREEZING

If meat is frozen slowly, large ice crystals are formed and their size breaks down the

tissues. When defrosted for use, the food spoils rapidly and taste is ruined. Fast freezing, from

0℃ to -15. Faster freezing also tends to produce a lighter colored product as the small crystals

scatter the light more than the large crystals and enhances the appearance of the meat products.

Meat placed in rapid freezers will freeze quickly, and when defrosted for use, even after long

storage, will still be tasty.

2.5 RELATIVE HUMIDITY

 Relative humidity is the second most important condition for storage of meat products.

Using proper temperature and relative humidity, the life of meat products can be extended.

Relative humidity in a storage space is affected by many variables, such as system running time,

moisture infiltration, condition and amount of product surface exposed, air motion, outside air

conditions, type of system control, etc. If proper humidity is not maintained, the meat products

will have surface drying also resulting into weight loss. Therefore to preventing the drying out of

the meat surface the relative humidity level should be maintained to about 90% to 95%. Thus,

the weight loss will be countered and freezer burns will also be avoided.

3 CALCULATION OF HEAT LOADS

The most accurate means of determining the refrigeration load is by calculating each of

the factors contributing to the load.

Mass = 200 kg
Initial temp of meat = 24℃
Freezing temp = -2℃
Final / storage temp. = -18℃
Specific heat of meat before freezing = 3.23 KJ/kgK
Specific heat of meat after freezing = 1.68 KJ/kgK
Latent heat = 233 KJ/kg

Solution:
To cool from 24℃ to -2℃ = 200 x 3.23(24 - (-2))
= 16796 KJ

To freeze = 200 x 233 = 46600 KJ

To cool from -2℃ to -18℃ = 200 x 1.68(-2 - (-18))

= 5376 KJ

Total = 16796 KJ + 46600 KJ + 5376 KJ

= 68772 KJ/24hr
= 800 W or 0.8 KW
 Heat transfer due to opening and closing of door

Hc = V x Ac x He
= (2 x 2 x 2 x) 34 x 1
= 3.148 x 10-3 KW

Heat load due to occupancy

At -18℃ heat released by a person is 1372 KJ/hr or 0.3811 KW

Ho = (No. of persons working) x (Heat released) x (Working time)

= 1 x 0.3811 x 1

= 0.3811 KW

Therefore,

Total heat load = 0.8 KW + 3.148 x 10-3 KW + 0.64 KW + 0.3811 KW

= 1.8242 KW

From the table of refrigerant 134a

H1= 386.7 KJ/kg H3 = H4 = 234.3 KJ/kg

And calculating, H2 = 420 KJ/kg

Therefore,

Compressor work = H2 – H1

= 420 – 386.7

= 33.3042 KJ/kg

Refrigerating effect = H1 – H4

= 386.7 – 234.3

= 152.4 KJ/kg

Coefficient of performance

COP = Refrigerating effect / Compressor work

= 152.4 / 33.3042
 COP = 4.57

(COP)Actual = (1/3) x COP

= 4.57 / 3

(COP)Actual = 1.52

4.

MATERIAL SELECTION

The selection appropriate of insulating material for preventing heat gain from the outside

surroundings is very important. Besides being a good heat insulating material, it should also be

economical, practical and durable. High and medium temperature cold storage rooms generally

need 10cm thick panel whereas low temperature cold storage and freezing cold storage rooms

need 12cm or 15cm thick panels. Another cold storage can use spray polyurethane foam. The

material is directly sprayed to brick or concrete which, after shape settled, is moisture proof and

heat insulating. Modern structures are developing fabricated cold storage rooms which make

moisture proof layers and insulating layers in advance and assembling is done on site. It

advantages in construction convenient, quick, mobile nut the highly cost. Therefore as per the
temperature considerations and also considering the economics and durability, Urethane is best

suited insulating material for the insulating panels of the refrigerating room. The thickness of the

panel will be about 10cm and for ceiling it will be about 12cm.

5. TYPE OF REFRIGERANT

The life blood of any refrigerating system is the refrigerant circulating inside the system.

It carries heat from the refrigerated space to the outside surroundings. During the operation the

refrigerant is subjected to cyclic thermodynamic processes. The refrigerant selected should have

following properties:

 The refrigerant should have low boiling temperature at boiling pressure.

 Freezing temperature should be below evaporator temperature.

 It should have low condensing pressure.

 It should have high latent heat of vaporization.

