National Horticulture Board

Heralding Golden Revolution

Initiative for the development of Technical Standards and their Adoption / Implementation
Dr. R.K. Sharma Senior Deputy Director National Horticulture Board Ministry of Agriculture, Govt. of India (Former Core Expert (FAO, UN)

Structure of Presentation
Background Status of cold chain in India and need analysis Technical Standards & sections Implementation protocols Conclusion

Background

Early Development CS in India

First cold store in 1940 UP for seed potato. Growth slow till 1950 with low speed compressors & diffuser system. With easy availability of insulating materials, compressors & technology in early 1960s, although quite primitive entailing power high consumption, a good numbers of cold storages were built. Competition started, large capacity, 6-8000 MT, potato consumption increasing, profitable. Promoters also came forward to help grow more & more potatoes. 1980s very little competition, a monopoly-like situation existed, with customer running after promoters to reserve space in cs and paying advance for entire years electricity bill, staff pay and maintenances. 1995 onwards, electricity charges went up every year, leading to no profits as rental rates did not go up. 1998 thinking to sell or revamp it. 1990s, compact coil evaporators also came into existence and were used in place of diffuser or bunker coil system but were not very popular due to their extra cost 2000, Government intervention through subsidy scheme for multi-chamber/-product stores; switch over from diffuser system to fin coil, removal of rental controls by State. Some coy introduced high speed compressors 800~400 rpm, easy maintenance, less power consumption, period also coincided with the diffuser system being replaced by the bunker coil system occupying more space. Recently, new entrepreneurs are more interested in cold storages for various vegetables (green peas, carrots) & fruits (apples, oranges) and milk products etc. to cash in on the 4 opportunities but no standards were in place.

Features of CS Development in India

Total cold storage capacity of 23.6 million MT; against approx total production of 190 million MT of F&V & 20 million MT of others (11%); 80% of existing storage capacity used only for Potato, 17% for multi-purpose and 2% others; More than 65% of existing cold stores located in two states only, namely Uttar Pradesh (41%) & West Bengal (24.5%); Average capacity utilization of cold stores in India is 48% due mainly to technology compatible to single commodity storage.
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Commodity-wise Distribution of Cold Storage (2008)

90.0% 80.0% 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% Potato Multipurpose Fruit & Veg Meat & Fish Milk & Milk Product 8.9% 2.9% 0.5% 0.8% 3.5% 0.3% 1.6% 0.1% Others 26.8% 21.4% 56.1% 76.9%

Number
Total Capacity in country is 24 million MT

Capacity

Total refrigerated (including insulated vehicles) vehicles 25,000 out of which 20,000 are engaged in milk transportation 6

Existing Technology Scenario

Not suitable for providing appropriate storage conditions of uniform temperature, humidity, air circulation and fresh air requirements System designed to store single commodity hence not suitable for maintaining variable temperature and humidity requirements for multiple commodities Skilled Manpower: Cold Stores managed by inexperienced staff, not aware of latest technology and techniques in handling and storing fresh perishable produce to international standards Paucity of literature at all levels: operators, middle level management, truckers, owners.
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Status of Cold Storage Technology

Methods of Cooling
High relative humidity Moderately high RH Ambient atmosphere Modified / atmosphere

Features
Prevents moisture loss produce, meat, flowers in

Status in India
Selectively used Widely used Widely used Started picking up

Short to long term storage with weight loss (potato) Short term storage

Controlled Oxygen sensitive products Long term storage

Status of Pre-cooling Technology in India

Methods of Pre Cooling
Room cooling Forced air cooling Hydro-cooling Forced air evaporative cooling Package icing Vacuum cooling

Status in India
Widely used Selectively used In Nascent Stage Non Existent Non Existent Non Existent

Standards for Cold Storages

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Technical Standards Committee

Terms of Reference DAC notified TSC in June 2009, in NHB to give recommendations in six months Suitable technical standards and protocols for cold chain infrastructure in the Country Mechanism of implementation of such standards and protocols Any other issue that the Committee may consider important or relevant for the subject or may be assigned to it by the Government TSC submitted 3 Standards in February 10.
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Standards - three categories

Cold storages for storage of fresh horticulture products which do not require pre-cooling (Technical Standards Number NHB-CS-Type 01-2010) Multi-commodity Cold storages for short term and long term storage of fresh horticulture products which require pre-cooling and varying storage requirements. Technical Standards Number NHB-CS-Type 02-2010) Control Atmosphere (CA) Storages: Active modified atmosphere systems, control of one or more gases (Oxygen, Nitrogen, Carbon dioxide) within an enclosed space, is a Non-chemical process. Technical Standards Number NHB-CS-Type 03-2010). Cold Rooms (BIS and NHB)
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Two new Standards - proposed

