GOVERNMENT POLYTECHNIC, KHAMGAON

(Department of Mechanical Engineering)

AN INDUSTRIAL VISIT REPORT ON

HIMALAYA ICE FACTORY

By The Students of Mechanical Engineering Department

Date of Visit: - 23TH FEBRUARY 2023

We visited HIMALAYA ICE FACTORY at 3:30 pm

Submited by
Roll No. Name Enrollment No.
57 Kirti Tikar 2000210406
58 Rugved Takwale 2000210407
59 Sakshi Ghate 2000210408

GUIDED BY
Dr. A.E.Dhole
 CERTIFICATE
This is certify that, Sixth Semester Diploma Course
in Mechanical Engineering of GOVERNMENT
POLYTECHNIC, KHAMGAON (0021) has
completed the Micro project satisfactorily under the
Course of RAC (22660) prescribed in
curriculum.
Roll No. Name Enrollment No.
57 Kirti Tikar 2000210406
58 Rugved Takwale 2000210407
59 Sakshi Ghate 2000210408

Course Teacher Principal

Dr. Dhole Sir Dr.Prabhune Sir
 Acknowledgement
The real spirit of achieving a goal is through the way of
excellence and lustrous discipline. I would have never
succeeded in completing my ask without the
cooperation, encouragement and help provided to me by
various personalities.
First of all we would like to thank our principal
Dr. S .S. Prabhune, who provided with the necessary
facilities and advice. We are also thankful to Dr. A.E.
Dhole Sir, Head of Mechanical Department for this
valuable suggestions and support. With great pleasure
we are really thankful to guide Dr.A.E.Dhole Sir for his
valuable suggestions, support and sincere guidance for
the completion of this project Also I would like to thanks
to all teaching and non-teaching staff of the department
for their encouragement, cooperation and help. My
greatest thanks are to all who wished me success
especially my parents, my friends whose support and
care makes me stay on earth.
 Contents


S.R Name Of Topics

No

1 Introduction

2 General Process Flowchart of Ice

Making Unit
3 Parts Of Ice Making Plant

4 Capacity, Process Cycle & Its Layout

5 Vapour Compression Refregeration

6 Applications

7 Conclusion

8 Refrences
INTRODUCTION
The demand for block ice is as great today as it ever
has been, despite advances made in the development
of modern refrigeration equipment. The chemical and
construction industries, for example, commonly use
block ice in situations where the use of such equipment
may not be practical. The fishing industry is also
another major consumer of block ice, which is used to
preserve the fish from the time they are caught, until
they are sold. It is also used to great extents by the
retailers of food and drinks to preserve food and/ or
chill drinks.

Block ice is the most popular type of ice sold for a

variety of reasons. It melts more slowly than other
types of ice and thus lasts longer. It can be placed in
open truck with only a tarpaulin to protect it from the
elements and shipped to a location of four hours away.
Its rectangular shape makes it easy to stack of up to 15
meters and store large amounts. Block ice has merits
of easy to transport and separate as well. Other types
of ice have the tendency to freeze into a solid mass,
making it difficult to work with. The ice making plant
outlined in this proposal is the result of years of
research and development done by FRESER. The
plant was designed to operate efficiently in tropical
areas, but should prove to be profitable in any climate.
GENERAL PROCESS FLOWCHART
OF ICE MAKING UNIT
PARTS OF ICE MAKING PLANT

The complete ice making plant consists of:

1. Ammonia Compressors
2. Condensers / Heat Exchangers
3. Ammonia Receiver
4. Cooling Coil / Evaporator
5. Chilling Tank
6. Paneling (Electrical Equipment’s)

1. AMMONIA COMPRESSORS:
• Ammonia compressors designed with state-of-
the-art technology for industrial & commercial
refrigeration and low temperature applications.

• Compressors are V belt driven and are suitable

to operate with Ammonia (NH3) & Freon [12
(CCl2F2), 22 (CHClF2)] as refrigerant.