The refrigerant, R134a was selected. It is an almost odorless liquid with a low boiling

point of - 26℃ at atmospheric pressure. It has low specific volume of vapor with a good

volumetric efficiency. It is non-toxic, non-corrosive, non-irritating and nonflammable.

6. DESIGN CALCULATIONS

 Compressor design

Mass flow rate of refrigerant (M) Compressor rated power

= Cooling load / H1 – H4 = compressor capacity / (COP)Actual

= 1.8242 / 152.4 = 0.3986 / 1.52 = 0.2622 kW or 0.35HP

= 0.01196 kg/s
Compressor capacity = M x compressor work

= 0.01196 x 33.3042

= 0.3986 kW or 0.5345 HP

= 1 HP

 Evaporator design

Evaporator capacity = M x Refrigerating effect

= 0.01196 x 152.4

= 1.82 kW or 3 HP

Rated evaporated capacity

= evaporator capacity / (COP)Actual

= 1.82 / 1.52 = 1.2 kW or 1.6HP

 Condenser design

Condenser capacity = M x condenser work Rated condenser power

= 0.01196 x (420 – 234.3) = condenser capacity / (COP)Actual

= 2.22 kW or 2.97 HP = 2.22 / 1.52 = 0.2622 kW or 2HP

= 3 HP

7. COLD STORAGE SYSTEM EQUIPMENTS

Equipment Storage
(0.5m x 2m x 2m)
COLD STORAGE
(2m X 2m X 2m)
 Refrigeration is accomplished by the evaporator as the refrigerant takes the heat from

inside. The dimensions of the refrigerating room are 2m x 2m x 2m. Selection of cold storage

cooling system is mainly the selection of refrigeration compressor and the evaporator

7.1 Evaporator

The evaporator can be classified as Shell and coil type, Shell and tube type or tank type

evaporators. The type of evaporator selected for the application is a bare tube coil, forced

connection, dry expansion; and made of aluminum material. It is forced connection because air is

forced over the coil by a fan, to increase heat transfer rate as well as distributing the cooling

effect evenly round the room. The bare tube is chosen because of its relatively low cost due to

ease of construction.

7.2 Condenser

The selection of a condensing unit depends on the type of condensing medium to be used,

air or water, the design ambient temperature or water temperature, and the capacity of the

condenser selected. The condensers are basically classified as air cooled type and water cooled

type. In air cooled condensers the air is used as the cooling medium. Abundant and free

availability of the air makes it suitable for certain applications. The condenser selected for the

cold storage is a base mounted, forced convection, air cooled type of condenser made of copper

material. It lies on the same base with the compressor. With the aid of the thermostatic system,

the air-blowing fan switches off when heat load is low and switches on when heat load is high.

This helps the air in circulation cool the refrigerant efficiently

7.3 Expansion Valve

The expansion valve used for our application is automatic type. The valve has a

diaphragm on one side and evaporator pressure on the other side. A rise in evaporator pressure

moves the diaphragm and reduces the flow of refrigerant through the valve and thereby reduces

the evaporator pressure. Similarly the flow is increased when evaporator pressure drops. Thus it

tries to maintain constant pressure in the evaporator.

7.4 GENERATOR

A generator system should have the capacity to maintain critical temperatures within the

cold storage facility. In case of failure of the electrical system the generator should be

immediately switched on. As the fall in temperature inside the cabinet will degrade the product

stored. The generator selected is capable of supplying 4HP of power and the fuel required for its

operation is diesel.

8. CONCLUSION

The refrigeration room of 2m x 2m x 2m will be designed having a total refrigeration

load of 0.52 TR. The equipment designed for handling the load was based on the load

calculations. The evaporator has a refrigeration capacity of 3 HP, the condenser has a capacity of

2 HP and the compressor required is of 1 HP. Also a generator of 4 HP is suggested along with

other equipment. The overall equipment and workmanship cost will be high depending on the

place where will it be created.

 REFERENCE

https://www.quora.com/What-are-the-benefits-of-cold-storage

https://www.crs.ie/latestnews/meat-cold-storage.html

http://www.fao.org/3/t0098e/T0098E02.htm

http://www.fao.org/3/t0098e/T0098E03.htm

https://blog.froztec.com/en/what-is-a-cold-room-and-why-do-you-need-it-for-your-products

https://www.researchgate.net/publication/316472114_Design_of_cold_storage_for_fruits_and_v

egetables

https://www.crscoldstorage.co.uk/knowledge/meat-cold-storage.html