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Cold Storage: A View of Energy Efficient Technologies and Practices

Conference Paper · December 2010

DOI: 10.13140/2.1.3937.6009

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 Cold Storage: A View of Energy Efficient Technologies and Practices

Vipin Yadav
Rajiv Gandhi Institute of Petroleum Technology (RGIPT), Rae Bareli, India 229 316
Email: [email protected]

Abstract
A cold storage facility is a complex thermal system that works for the preservation and efficient utilization of perishable
food commodities. It generally comprises a specifically designed building space, one or more refrigeration unit/s, material
handling provisions, ancillary power generation unit and several other critical components. Considerable technology up-
gradation has occurred around the globe in this regard and consequently, highly energy efficient refrigeration units,
excellent performance thermal insulations, innovative techniques to further reduce the building heat loads etc. are now
available.
India is a country with above 17 percent of world population, widely spread agricultural land with mostly favorable
meteorological conditions. Country is yet striving hard for self-sustenance in terms of all kinds of food products. Time and
space non-uniformity in food production is a challenge that can be only dealt with by adopting standard technological
measures. There are nearly 5400 working cold storage units with over 23.6 million metric tons of storage capacity; and the
expansion to higher capacity is desperately needed. The paper begins with basic relevant information regarding cold
storages particularly in Indian context.
Sparsely available reliable information indicates below the mark (in fact, poor) performance of majority of these units
in terms of overall energy consumption, energy auditing and overall facility management. Gross-wastage of high grade
energy can be easily averted through little but sincere efforts. In order to reduce the overall energy consumption levels by a
cold storage unit, few critical points are discussed which need to be taken care off during design, construction and
application phases.
Incorporation of energy efficient refrigeration units can significantly improve the overall performance of any cold
storage utility. Technical information is presented regarding the more energy efficient refrigeration units. Bottlenecks in
employing other alternate sources of energy which are cheap and readily available are also explored.
The emission of carbon dioxide and other green house gasses into the atmosphere at large scales is a big issue. The paper
concludes emphasizing, firstly, the need of elevating the cold storage units to higher energy efficiency levels, and secondly,
employing renewable energy sources like solar energy for the operation of such facilities.
Keywords：cold storage, energy efficiency, alternate energy sources, clean energy

1. INTRODUCTION
Any building or section of building that achieve controlled storage conditions using refrigeration can be regarded as a cold
storage facility. Technically speaking, cold storage is a special kind of room, the temperature of, which is kept very low
with the help of machines and precision instruments. Such a facility is usually employed for the preservation of perishable
food products for extended time duration. Most countries adopt well recognized standards to be followed while designing
and operating of all kinds of cold storage facilities [1-3].
Energy efficiency in buildings employed for operating cold storages is achieved through a multipronged approach
involving adoption of bioclimatic architectural principles responsive to the climate of the particular location; use of
materials with low embodied energy; reduction of transportation energy; incorporation of efficient structural design;
implementation of energy-efficient other building system components; and effective utilization of renewable energy sources
to power the building [4]. Thus, design and development of cold storages in India has always being a big issue in this sense.
Indian climate can be easily classified into six major zones: cold and sunny, cold and cloudy, warm and humid, hot and dry,
composite, and moderate. Translation of bioclimatic architectural design in the Indian context, therefore, provides a
plethora of experiences and success stories to learn from. Several buildings have come up, fully or partially adopting the
above approach to design [5].
India is having a unique geographical position and a wide range of soil producing variety of fruits and vegetables like
apples, grapes, oranges, potatoes, chilies, ginger, etc. Marine products are also being produced in large quantities due to
large available coastal areas. The present production level of fruits and vegetables is more than 100 million MT and
keeping in view the growth rate of population and demand, the production of perishable commodities is increasing every
year [6]. Number of cold storage units and total storage capacity in some major states of the country are provided in Table 1.
 The farmers usually seek for favorable combination of circumstances to produce cash crops and earn remunerative
prices. The consumers get the supply of perishable commodities with lower fluctuation of prices. Besides the role of
stabilizing market prices and evenly distributing commodities both on demand basis and time basis, the cold storages also
render several other benefits to the farmers and the consumers [4]. Expensive raw materials like dry fruits, chemicals,
essences and processed foods such as fruit juice/pulp, concentrate dairy products, frozen meat, fish and eggs are also stored
in cold storages to properly regulate marketing channels of these products [3, 7].