• Robust construction, excellent performance and

power saving features and hallmarks of the
products.
 2. CONDENSERS/HEAT EXCHANGERS:

Condenser is a heat transfer surface, generally

which are divided in to three types.

• Air Cooled Condenser: Employ air as the

condensing medium.

• Water Cooled Condenser: Utilize water to

condense the refrigerant.
Evaporative Condenser: Use both air and water as
the condensing medium. The function of the air
is to increase the rate of evaporation by carrying
away the water vapor results from evaporation
process.

3. AMMONIA RECEIVER:
• Ammonia receiver can control the supply and
demand relation between the condensers and the
evaporator, prevent excessive liquid ammonia
from staying in the condenser, maintain a certain
level in the liquid receiver to prevent gas from
going into the liquid pipe line.

• The ammonia in the system can be stored in the

ammonia receiver to avoid loss of the ammonia
 before the refrigerating system is repaired.
Therefore, the volume of the ammonia storage
should be considered before buying it.

4. COOLING COIL/EVAPORATOR:

• Cooling Coil / Evaporator is used as heat

transfer surface in which a volatile liquid is
vaporized for the purpose of removing heat
from refrigerated space.

V shape cooling coils are available in

different sizes, usually custom made to the
individual applications.

5. CHILLING TANK:

Chilling Tank consists of three parts:

A) Ice Tank
B) Insulation of Ice Tank
C) Ice Block
A. ICE TANK:
Ice tanks are made of such material as wood, steel
or concrete. As wooden tanks do not last long
enough and are liable to leak, they should
preferably be made of steel well coated with
waterproof paint. Tanks made of reinforced
concrete are also recommended as superior to those
of wood.

The ice tank contains the direct expansion coils,

equally distributed throughout the tank and these
coils are submerged in brine. The tank is provided
with a suitable frame of hard wood for support the
ice cans and a propeller or agitator for keeping the
brine in motion: the brine in the tank acts as a
medium of contact only, the ammonia
evaporating in the ice coils extracts the heat from
the brine, which again absorbs the heat for the
water in the cans.

The tank itself should not be much larger than

is necessary to hold the cans, the coils, and the
agitator. About two inches should be left between
the moulds and three inches between the pipes
and the moulds.
B. INSULATION OF TANK:
Insulation of the ice tank is accomplished by using
twelve to eighteen inches of good insulating material
on each of the sides and not less than twelve inches
under the bottom.
 C. ICE BLOCK:
Commercial sizes of Ice cans vary with the
weight of ice cakes required. The cans are made
to contain about 5% more than their rated
capacity to compensate for thawing.

6. PANELING (ELECTRICAL EQUIPMENTS):

The Himalaya Ice Factory is furnished with
electrical control panel with compressor starter,
all necessary safety switches and press stats,
Voltmeter, Ammeter, Temperature Sensor etc.

Fig 2. Flow Chart

 CAPACITY, PROCESS CYCLE AND ITS
LAYOUT:

Ice cans are placed in can grids and moved to

beneath the filling tank which automatically fills
each can with proper level of pre-cooled water
and then stop. Potable water must be used to
make ice intended for human consumption.
The cans are then hoisted and carried to the brine
tank and immersed inside. The brine, which is a
calcium chloride solution kept at a temperature of
-10 , is constantly circulated by agitator in order
to keep the temperature consistent throughout the
tank.

Air is blown into the center of the can to induce

a swirling motion. This causes any impurities and
air bubbles in the water to be collected in the
center of cans. Prior to finish freezing, this core
is removed by a suction pump and replaced with
fresh pre-cooled water.

The time required for the water to be frozen

varies according to the size of cans being used,
150lbs. block requires 24 hours, 300 lbs. Takes
48 hours. When the ice has completely formed,
 the grids are lifted up from the brine tank and
moved to place in the thawing tank. Using the
warm water heats the can, until the ice allowed to
be slid out. The block ice is then removed from
the can by a can dumper. In POF 150 block per
day are going manufactured and mass of each
block is 50KG. The capacity of that plant is 5.5
TONS.

