LLOYD INSULATIONS (INDIA) LIMITED

1. LLOYD INSULATIONS (INDIA) LIMITED MODERN COLD STORE FOR TODAYS COLD CHAIN INDUSTRY

2. INDIA’S FOOD ECONOMY • India is one of the largest producers of fruits and vegetables in the world. • Inadequate handling infrastructure and methods result in a value-loss of over 30% of all fresh produce. • There is no proper Cold Chain for any Agricultural/Horticultural Products

3. THE COLD CHAIN • Harvest • Cooling (pre-cooling) • Cold Storage • Transport to market • Handling at Destination • Handling at home or food service

4. MAINTAINING THE COLD CHAIN FOR PERISHABLES • Protect the product from the sun • Transport quickly to the packinghouse Harvest • Minimize delays before cooling • Cool the product thoroughly as soon as possible Cooling • Keep the product at optimum temperature • Ship to market as soon as possible TemporaryStorage

5. SHADING TO PROTECT PRODUCE FROM SUN

6. COLD STORAGE FACILITIES

7. WHOLESALE MARKET

8. DISTRIBUTION CENTER

9. RETAIL DISPLAYS

10. MODERN COLD STORES FOR TODAYS COLD CHAIN INDUSTRY Cold Stores Plays an Important Role in the Cold Chain

11. DEFINITION OF A COLD STORE • A ColdStore IS A BUILDING OR A GROUP OF BUILDINGS WITH THERMAL INSULATION AND A REFRIGERATION SYSTEM, IN WHICH PERISHABLE FOODSTUFFS CAN BE STORED FOR VARIOUS LENGTHS OF TIMES IN SET CONDITIONS OF TEMPERATURE, HUMIDITY AND APPROPRIATE ENVIRONMENT TO SLOW DOWN DETERIORATION AND SPOILAGE, WHICH WOULD OCCUR IN A NATURAL ENVIRONMENT.

12. DEFINITION OF A COLD STORE • A Cold Store may also be defined as a sealed structure the internal volume of which is maintained at a temperature generally below ambient & and other conditions and used for the storage of goods of all types, mainly foods.

13. DESIGN ASPECTS OF A COLD STORE The design of Cold Stores Stores follows what is known as a ‘Cold Store LOGIC’. The starting point is ‘Product to be stored’. Once the ‘Product’ is identified, it defines the ‘Optimum Storage Conditions’ (Temperature, Humidity and Environment). The ‘Packaging of the product’ both as received and as required at delivery (Handling) determines the type of Racking. The ‘Quantum’ to be handled and Held in Storage outlines the size of the store. The Location and its Ambient conditions then ensure the proper selection of the Five Elements of a Cold Storage.

14. ELEMENTS OF A COLD STORAGE • The five important elements of a Cold Storage are: • Land &Civil Building • Thermal Insulation (of Structure and Piping) • Refrigeration • Material Storage System (Racks) • Product Handling Techniques • Services (Electricity, Water )

15. COLD STORE-SPECIFICATIONS THE CONDITIONS OF STORAGE • Normal temperatures of storage • Differential of controls • Duration of storage, by product or category of product • Method of handling the loads (hand truck, pallet truck, fork-lift truck, rail) • Method of stacking ( height of stacks, size of load units) the • produce which may if necessary, be stored together

16. COLD STORE - SPECIFICATIONS • The Store • Whether it is to be set up in an existing building or a new building is to be constructed • Number of Refrigerated rooms and their configurations • Layout of the store and the machine room • Means of access • Characteristics of pre-existing equipment • Constraints if any • Extensions and future expansions

17. COLD STORE - SPECIFICATIONS • The Environment • Climate: • External temperatures during 6 hour period ( from 9.00 to 15.00) • Maximum • Minimum • Annual mean • Relative humidity : • Extreme values • Rainfall : • Frequency, • Degree of precipitation

18. COLD STORE - SPECIFICATIONS • The Resources Available • Energy resources: • nature, power, method of supply • Water resources: • origin ( river, well, sea ) • temperature and flow • chemical composition • presence or absence of mud or sand • Labor resources: • local availability of labor • technical operating and control personnel • handling and general maintenance • personnel

19. COLD STORE - SPECIFICATIONS Other Specifications: Maximum allowable heat ingress via the walls (5 to 6 W/m2 in frozen and 8 to 10 W/m2 in chill storage as per IIR guidelines) Special requirements of construction (e.g. resistance of the insulation to fire and insects, toxicity of the refrigerant fluid etc.)