Table 1: Distribution of Cold storage units in some major states

Cold storages are also essential for extending the shelf life, period of marketing, avoiding glut, reducing transport
bottlenecks during peak period of production and maintenance of quality of produce. The development of cold storage
industry has therefore a very important role to play in reducing the wastages of the perishable commodities and assuring
remunerative prices to the growers.

2. FUNCTIONS OF COLD CHAIN

Cold storages play significant role in stabilizing market prices of various edible products and also evenly distributing them
on demand and time bases. A simple schematic of edible product movement from producer to consumer level is illustrated
in Fig. 1.

Fig. 1: Place of cold storage in cold chain

Around the world, most cold storages provide additional services for their clients which include freezing fresh products,
packing, transport, order picking, distribution, stock control etc. [8, 9]. Typical views of an Indian cold storage is given in
Fig. 2.
The Directorate of Marketing and Inspection, Government of India, Ministry of Rural and Employment is Regulating
Cold Storages industry under Cold Storage Order, 1980 promulgated under Essential Commodities Act 1955. Order
extends to the whole of the India except U.P., West Bengal, Punjab and Haryana. Under the order, it is obligatory on every
operator of the cold storage to obtain a license from the Licensing Officer before using the installation for storing purpose.
 The Government of India also constituted a Central Cold Storage Advisory Committee consisting of official and non-
official members representing the growers, owners, machinery manufacturers, research organizations etc. This Committee
gives advice to the Government on all matters pertaining to enforcement of cold storage orders and the future development
of the industry.

Fig. 2: Outside view of typical cold storages in India cold chain

3. BASIC CLASSIFICATION OF REFRIGERATED STORAGE

Much popular classification for refrigerated storages is based on the preferred temperature range inside the cold
room which is also the most important design parameter. Some broad categories are mentioned below:
1. Controlled atmosphere for long-term vegetable storage;
o
2. Coolers at temperatures of 0 C and above;
o
3. High-temperature freezers at -2 to -3 C;
4. Low-temperature storage rooms for general frozen products, usually maintained at -20 to -29 oC; and
5. Low-temperature storage at -20 to -29 oC, with a surplus of refrigeration for freezing products received at above -18 oC.

3.1 One Storied Refrigeration Facility

In Indian scenario, refrigerated facilities are preferred as single-story structures (a typical one is shown in Fig. 3). Several
modified versions one-story designs are also employed so as to reduce horizontal traffic distances and land costs. A often
preferred alternative is to locate nonproductive services (including offices and the machinery room) on a second-floor level,
usually over the truck platform work area, to allow full use of the ground floor for production work and storage.
Refrigerated spaces are constructed around 8.0 to 11.0 m high. Free space above the pallet stacks is necessary for attaching
air units, air distribution, lighting, and sprinkler lines. Also, adequate clearance between the floor and the structural steel is
desirable for proper forklift operation. Greater clear heights are usually required if automated or mechanized equipment is
used. The amount of floor area required to deal with diverse merchandise storage can be calculated on the basis of 130 to
160 kg per gross cubic meter allowing about 40% for aisles and space above the pallet stacks.