Indian Cold Chain Industry is going through transformation, to fall in harmony with the international standards, and improve the overall economics. The entrepreneurs and end users are seeking information on appropriate technologies & specifications for other related components of cold chain like ripening units, reefer trucks & pack houses etc. Proposal of CII originally to the Task Force, was further improved during the committee meeting, 13.08.2010 in Small Farmers Agri-Business Consortium, after public comments, & workshop 23.10.2010 in NAAS, New Delhi; for Fruit Ripening Standards, and Technical Standards and Protocol for Transportation of Perishable Foodstuff in India
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Standards - sections
Technical Standards Lay-out options Basic Data Sheet Protocols for Implementation Typical Designs as Examples WFLO storage conditions and storage diseases National and international standards and codes

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Standards Database - Word Food Logistic Organization (WFLO)

Temperature Humidity range Carbon dioxide level Loading rate Pull down time Air circulation Ventilation requirement etc
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Standards-Minimum Requirement
Contribution of CII, BIS, BEE, IITD, CBRI, CPRI, GCCA, APEDA, NCDC, DMI, etc. Indian Standards / Codes referred Relevant standard codes of ISHRAE / ASME / ASHRAE/IIAR, & International Codes of ISO Ensure system integrity, efficiency and overall safety, operation, maintenance & servicing etc. Not to be construed as limiting good practice.
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Standards - Emphasis
Coefficient of performance (CoP) Aspects of environmental concerns Safety concerns Human Resource Development As much compatible with the World standards as possible by relying on ISO Standards
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Standards - Coefficient of Performance (CoP)

Optimum energy efficiency should be determining criteria for CoP e.g. optimum values for potato store; CoP of minimum 3.6 at peak load condition 3.3 for holding period, and about 2.5 during lean period is recommended.
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Standards variation/amendment Clause

The standards prescribed are not intended to prevent or discourage variations arising out of new concepts, innovations and R & D in building design & construction, thermal insulation, cooling &refrigeration technology etc. However, any variations or deviations from the prescribed standards must be supported by scientific/ technical details for prior approval of the competent authority, on the basis of merit who may decide the proposal in view of relevant technical details including critical storage requirements, energy efficiency (CoP), availability of Standards, environmental concerns, safety etc. Periodic amendment of standards may also be undertaken by the NHB; in consultation with a committee of subject matter experts duly constituted for this purpose.
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Technical Standards - Protocol for Implementation

New System of Letter of Intent (LoI) introduced
Detailed project report, and pre-inspection Information in Basic Data Sheet with requisite documents Certificate of approval of the building plan by local planning authority Insulation and refrigeration system certified in form of technical data sheet by the manufacturer as per prescribed standards Certificate of registered civil design engineer for BIS, prescribed standards and safety Certificate by site engineer / architect for construction of civil work as per approved building plan, design and completion as per plan and standards by a team constituted by NHB, at insulating & commissioning stages Manufacturer/refrigeration contracting agency certificate of satisfactory commissioning of cooling system, and to provide as built drawings, layout, P&I, electrical drawing and an operation & maintenance manual along with a list of essential spare parts. A set of above documents duly signed by an authorized graduate engineer of the company/agency must be submitted at the time of claim.
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Documents for Civil Structure

Site inspections

Fruit Ripening Standard

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On the basis of ripening behaviour, banana is classified as climacteric fruits, harvested hard and green but fully mature, in which ripening is induced ethylene & controlled by production of ethylene and CO2

Background - Shortcomings
Inadequate building design. Inadequate/ unreliable insulation material. Obsolete and energy inefficient refrigeration unit. Air flow circulation un-uniform. Lack of controlled conditions and technology for ethylene, temp. & RH. Improper ventilation systems and exhaust fans for Co2 emission. Lack of monitoring, control system and display devices. Use of unsafe electrical devices.
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Typical Layout: Number of chamber will depend on

ripening cycle in terms of number of days for which system has been designed, pack house may not be necessarily an integral part of ripening unit, may be at a different site also.

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Type-1. Insulated cold room, ethylene equipment, ceiling mounted fin coil evaporator
(close to wall panel, leaving some gap for suction), condensing unit outside, Perforated plastic crates. Air is allowed through the plastic crates by modifying its flow by tarp etc. ensuring uniform air circulation, uniform ethylene distribution and fruits ripening. Simple ventilation system to provide automatic or manual vent control to keep CO2 within the limits. In an automatic ventilation system, a dual inlet/discharge damper operates in parallel with the fan to allow fresh air from outside to replace the air within the room when venting is required. In manual ventilation, effect is achieved by opening the doors for about 20 minutes every 12 hours after the first 24 hours of ripening. Stacking on floor (single tier) to a reasonable height that facilitate inspection of fruits ripening status. Single tier system generally, (forklifts) need not required; simple hand pallet trucks are more than sufficient.