20. NEED FOR EFFECTIVE LOW TEMPERATURE COLD STORAGE IN INDIA. India is a large producer of all kinds of Foods, of both Plant (living) and Animal Origin. India is also classified as having a Warm Tropical type climate for most of the year. With high ambient Temperatures (+35°C) and high humidity conditions, preservation techniques involving low temperature storage are mandatory for slower aging, for extending the Shelf Life and less loss of weight, inhibiting the growth of spoilage organisms, and restricting the development of Toxins.

21. NEED FOR LOW TEMPERATURE STORAGE (CONTD.) Fresh fruits and vegetables, being ‘living items’, are affected by the conditions under which they are stored and handled. They continuously influence their storage environment by heat of respiration, by gases exchanged (O2, CO2, C2H2), and the effect of Humidity. Correctly Designed and Operated Refrigerated Storage and proper handling Techniques as envisaged in a Cold Chain have a direct influence on quality at point of Sale and therefore the returns from the produce.

22. CONVENTIONAL COLD STORE • The basic rules for insulation system are : • Using good insulating material having a high insulating value, characterized by a low thermal conductivity • Protection to the insulant against vapour ingress, by providing a Vapour Retarder applied directly to the wall to restrict migration of ambient atmospheric moisture into the cold room interior. Brick wall Final finish Thermal insulation cement plaster Bitumen Vapor barrier Metal mesh • Use an interior lining on insulation essentially to prevent mechanical damage Plaster+Brick+Plaster+VB+Insulation+Finish Approx. 360mm wall LLOYD INSULATIONS INDIA LIMITED

23. CONVENTIONAL COLD STORES EXISTING SITUATION Insulation Material – Expanded Polystyrene, PUF in 100 – 150mm on walls, fixed between wooden framework, Polythene sheet vapour barrier. Floor Insulation with EPS /PUFslabs – 50-100mm. LLOYD INSULATIONS INDIA LIMITED

24. EXISTING COLD STORE - PROBLEMS • Moisture ingress thru porous plaster into insulation resulting into cold spots, Algae formation • Ineffective insulation • Improper Storage • Product decay • Unhygienic conditions • More energy consumption due to more compressor running time LLOYD INSULATIONS INDIA LIMITED

25. EXISTING COLD STORE – PROBLEMS, CONVENTIONAL PRACTICE Sequential application of vapor barrier, insulation & plaster finish What about moisture ingress from inside & life of plaster finish Basic Thermal & Civil Engg. Design problem Brick wall ? Thermal insulation Final finish cement plaster Bitumen Metal mesh Vapor barrier LLOYD INSULATIONS INDIA LIMITED

26. EXISTING COLD STORE – PROBLEMS CAUSES OF THERMAL INSULATION SYSTEM FAILURE • Continuous moisture ingress through plaster • Insulation becoming wet & resistivity decreases • Plaster chipping off • Vapour barrier becomes weak • Formation of cold spots • Deterioration & failure of Thermal Insulation System 1 % OF MOISTURE INGRESS = 5 % REDUCTION IN ‘R’ VALUE DOUBLE MOISTURE ATTACK LLOYD INSULATIONS INDIA LIMITED

27. INSULATION LIFE • Insulation needs to be properly fixed to surface • Insulation needs to be covered & protected • Cold Insulation needs vapour barrier on warm side • Cold storage Insulation needs vapour barrier on both sides to counter moisture attack on both sides. LLOYD INSULATIONS INDIA LIMITED

28. ELEMENTS OF A MODERN COLD STORE The MODULAR Cold Stores requires the following: a) Pre-fabricated Steel Building (Single/Multi Level of storage) b) Pre insulated factory finished sandwich panels c) Energy Efficient Refrigeration systems d) Insulated Doors, e) Loading docks f) Racking system g) Energy Efficient Lighting and Controls h) Forklift Trucks

29. PRE - ENGINEERED BUILDINGS

30. PRE-ENGINEERED BUILDING Pre-Engineered Building is a systematic arrangement of manufactured Engineered components at site.