3.2 General Classification of Refrigeration Systems

Refrigeration units commonly employed with the cold storages have two broad categories [2] that are briefed below.
Unitary systems: These are designed by manufacturers, assembled in factory, and installed in cold storage building as a
prepackaged unit. Heat rejection and compressor units are either within the same housing as the low-temperature air
cooling coils or separated from cooling section.
Applied units: These are designed and build from standard components obtained from one or more suppliers. Key
components include compressors, motors, fan-coil units, receivers, pump circulation systems, controls, refrigerant
condensers, and other pressure vessels. Such units denote field-engineered and field-erected systems and form the vast
majority of large cold storages. These generally have a central machinery room or series of machinery rooms convenient for
electrical distribution services, outside service entrance etc. Locations are close to the refrigerated space so as to reduce
piping losses, piping costs, refrigerant charge, thermal losses etc.
 Fig. 3: Schematics of a typical single storied refrigeration facility

4. PLANNING FOR REFRIGERATION SYSTEMS

Refrigeration systems for a refrigerated facility should be selected in an early stage of planning process.
The central compressor room has been accepted standard for larger installations where energy conservation is very
important factor [10, 11].
If the facility is single-purpose like low-temperature storage building, selection of the system type is bit easier. However,
if the commodities to be stored require different temperature-humidity conditions, a system must be selected that can meet
the requirements of isolated rooms at different storage conditions.

4.1 Choice of Refrigerants

For the sake of the environment, the Ozone Depletion Potential (ODP), the Global Warming Potential (GWP) and the Total
Equivalent Warming Impact (TEWI) are the leading criteria in the choice of refrigerant today.
The classic refrigerant is Ammonia (NH3). It is environment friendly (Zero ODP and zero GWP) and has excellent
thermodynamic characteristics. However, under exceptional conditions the gas is toxic and flammable. In case of leakage,
the quality of stored products is affected. At the other hand, hydroclorofluorocarbons (HCFCs) are to be phased out [12-14].
The best emerging technical solution for cold storage refrigeration is now NH3/CO 2 cascade system.
Few important points from preferred refrigerant selection criteria are stated below:
a) Ammonia- low cost, higher COPs, better heat transfer, greater detectability, but toxic. Suitable for food
refrigeration, ice production, pharmaceuticals.
b) CFC family: R-12, Freon- domestic refrigerators, automotive air-conditioning.
c) R-11 large capacity water chillers serving building A/C.
d) R-22 window a/c, large industrial refrigeration systems and a/c commercial buildings. (competes with ammonia)
e) R-502 commercial refrigeration systems (supermarkets)
f) Household refrigerant and air-conditioners: R-134a
g) Evaporator side; -10 C refrigerated space means temp of refrigerant about -20 C (to prevent air leakage) 1 atm:
ammonia, R-134a [15].

4.2 Natural Refrigerants

Natural refrigerants suit nearly all cooling applications. Many substances that occur naturally fall this category. For
example: air, water, carbon-dioxide, ammonia etc. Natural refrigerant have a long track record that proves them to be
efficient, reliable, viable and long lasting system component. The most energy efficient and sustainable cold storage
systems in the future can be expected to be based on natural refrigerants only. The selection of natural refrigerants for a
refrigeration system is usually based on the system’s operating temperature range (see Fig. 4).
 Fig. 4: Selection of natural refrigerants based on operating condition

5. EMERGING ENERGY SAVING CONCEPTS AND PRACTICES

Cold storage, as they are conceived and utilized in present day, reflect uncontrolled consumption of energy. The electric
energy consumption of existing cold storages range between 30-50 kWh/m 3/year.
For blast freezers, electricity consumption levels are as high as 70-130 kWh per ton of product and for plate freezers
typically the range is 60-100kWh per ton. The power consumption depends on the quality of the building, room size, stock
turnover, temperature of the incoming produce, outside temperatures, food condition (whether chilled or frozen) etc. The
total cost of electric energy is near 15-20% of the total running cost [16]. Energy efficiency improvements are targeted not
only at cost reduction but also on environment protection. Some simple but very effective energy saving measures are
discussed in the following subsections.

