Dr. R.T. PatilDr. R.T. PatilFormer Director, CIPHET, LudhianaFormer Director, CIPHET, LudhianaChairman & ED, Benevole for PHT, Chairman & ED, Benevole for PHT,

Bhopal (ramabhau@gmail.com)Bhopal (ramabhau@gmail.com)

Cold Chain Management Cold Chain Management Requirement in India for PerishablesRequirement in India for Perishables

Production & Post Harvest ScenarioProduction & Post Harvest Scenario

•Agriculture contributes about 16% of GDP, employees 57% workforce and sustains approx over 70% of the population •India produces about 265 million tons of fruits and vegetables and ranks second in world •Post harvest losses are 3-18% amounting to Rs. 45000 crores•Low level of processing of fruits and vegetables at only 2% mainly due to perishability & unprocessable varieties.•Food processing is employment intensive, creates 1.8 jobs directly and 6.4 indirectly for every Rs. 10 lakh investment

High Value Products from WastesHigh Value Products from Wastes

• Pectin from fruit and vegetable peels• Lycopene from tomato peel and oil from seeds• Bio-colour from arhar husk and used flowers • A low calorie sweetner (xyletol) from corn cob and

bagasse • Beta amylase and Xylanase from cereal bran and husk • Enzymes (protease, laccase, peroxidase and polyphenol

oxidase) from green gram husk and wheat germ • Gelatin / Peptides from slaughter house waste• Dietary fibres from fruit pomace• Bio-plastics from tapioca • Aniti oxidents and phenolic compounds from cereal

brans and pulse husks

Integrated Cold ChainIntegrated Cold Chain

Primary Segments 1)Washing and cooling fresh produce, 2) Cool or cold storage (short or long term warehousing of chilled or frozen condition), 3) Distribution (cold transport and temporary warehousing under temperature controlled conditions) 4) Marketing (refrigerated or freezer storage and displays at wholesale markets, retail markets and foodservice operations).

Losses in Absence of Cold ChainLosses in Absence of Cold ChainVariable Global Developed

countries Developing countries

Refrigerated storage capacity (m3/1000 inhabitants)

52 200 19

Food losses (all products)

25% 10% 28%

Losses of fruits and vegetables

35% 15% 40%

Losses of perishable foodstuffs due to lack of refrigeration

20% 9% 23%

Source: IIR. 2009

Benefits of Cooling of Horticultural Benefits of Cooling of Horticultural ProduceProduce

• Reduces respiration: lessens perishability • Reduces transpiration: lessens water loss,

less shriveling • Reduces ethylene production: slows ripening • Increases resistance to ethylene action • Decreases activity of micro-organisms • Reduces browning and loss of texture, flavor

and nutrients • Delays ripening and natural senescence

Effect of Cooling on Storage Effect of Cooling on Storage Food products

Storage potential

at optimum cold temperature

optimum temperature + 10°C

optimum temperature + 20°C

optimum temperature + 30°C

Fresh green vegetables

1 month at 0°C

2 weeks at 10°C

1 week at 20°C

Less than 2 days at 30°C

Potatoes 5 to 10 months at 4 to 12 °C

Less than 2 months at 22 °C°

Less than 1 month at 32 °C

Less than 2 weeks at 42 °C

Mangoes 2 to 3 weeks at 13°C

1 week at 23°C

4 days at 33°C

2 days at 43°C

Apples 3 to 6 months at -1°C

2 months at 10°C

1 month at 20°C

A few weeks at 30°C

Cooling Methods & Steps Cooling Methods & Steps Cold chain step Small-scale Large scale Pre-cooling systems Portable forced air

cooling systems Vacuum cooling Forced air cooling Hydro-cooling

Cold Storage Walk-in cold rooms CoolBot™ equipped cold room

Refrigerated warehouses

Processing- chilling or freezing

“Direct expansion” chilling of bulk milk “instant” chilling of milk

Blast freezing IQF Vacuum cooling of packaged meats

Refrigerated transport USDA Porta-cooler Reefer vans Refrigerated marine containers Refrigerated intermodal containers (for road, rail and sea shipping)

Cooling Methods & Steps Cooling Methods & Steps Cold chain step Small-scale Large scale Pre-cooling systems

Portable evaporative forced air cooling systems

Slurry ice

Cold Storage Zero energy cool chambers (ZECC) Evaporatively cooled cool rooms (charcoal coolers) Underground storage (root cellars) Night air ventilation High altitude storage Radiant cooling Solar chillers

Evaporatively cooled warehouses Underground storage (caves) High altitude storage Radiant cooling

Processing- chilling and freezing

None available None available

Refrigerated transport

Evaporatively cooled insulated transport boxes or trailers

Passive cooling (insulated pallet covers

Storage Life in ZECC Storage Life in ZECC Fruit/Vegetables Months Storage Life (days)