31. ADVANTAGES OF PEB • Low construction time • Reduced cost • Large clear spans • Low maintenance cost • Ease of future expansion

32. COMPONENTS OF PEB

33. TYPICAL PEB FRAME

34. TYPES OF FRAMES

35. PEB DETAILS

36. GREEN FOOD PARK LTD., BHAGALKOT

37. M/s. EASTERN CONDIMENTS, THENI

38. PRE-FAB PUF/POLYISO PANELS

39. SALIENT FEATURES OF PUF/POLYISO PANELS • High Strength to weight Ratio with Significant saving in Steel works and Load Bearing Foundation resulting in Large Spans • High Thermal Efficiency ensures low Heat Transmission and Low Refrigeration Cost • No Deterioration in Thermal Efficiency with Time • Vertually Maintenance Free • Dimensionally Very Stable • 12 m length Panels ensure less no of Joints and Fast Construction

40. LLOYD PRE-FAB PANELS • LLOYD PRE-FAB PolyIso Panels Have been Tested at FM Approvals Lab at Rhode Island USA and are awarded FM Approvals 4880 Class I Certification. • This is an Unique Achievement for an Indian Manufacturer

41. LLOYD PANEL SYSTEM- FOAM PROPERTIES - THERMAL • Thermal Conductivity @ +10 C -0.023 W/mK or 0.0198 Kcal/hr m deg C • Temperature Range- -180 C - +95 C • Water vapor permeability - 0.12 ng/pasm

42. LLOYD PANEL SYSTEM- FOAM PROPERTIES - MECHANICAL • CFC/HCFC FREE material -blowing agent Pentane • DENSITY - 40 +/- 2 Kg/m3 PIR -45+/-2 Kg/m3 • Compressive Strength @ 10% deformation- 2.1 kgf/cm2 • Tensile Strength- 2.5Kg/cm2 • Bending Strength - 3.0 kgf/cm2 • Dimensional Stability (48 hours)- -25 C - 2.0% +70 C - 2%

43. LLOYD PANEL SYSTEM - FACINGS AVAILABLE • SS 304 with - 0.5 /0.6 mm thickness with Strippable Plastic Film • STELVATITE special Foodsafe coating of British Steel UK - 0.6 mm , 275 GMS/m2 , 15 0 microns film • PLASTISOL COATING HP 200 PVC coated steel 0.6 mm hot dip zinc coated steel to BS EN 10 142: 1991 in Fe PO2 G (Galvatite) with 275 GMS/m2 Galvanizing, • SMP Coated 175 GMS/m2 Galvanized, 240 MPA steel

44. LLOYD PANEL SYSTEM - FOAM PROPERTIES- FIRE RESISTANCE • Horizontal Extent of burn as per BS 4735- < 125 mm (PUF) < 25 mm (PIR) • Fire retarded Foam giving a self- extinguishing Character on removal of ignition source

45. LLOYD PANEL SYSTEM- PANEL DETAILS • DIMENSIONS • Length : upto 12 m long (no joint) • Width : 1000 mm • Thickness : 40/50 60/80/100/120/150/200 mm • JOINING a)Tongue & Groove b) Labyrinth Joint from a continuous line

46. LLOYD PANEL SYSTEM- DOOR DETAILS FREEZER & CHILL DOORS HINGED • Dimensions : 900 mm x 1800 mm 1200 mm x 2000 mm SLIDING • Dimensions : 1500 mm x 2500 mm 2000 mm x 2500 mm • Doors from BG Doors Holland, • Metaflex India

47. LLOYD PANEL SYSTEM - ACCESSORIES DETAILS • Insulated Beam • Foam Tape & Silicon Sealant • Butyl Sealant • One Component Foam • Pressure Relief Valve • Aluminum Extrusions with PVC profiles • PVC Bump rails • Inner & Outer Flashing

48. CONSTRUCTION OF COLD STORAGE WITH LLOYD PANEL SYSTEM LLOYD INSULATIONS INDIA LIMITED

49. COLD ROOM FIXING DETAILS LLOYD INSULATIONS INDIA LIMITED

50. COLD ROOM FIXING DETAILS LLOYD INSULATIONS INDIA LIMITED