5.1 Advancing Refrigeration Technology

Intense research is on for past several decades only targeting to develop refrigeration systems with better operating
characteristics, improved energy efficiency and low power consumption. Systems that can run on low grade thermal energy
such as cheaply available waste heat from near by process industries are under intense improvement phase.

5.1.1 NH3/CO2 Cascade System

In such systems ammonia and carbon dioxide are employed as refrigerants in two different refrigeration cycles. Such
systems are still in development stage and newly introduced design instillations are under trial around the globe. The
amount of ammonia charge is very low and safety problems are considerably reduced as ammonia circuit is not in direct
contact with the cold room. At the other hand, carbon dioxide is harmless for most edibles as it is non-toxic, odorless and
non-inflammable. The energy consumption by such a system is lesser compared to conventionally employed units. These
systems are the most promising development for future [17].

5.1.2 Ammonia Absorption Refrigeration Plants (AARP)

At fundamental level, in such a unit, instead of employing a compressor unit, NH3 vapors are caused to be absorbed by
weak solution (changing it to strong solution) which is then pumped to high pressure side [18-20]. Such systems are
designed to run mostly on heat energy and can therefore, very easily operate on thermal energy sources liked waste steam,
hot water, superheated water, hot oil, direct heating, engine/gas turbine/furnace exhaust, low pressure steam from steam
turbine exhaust etc. AARP systems are now also available with 2-stages units. Some advantages of cold storages based on
AARP are given below:
a. The total electricity requirement reduces substantially. Only small DG set is adequate for auxiliary power needs of
cold storage.
b. The bio-mass and other agro-fuels which are available locally can be used to derive AARP. The operating cost and
maintenance cost of the cold storage is very low.
c. The cold storage can store wide range of products at different temperatures due to versatile AARP.
d. Any other simultaneous refrigeration load such as ice Plant and milk chiller can also be met with the same plant.
 Fig. 5: A typical NH3/CO 2 cascade unit available in market

5.2 Energy Saving Strategy during Design & Construction

Construction of an energy efficient refrigerated facility demands:
(i) Correct design,
(ii) High quality material,
(iii) Good workmanship, and
(iv) Very close supervision.
Close coordination between general, roofing, insulations procedures increases the likelihood of a successful good quality
installation. Very spectacular results can be obtained by accurately designing and building new cold storages; performance
efficiency can be improved in several ways [21, 22]. Some measures are stated below:
1. Thicker floor, wall and roof insulation;
2. Surface to be insulated should be completely moisture proof and be reasonably even, free of lumps or holes.
3. Ceiling must be cured before the surface is insulated.
4. Partition wall between the chambers should be insulated both the sides.
5. Use of infeed and outfeed conveyors with lock gates for pallets instead of doors;
6. Selection of right compressor and refrigerant;
7. Appropriate selection of components of the refrigerating process;
8. Application of speed control for compressors to achieve full-load during refrigeration;
9. Use of speed controls for fans;
10. Electronic expansion valves;
11. Adequate pipe dimensions and insulations;
12. Advanced lighting methods;
13. Defrosting using hot gas; and
14. Computer based monitoring, data processing and control system.

5.3 Air Distribution Network

Spatial distribution of the air velocity, temperature and relative humidity is of utmost importance for the adequate
protection of agricultural products in the cold storages. An efficient distribution minimizes the volume of cold air to be
handled and thus reduces over all power consumption [23-27].
 Fig. 6: A schematic of supply and return air arrangement inside a cold room

Fig. 7: Various supply duct configurations

5.4 Energy Saving during Application Phase

In the recent times, the energy efficiency of existing cold stores can be improved considerably. This can be easily achieved
by good house keeping practices. Some of which are mentioned below:
1. Better door discipline,
2. Automatic closing doors,
3. Improved electromechanical control systems,
4. Efficient motors,
5. Minimized pressure difference between compressor and condenser of refrigeration unit,
6. Use of additional insulation, etc.