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This has special air flow system which generates desired static pressure in ripening chamber. Insulated cold rooms have a system of false ceiling, separated and sealed annular space between wall and palletised crates / CFB boxes, with or without air-inlet locking system to isolated designated pallets etc. cool air is routed through false ceiling in to boxes with perforated holes of crates/ CFB boxes which, in turn are stacked in single/ multi-tier system. In case of multi-tier stacking, fork lift operation is necessary.

Type-2:

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Temperature & Humidity Levels

Relative Humidity Level of 90-95%
Produce Banana Mango Papaya Pears Tomato Ethylene Ethy.Expo Ripening Storage Conc.ppm sure (hr) Temp. oC Temp. oC 100-150 24 14-18 14 100- 150 100- 150 100 100- 150 12-24 24-48 20-24 3-5 days * 20-22 20-25 20-25 20-25 About 1314 About 7 About 0 10-13

*To reach breaker stage & 5-16 days for full red stage At a lower temperature but above level of chilling injury

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Banana Ripening Room -Basic Design Data

Room (Specifications, Storage Capacity, Room Volume, Room size & Number of ripening rooms) Palletisation (Type of pallets, Size & Number of pallets, Nos of crates/box layers on a pallet, Number of stacks in case of multi-tier stacking & Pallet lifting system) Temperature (Design based on Ambient Temperature, Target Fruits, Ripening Room Temperature, SST, RH in ripening room, Product Incoming Temperature & Pull Down Period) Insulation (Wall/Ceiling/Floor Insulation; Values of Thermal Insulation; thickness of Insulation for wall, ceiling, floor; Type and thickness of cladding) Door (Door size (w x ht x thick), Hinged door size, Sliding door size & Other type) Refrigeration Load (Tube light fittings, Design Ripening period, Refrigeration Load, Suggested Refrigeration Units, Indicative power input data for refrigeration system & Humidification Load) Ethylene (Details of Ethylene application system, Details of sensors, Details of control system, Electric system of chamber, Details of Humidifier, Measures to ensure proper quality of water for humidifier & CoP)
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Technical Standards and Protocol for Transportation of Perishable Foodstuff in India

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Basis of Standards
European Standards : (ATP Agreement ) Agreement on the international carriage of perishable foodstuffs and on the special equipment to be used for such carriage.

Prescribed by United Nations Economic Commission for Europe (UNECE) & Inland Transport Committee

Established at Geneva on 1Sept.1970, entered into force on 21 Nov.1976. The Agreement and its annexes have been regularly updated. Presently there are 41 contracting parties including Europe, the Russian Federation, United States of America and Uzbekistan.

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Definitions of Various Equipment

1. 2. Insulated equipment Refrigerated equipment Insulated equipment using a source of cold (natural ice, with or without the addition of salt; eutectic plates; dry ice, with or without sublimation control; liquefied gases, with or without evaporation control, etc.) other than a mechanical unit 3. Mechanically refrigerated equipment Class A. between + 12 C and 0 C inclusive; Class B. between + 12 C and - 10 C inclusive; Class C. between + 12 C and - 20 C inclusive. Class D. equal to or less than 0 C; Class E. equal to or less than - 10 C; Class F. equal to or less than - 20 C. 4. Heating equipment
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Testing Procedure
Steps for checking of mechanically refrigerated equipment
Mean inside temperature to be at the outside temperature (+ 30 C). Close all doors & other openings. The refrigerating appliance to be started up at maximum capacity. Readings of outside & inside temperature taken once every 30 minutes. The test to be continued for 12 hours after the mean inside temperature of the body has reached: (a) Either the lower limit of the prescribed class (A = 0 C; B = - 10C; C = - 20 C); or (b) A level not lower than the upper limit for the class (D =0 C; E = - 10 C; F = - 20 C). 6. The test shall be deemed satisfactory if the refrigerating appliance is able to maintain the prescribed temperature conditions during the 12 hour periods.
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1. 2. 3. 4. 5.

Testing Procedure
Refrigeration capacity testing methodology
Ambient temperature +30C

Capacity @ -20C / -10C / 0C

Objective : Refrigeration capacities must be certified Outcome : Test results are valid 6 years
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Measurement & Definitions

Methods and procedures for

measuring and checking the insulating capacity and the efficiency of the cooling or heating appliances.
Definitions of :

K coefficient. The overall coefficient of heat transfer (K coefficient) which represents the insulating capacity of the equipment. Mean surface area S of the body. Mean inside temperature of the body (i).

