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Simulating Produce Coolers: Challenges and Opportunities

Simulating Produce Coolers: Challenges and Opportunities. Khaled Mabrouk Operational Engineering Leader - SPS. Presentation Outline. Ag/Produce Business in California Operational Engineering & Farming Produce Cooler Processes Produce Cooler Simulation. America’s Salad Bowl.

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Simulating Produce Coolers: Challenges and Opportunities

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  1. Simulating Produce Coolers: Challenges and Opportunities Khaled Mabrouk Operational Engineering Leader - SPS

  2. Presentation Outline • Ag/Produce Business in California • Operational Engineering & Farming • Produce Cooler Processes • Produce Cooler Simulation

  3. America’s Salad Bowl • Top Crop States:CA $44.7B, IA 31.9, NE 24.4, TX 22.7, MN 20.5 • CA generates 15% of USA crops,and 50+% of USA grown fruits, nuts, and vegs • Watsonville & Salinas Valley generates $4.7B

  4. Along Central Coast (South of Bay Area)

  5. Produce Business • Some companies only fill one or two of these roles, and some are totally vertically integrated.

  6. High Level Look at Growing Process

  7. Detailed Look at Growing Process

  8. OE & Produce Growers Shippers • Optimization models for field planting selection • Best Practice Standard Work for field work • Predictive Maintenance for Field Equipment • Simulation of Produce Coolers

  9. Produce Cooler Example

  10. Produce Cooler Processes

  11. Arrival Rates

  12. Cooling Approach By Product

  13. Produce Cooler Challenges • Produce degrades quickly • Must be in cooler within 2.5 hours of harvesting, takes 30-60 minutes for product to arrive • Each product has it’s own cooling requirements; process and time in process • Different forklifts for inside vs. outside cooler; concern about emission affect on product

  14. Produce Cooler – Simulation Challenges • Must keep track of every pallet • Arrival pattern varies by time of day • Should wait for sufficient number of pallets of a product type before starting cooling process • Use shade bay for staging • 12 pallet forklift

  15. Produce Cooler - Sample Model • There are many excellent simulation software products. • The use of a specific product on this project is not an endorsement for any one specific simulation software. • Let’s RUN THE MODEL

  16. Lessons Learned • Tube capacity should be a multiple of 12 • Extra receiving personnel needed during busy period to reduce in-bound trucks queuing • Room available in Shade Bay Area to convert to other use • Both Dry & Wet Boxes are sized appropriately • Single move for AFC products has significant impact on Average Time to Complete Cooling Process

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