The empty cans are returned to filling tank for

next ice making cycle. The ice is moved to ice
storage and stacked by an ice stacker, or it can be
delivered to customer right away upon requested.

VAPOUR COMPRESSION REFRIGERATION:

Vapor-compression refrigeration is one of the
many refrigeration cycles available for use. It
has been and is the most widely used method for
airconditioning of large public buildings,
offices, private residences, hotels, hospitals,
theaters, restaurants and automobiles. It is also
used in domestic and commercial refrigerators,
large-scale warehouses for chilled or frozen
storage of foods and meats, refrigerated trucks
and railroad cars, and a host of other
commercial and industrial services. Oil
refineries, petrochemical and chemical
processing plants, and natural gas processing
plants are among the many types of industrial
plants that often utilize large vapor-compression
refrigeration systems. Refrigeration may be
defined as lowering the temperature of an
enclosed space by removing heat from that
space and transferring it elsewhere. A device
that performs this function may also be called a
heat pump.

Fig 3. Single Stage Vapor Compression Refrigeration

The vapor-compression uses a circulating liquid

refrigerant as the medium which absorbs and
removes heat from the space to be cooled and
subsequently rejects that heat elsewhere. Figure 1
depicts a typical, single-stage vaporcompression
system. All such systems have four components:
a compressor, a condenser, a Thermal expansion
valve (also called a throttle valve or Tx Valve),
and an evaporator. Circulating refrigerant enters
the compressor in the thermodynamic state
known as a saturated vapor and is compressed to
a higher pressure, resulting in a higher
temperature as well. The hot, compressed vapor
is then in the thermodynamic state known as a
superheated vapor and it is at a temperature and
pressure at which it can be condensed with
typically available cooling water or cooling air.
That hot vapor is routed through a condenser
where it is cooled and condensed into a liquid by
flowing through a coil or tubes with cool water or
cool air flowing across the coil or tubes. This is
where the circulating refrigerant rejects heat from
the system and the rejected heat is carried away
by either the water or the air (whichever may be
the case).
The condensed liquid refrigerant, in the
thermodynamic state known as a saturated liquid,
is next routed through an expansion valve where
it undergoes an abrupt reduction in pressure. That
pressure reduction results in the adiabatic flash
evaporation of a part of the liquid refrigerant. The
autorefrigeration effect of the adiabatic flash
evaporation lowers the temperature of the liquid
and vapor refrigerant mixture to where it is colder
than the temperature of the enclosed space to be
refrigerated.
The cold mixture is then routed through the coil
or tubes in the evaporator. A fan circulates the
warm air in the enclosed space across the coil or
tubes carrying the cold refrigerant liquid and
vapor mixture. That warm air evaporates the
liquid part of the cold refrigerant mixture. At the
same time, the circulating air is cooled and thus
lowers the temperature of the enclosed space to
the desired temperature. The evaporator is where
the circulating refrigerant absorbs and removes
heat which is subsequently rejected in the
condenser and transferred elsewhere by the water
or air used in the condenser.
To complete the refrigeration cycle, the
refrigerant vapor from the evaporator is again a
saturated vapor and is routed back into the
compressor.
 APPLICATION

Ice Making plants are used in different

applications like:

 Fisheries
 Hospital
 Chemical
 Pharmaceutical
 Commercially used in different industrial
applications

CONCLUSION
Ice plant is a big size domastic refrigerator
freezer. The working principal of ice making is
the same as that of the domastic refrigerator
but the ice making is done by taking heat from
water using a brine solution & this water now
gets converted into ice.
REFERANCE

https://www.qsqtech.com/2021/03/12-
steps-of ice plant.html?m=1 2.

https://uk.indeed.com/career
advice/career-development/what-are ice
plant#:-text

Visit to ice factory & collect the

information about formation of ice.