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Measurement
A.T.P. Rules for Bodybuilder
MEASUREMENT OF THE ISOTHERMAL FACTOR BY THE METHOD OF THE INTERNAL HEATING IN PERMANENT RUNNING (W = ct ET = ct)

Define a K factor of isolation Certificate valid 6 years

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Guidelines For Operators

Transport Temperatures
Frozen products -25C Ice and ice cream -18C Deep frozen foods & Fishery products Chilled products +2C Fresh fish +3C Processed foods, pastry creams, fresh pastries. +4C Milk, fresh cream, cottage cheese and curd Without prior chilling +4/6C Fresh fruit and vegetables +4/6C Flowers
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Guidelines For Operators

Good Loading Practices The refrigerated vehicle is not designed to cool products but to keep products cool. Poor air distribution is one of the primary causes of product deterioration even when unit capacity is more than adequate. Obstruction anywhere around the load can result in hot spots.

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Guidelines For Operators

Airflow

Do not obstruct the evaporator with the loaded goods. Make sure that air circulation is not impeded. Defrost 30 minutes after loading for fresh products. In hot climate vehicle should be parked in the shade. Stop the unit when you open the doors (door switch option). Before loading, pre-cool the box to a temperature at least as low as that of the goods to be transported.
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Conclusion

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Cold Chain - Investment Opportunities

Year 2012-13 Particulars Production 2,575 9,379 64,369 76,293 40,545 650 107,240 148,639 Required Capacity** 386 1,407 9,655 11,444 26,760 98 16,086 22,296 8,424 36,052 Additional Capacity required 346 1,287 9,655 11,284 8,280 68 15,586 3,286 1,944 28,882 Estimated Investment (Rs. In Cr.) 1,558 1,544 1,352 4,454 6,624 54 2,182 8,860 3,888 4,833 22,035 Production 2,958 10,581 71,330 84,820 44,600 750 118,117 163,808 Year 2015-16 Required Capacity*** 1,183 4,233 28,532 33,928 35,680 300 47,247 83,227 9,720 91,195 Additional Capacity required 1,143 4,113 28,532 33,768 17,200 270 46,747 64,217 3,240 84,025 Estimated Investment (Rs. In Cr.) 5,144 4,935 3,994 14,073 13,760 216 6,545 20,520 6,480 14,000 55,074 Apple Other long term storage fruits (e.g. Citrus etc.) Other Fruits Total Potato Other long term storage Vegetables (e.g. Carrot etc.) Other Vegetables Total Multipurpose Storage Transport & Containers Grand Total

*Production & CS capacity in 000 MT ** Estimation targeting 15% of total production except Potato (66%) *** Estimation targeting 40% of total production except Potato (80%)

Source: GAPL Analysis

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Enhanced Capital Investment Subsidy linked to Standards

Pattern of assistance: Credit linked back-ended subsidy @ 40% of the capital cost of project in general area and 55% in case of Hilly & Scheduled Areas limiting to 5000 MT storage capacity per project 1. Multi-chamber CS with mezzanine floors of RCC and or wooden structure: not requiring pre-cooling; civil structure, insulations and cooling system as per prescribed Standards; minimum two chambers - @ Rs 6,000 per MT 2. Multi-chamber and Multi-Product CS: excluding mezzanine floors CS & cost of pre-cooling system; having rack pallets system & forklift, bins, crates and safety devices against accident; civil structure, insulations and cooling system as per Standards - @ Rs 7,000/ MT 3. Multi-chamber and Multi-Product CS: excluding mezzanine floors CS; having on- or off-farm pack house facility of washing/de-sapping, drying, sorting, grading, waxing, packing, pre-cooling system, rack pallets system & forklift (as per site conditions), bins, crates and safety devices; civil structure, insulations and cooling system as per prescribed Standards - @ Rs 8,000/MT 4. Modernization of Cold Storages: up-gradation of thermal insulation, cooling system, refrigeration, air flow, electric installation, handling devices, safety devices etc. Project based @ maximum Rs 1000/MT for (2) and upto Rs 2000/MT for (3) 41 5. CA Storages: @ Rs 32,000 per MT

Possibility for generating synergy

Firming up critical storage condition for fresh Fruits & Vegetables for Indian conditions taking into account locally produced varieties of F&V and agro-climatic condition; so far we have been adopting WFLO standards without fine tuning them for Indian condition Economically viable technology solutions in terms of integrated cold chain for tropical fruits like mangoes, banana and mandarin; so far cold chain technology solutions are, generally, not fitting into economics of trade HRD for middle level managers of industry may be with help of institutions (SUPCO & heat-load). 42

Thank You
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