Ambient conditions

Cool Chamber

Bitter gourd May-June 2 6Carrot Feb.-March 5 12Cauliflower Feb.-March 7 12Cucumber May-June 3 8Green chilies May-June 3 6Kinnow January-March 8 60Ladies finger May-June 1 6Mango July 8 15Peas Feb.-March 5 10Plum June 4 10Spinach Feb.-March 3 8

Cold Chain, Food Security and Economic Cold Chain, Food Security and Economic DevelopmentDevelopment

Variable Global Developed countries

Developing countries

Refrigerated storage capacity (m3/1000 inhabitants)

52 200 19

Food losses (all products)

25% 10% 28%

Losses of fruits and vegetables

35% 15% 40%

Losses of perishable foodstuffs due to lack of refrigeration

20% 9% 23%

Source: IIR. 2009. The role of refrigeration in worldwide nutrition

Relationship between Temperature, Relationship between Temperature, Respiration Rate and Deterioration Rate of a Respiration Rate and Deterioration Rate of a

Non-Chilling Sensitive PerishablesNon-Chilling Sensitive Perishables

Temp. °C Assumed Q10

Relative velocity of deterioration

Relative shelf life

Loss per day (%)

0 - 1.0 100 1

10 3.0 3.0 33 3

20 2.5 7.5 13 8

30 2.0 15.0 7 14

40 1.5 22.5 4 25

Product degradation rate decreases by a constant factor (Q10) when the storage temperature is lowered by 10oC

Equiments/ Equiments/ Gadgets Gadgets

for Cool Chainfor Cool Chain

Mobile Cool ChamberMobile Cool Chamber

• The insulated box was designed such that it could hold 8 plastic crates of size 540x360x295 mm in two layer of four each

• Capacity of storage was 100 kg of fruits with 80% filling of each plastic crates

• Costs around Rs. 18,000-20,000/-

Low cost unit saves the fruits from exposure to sunlight and preserves the quality.

Refrigerated transportRefrigerated transport• Further a refrigeration unit is mounted on top for cooling the solution of ethylene glycol and salt stored in the jacket of insulated box.

• This solution is cooled to subzero temperature by running the refrigeration unit by plugging to power source for 8-10 hours before use.

• The refrigerated transport vehicle can lower the product temperature up to 5 °C.

• The wattage of compressor is 0.65 kW.

Ventilated Rail Transport Ventilated Rail Transport • Ventilated rail cars have been

developed by NHB where the slotted holes were provided on front bottom, front and rear ends to accommodate vertical forced air and natural convection due to holes at the bottom.

• At least 15% of total floor area was perforated and labyrinths provided for the protection from rain where ever essential.

• The design provides 5% area at the bottom and 10% area on the top at both from and rear ends.

• The rail trasnports the material as fresh over very long distances

Evaporatively Cooled Room for Storage of Evaporatively Cooled Room for Storage of Fruits and VegetablesFruits and Vegetables

Compared on the basis of 10% physiological loss in weight (PLW) the shelf life inside the room was 34 days for early kinnow, 23 days for late kinnow, 11 days for cauliflower and 4 days for spinach as compared to 21, 11, 5 and 2 days respectively in an ordinary room at the same time.

The cost of the chamber is Rs. 75000 and capacity is 2 tonnes.

•An evaporatively cooled (EC) room (3x3x3m. size) was developed for on-farm storage of fruits and vegetables. •The summer temperature inside the EC room was 5-8C lower than that inside the ordinary room and winter temperature was 5-8 C higher than that inside the ordinary room.

CIPHET Evaporative Cooled Storage Structure CIPHET Evaporative Cooled Storage Structure

• Storage of fruits and vegetables• Evaporatively Cooled Structure (ECS)

maintains a moderate low temperature and sufficiently high relative humidity for short term storage of fresh fruits and vegetables.

• Advantages Low level consumption of

electricity Less initial investment Negligible maintenance cost

• Features– Special design of roof, orientation – Uses wetted pad as cooling medium – 20oC below the outside temperature – An ECS of about 5 -7 tonne storage

capacity may cost about Rs. 1.5 – 1.8 lakh.

Earth Tubes for CoolingEarth Tubes for Cooling • Earth tubes is a passive heating and cooling

technique that uses the constant 50 degree F temperature of the earth to pre-heat incoming air in the winter and pre-cool incoming air in the summer by passing the air through tubes buried under the earth.

• This is an ancient technique used for thousands of years.

• It is best suited for climates that have extreme weather conditions...extreme heat and cold.

• Use of this system reduces the energy demands for cooling and heating the structure and creates better and healthier indoor air environments than conventional systems.

Contd...

Earth Tubes for CoolingEarth Tubes for Cooling • The system provides 67% of the energy required to

heat and cool the required (i.e. 800cfm) exchanged air.

• The tube Length should be max 80 ft as the majority of the heat transfer occurs in first 80-100ft of tube.

• The tube be placed at 6-8 ft below the surface of the earth with slope of the tube at a 2% grade.

