What Is Cold Storage - Things you need to know

 The term 'cold storage' has existed since immemorial, yet its meaning remains mysterious to many. Have you ever wondered what cold storage is and how it works? It's a fascinating concept that has been around for decades yet remains relatively mysterious to many people. In this blog post, we'll unlock the mystery of cold storage and provide an overview of what it is and how it works.

What Is Cold Storage?

Have you ever marvelled at the abundance of exotic fruits, vegetables, groceries, and ice creams from around the world available to us throughout the year? Well, let me introduce you to the wonders of temperature-controlled warehouses, known as cold storage. These facilities play a pivotal role in our modern food supply chain by providing low temperatures that help perishable products last longer, ensuring a continuous supply of goods all year round. The cold storage sector is experiencing significant growth, with the government focusing on food preservation.

In developing countries, approximately 30% of the food consumed is perishable. The inherent perishability of these products contributes to high market prices, which, in turn, drives the demand for cold storage solutions. Cold storages range from small walk-in coolers or freezers measuring 1,000 square feet or less to massive warehouses spanning 200,000 square feet or more. They are designed to maintain freezing or cooler (chiller) temperatures to cater to various storage needs.

Applications of Cold Storage

The applications of cold storage extend far and wide. These facilities store diverse items such as fruits, vegetables, processed meat, dairy products, spices, dry fruits, jaggery, pulses, frozen foods, chemicals, and pharmaceutical products. By prolonging and preserving the shelf life of food without compromising its nutritional value, cold storage facilities contribute to reducing food waste.

Storing perishable foods at the right temperature is crucial to prevent spoilage, which can lead to undesirable changes in colour, texture, and flavour due to microbial and bacterial activity. Cold storage units provide the ideal environment for product preservation and offer infrastructure facilities throughout the entire supply chain. This includes pre-cooling, weighing, sorting, grading, waxing processes, packaging, and delivery services worldwide through refrigerated couriers. This ensures that the prescribed temperature of the product remains constant until it reaches the hands of the consumer.

Why Cold Storage Today?

Why are cold storages in high demand today? The COVID-19 pandemic and subsequent lockdowns have resulted in increased farm output. Existing cold storage facilities are filling up rapidly due to this growth, and new facilities are expected to emerge to meet the rising demand. This trend also brings stability to the prices of agricultural produce. For example, commodities like onions, which have historically experienced significant price fluctuations, will benefit from sustained supply and more predictable pricing.

The growth in farm output can be attributed to several factors, including migrant and factory workers seeking livelihood opportunities during the lockdown by engaging in agriculture. Favourable monsoon seasons and increased sales of tractors and other farm equipment have further accelerated this growth. As a result, expanding cold storage facilities will help reduce farm produce wastage to less than 15% of total production, ensuring better value for all stakeholders in the supply chain.

Specifications/Requirements of a Basic Cold Storage Unit

It's essential to consider their specifications and requirements regarding cold storage facilities. These include 

100% Power Backup Generators 

Cold storage units require reliable backup generators to ensure continuous power supply, maintaining the required temperature and operating conditions.

Specialised Doors (PUF) or Similar Paneled

These doors are designed with specialised insulation materials like PUF (polyurethane foam) to minimise heat transfer and maintain optimal temperature levels within the storage unit.

Programmed Logic Controller (PLC) Equipment

PLC systems are essential for precisely controlling and monitoring various parameters such as temperature, humidity, and ventilation. They automate processes, ensuring accurate and consistent environmental conditions.

Dock Leveler System 

The dock leveller system allows for the smooth loading and unloading of goods by bridging the height difference between the cold storage unit and delivery vehicles. This system ensures efficient and safe movement of products during logistics operations.

Central Plants Using Ammonia Refrigerant (Freon is Preferred)

Cold storage units traditionally used ammonia refrigerants for cooling purposes. However, the preference has recently shifted to safer alternatives like Freon due to its lower toxicity and environmental impact.

Modernised Insulation Panels

High-quality insulation panels with improved thermal properties are crucial for minimising heat transfer and maintaining consistent temperatures within the cold storage unit.

Reefer Container

A reefer container is a specialised shipping container designed for transporting temperature-sensitive goods. It is equipped with built-in cooling systems, allowing for the safe transportation of perishable products.

Advanced Grader

An advanced grader is used for the automated sorting and grading of products based on various quality parameters such as size, weight, and appearance. This helps streamline operations and maintain product quality standards.

Shuttle Racking System with Remote Control Operation, Bins, Pallets

A shuttle racking system provides efficient storage and retrieval of goods within the cold storage unit. A remote control allows for easy movement of bins and pallets, maximising storage space utilisation.

Automatic Doors

Automatic doors enhance operational efficiency by facilitating the smooth movement of goods in and out of the cold storage unit. They help maintain consistent temperatures and minimise temperature fluctuations during loading and unloading.

Vapour Absorption

Vapour absorption systems utilise heat energy to drive the refrigeration process, providing efficient cooling capabilities for the cold storage unit.

Solar PV Panels

Solar photovoltaic (PV) panels can be installed to generate renewable energy and reduce the reliance on conventional power sources. This helps in achieving energy efficiency and sustainability goals.

These specifications and requirements contribute to the efficient and safe functioning of a basic cold storage unit, ensuring the preservation of perishable products at optimal conditions.

Safety in Cold Storage Units

Safety is of paramount importance within cold storage units. Low temperatures can pose risks to employees, leading to illnesses such as frostbite, frostnip, hypothermia, and trench foot, ultimately impacting their performance. Cold storage using ammonia as a refrigerant can be hazardous and cause burn injuries, whereas those utilising safer alternatives like freon offer improved safety for personnel.

Several precautions should be taken to ensure safety within a cold storage unit. These include monitoring the temperature consistently.

• Providing employees with proper equipment and clothing in adherence to safety standards and implementing a well-designed air distribution system

• Install radiant heaters, warm plates, and air jets.

• Incorporate emergency exits with clear signage.

• Employ alarm systems in case of lock-ins. 

• Ensure emergency lighting with battery backup. 

• Conduct area checks before locking. 

• Strictly limiting access to authorised personnel only

These safety measures foster a secure working environment and enhance overall operational efficiency.

Final Thought

In conclusion, cold storages play a vital role in our modern food supply chain, enabling us to enjoy a diverse range of products worldwide each year. By providing controlled temperatures, these facilities extend the shelf life of perishable items, reduce food waste, and contribute to price stabilisation.