Compliance with the above measures can result in improvement of energy efficiency by as much as 20% when compared
with what is achieved during normal practice [28].

5.4.1 Energy Saving Lighting System

Installed light systems in cold space contribute in heat load on refrigeration unit [16]. Some suggestions in this regard are
summarized in the Table 2.
 Fig. 8: Typical views of air duct designs and arrangements

5.4.2 Optical Fiber based Lighting System (For Daytime)

Optical fibers are employed for transmitting light signals from one location to another. Same technology is now extended to
carry the out-door light inside the building. Process prevents the entering of heat component of the solar radiation. This can
be very easily extended for cold storage application.

Table 2: Some suggestions to minimize lightening heat load

5.4.3 Initiative in Power Quality & Distribution

As the most of the equipment run on electric power during normal operations, any improvement in power factor at local
level is highly desirable. Some proposed measures in this regard are:
a. Power Factor (PF) may be as low as in the range of 0.70-0.76 and can be easily brought to the range of 0.96 – 0.99.
 This can be achieved by installing capacitors in the electrical system.
b. Maximum efficiency of transformer is near 35% at full load capacity. Thus, if the load on the transformer increases
beyond 80% of the designed capacity, it is advisable to go for a new and bigger transformer.

5.4.4 Initiative in Heat reduction in Buildings

o o
During the summer, building roof temperature is found exceeding 70 C and may reach up to 100 C [29-31]. Following
measures may be useful:
a. By introducing XPS insulation (of about 25 mm thickness) over-deck the incident solar radiation penetration can
be reduced and power consumption can be saved to the tune of 30%.
b. Phase change materials (PCMs) can be employed at the roof surface to absorb solar radiation during the day time
and release the stored heat back to the ambient during night time.
c. Building envelope colour has been chosen considering the optical properties of different colour.
d. It is an established fact that darker colour can absorb and transmit more solar radiation than lighter colour.
e. Light cream shade with light sky border combination can be adopted.
f. Albedo coating for roofs can be applied.

5.4.5 Application of Phase Change Materials (PCMs)

Lot of research investigations are going on in latent heat storage techniques. Employing suitable PCMs, the technique can
be extended to maintain the temperature of the cold room even when refrigeration unit is not running [32]. Some
advantages of using PCMs are mentioned below:
a. Cold applications often need small temperature range.
b. Load curve of cold demand is similar to load curve for electricity demand; this technique may be very helpful
during peak load periods.
c. Cold production is more efficient at lower target temperature.

5.4.6 Solar Photovoltaic Applications

Solar photovoltaic cells directly convert sunlight into electricity. Incorporation of photovoltaic solar cells for generation of
electricity for running cold storage appliances including compressors is keenly awaited. As the technology available now,
monocrystalline cells offer 14-20% conversion efficiency, close to these are the poly or multicrystalline cells with10-12%
conversion efficiency. Cheaper and better technology can certainly change the very face of cold storage industry [33, 34].

Table 3: Examples of Solid-Liquid-Gas PCMs

6. CONCLUSIONS
Some notable points are as given below:
(i) Major portion of electricity is produced by combustion of fossil fuels. This results in increased emission of carbon
dioxide into the atmosphere.
(ii) There is rising awareness amongst the government and common man regarding saving of electrical energy to the
maximum possible extent.
(iii) Cold storages run on electric power and their energy efficient operation can certainly be helpful in achieving
above objectives. This becomes much more important, as in country like India; we need more successfully
operating cold storage units with an even distribution.
(iv) We must timely understand the need of energy efficient cold storage units and prepare for upgrading ourselves
with better technology.
(v) The energy efficiency can be increased by optimizing the freezing processes. Coefficient of performance of
compressor or if definable, the coefficient of performance of whole system can be taken as basis for optimization
analysis.
(vi) These efforts can improve energy efficiency by as much as 50% when compared with normal practice.

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