• The material of tubes matters little, as long as they are not insulated because the thickness of the material absorbing the heat is actually the tube plus the ground around the tube.

• Avoid draining any roofs or ground areas into the area of the earth tubes.

Refrigerated Cold Storage Refrigerated Cold Storage Cold storage rooms are made of PolyUrethane Foam (PUF) having density of 40+/-2 Kg/ cubic m. Flooring is either bare slab and concrete or aluminium chequered with ply wood. Cladding of the PUF is with 0.5/ 0.6 mm pre-painted galvanised iron (PPGI). Any other cladding viz. SS, aluminium can also be provided.

The facilities in a cold chain are composed of pre coolers, packing houses and cold storage rooms and trucks for transport.

•Pre coolers-to remove field heat rapidly right after harvest to acquire desired conditions. •Packing houses-prepare the vegetables by trimming and cleaning, sorting defective products.•Cold storages-to maintain vegetables at high quality as produced. •Refrigerated trucks/container vans collect to transport them.

ExamplesExamples

Evaporative Cooled Room

Surinder SinghVill Jalalabad, Moga PunjabProfession: Vegetable Farmer

Cold Room used for on-farm short term storage of fruits and vegetables

Cost of structure: Rs 75,000

Cold Chain Initiatives by Madhya Cold Chain Initiatives by Madhya PradeshPradesh

• The Government of Madhya Pradesh proposes to develop modern cold chain facilities in the State.

• The key component of the facility would be the temperature controlled warehouses of varied capacities, refrigerated transport vehicles and other auxiliary facilities.

• Controlled atmospheric conditions are necessary for storing raw materials, intermediate and finished goods.

• The key storage unit will be established at Ratlam on over 1.5 acres of land and would be linked with large number of villages (collection center) via the refrigerated transport vehicles.

• A new concept of village refrigerator would be employed under which 5 – 10 tonnes refrigerator (village refrigerator) would be established in far off villages and would act as miniature cold storage units.

• The key components of the envisaged cold chain are as follows: Two Cold Storages of 3000 MT each and 5 Refrigerated Transport Vehicle of 4 – 5 tonnes along with 20 village Refrigerators of 5 – 10 tonnes each and 50 Cold Chain Containers of 0.5 – 1 tonnes

McDonald’s India’s Cold Chain McDonald’s India’s Cold Chain • McDonald's unique 'cold chain’has been able to both cut down on its

operational wastage, as well as maintain the freshness and nutritional value of raw and processed food products.

• This has involved procurement, warehousing, transportation and retailing of perishable food products, all under controlled temperatures.

• It involved the transfer of state-of-the-art food processing technology by McDonald's and its international suppliers to pioneering Indian enterprises.

From Field to 2º C in 90 Minutes• Trikaya Farms in Talegaon, Maharashtra, is now able to grow iceberg

lettuce all the year round. • Facilities include a pre-cooling room, a large cold room and a

refrigerated van for transportation. • Vegetables are moved into the pre-cooling room within half an hour of

harvesting. The pre-cooling room ensures rapid vacuum cooling to 2º C within 90 minutes.

• The pack house, pre-cooling and cold room are located at the farms itself, ensuring no delay between harvesting, pre-cooling, packaging and cold storage. With this cold chain infrastructure in place.

McDonald’s India’s Cold Chain McDonald’s India’s Cold Chain Flavour and Freshness Locked in at - 35° C •Vista Processed Foods Pvt. Ltd., McDonald's suppliers for the chicken.•The facility includes hi-tech refrigeration plants for manufacture of frozen food at temperatures as low as - 35° C. •The frozen product is immediately moved to cold storage rooms. •Vista has installed hi-tech equipment for both the chicken and vegetable processing lines, which reflect the latest food processing technology (de-boning, blending, forming, coating, frying and freezing). •For the vegetable range, the latest vegetable mixers and blenders are in operation. From Farm to Bulk Cooler in Less than 90 Minutes •McDonald's suppliers of cheese, Dynamix Dairy•They have bulk coolers at all milk collection centres in Baramati•On receipt, the milk is immediately stored in the bulk coolers at the collection centres, to prevent growth of bacteria in the milk and preserve its freshness.

McDonald’s India’s Cold Chain McDonald’s India’s Cold Chain

In the End Bringing it to the Consumer

•Radhakrishna Foodland, which operates distribution centres (DCs) for McDonald's restaurants in Mumbai and Delhi. •DC receives items from different parts of the country. •These items are stored in rooms with different temperature zones and are finally dispatched to the McDonald's restaurants on the basis of their requirements. •The company has both cold and dry storage facilities with capability to store products up to -22º C as well as delivery trucks to transport products at temperatures ranging from room temperature to frozen state.

Growing Processable Varieties and Providing Low Cost Cool Storage are essential for

increasing level of processing and reducing the post harvest losses.

The GDP growth in Agriculture is three times more effective to reduce the poverty compared

to GDP growth from other sources