THERMAL CONTROL BUSINESS UPDATE - JANUARY 2020

Title-Code: MAHENG14481 Vol 01 Issue 11 • Pages 44 • Mumbai January 1, 2020 • `200 • www.thermalcontrolbusinessupdate.com

Industry leaders craft a comprehensive discussion on the trending investment and opportunities to bloom the cold chain infrastructure, and challenges faced by the cold chain industry in terms of transportation.

Also Read: Energy-efficient cold store construction with fire rated panels

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Low GWP refrigeration for practical environmental solutions

thermal-control-business-update

Conserving consolidated performance of cold room doors

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CONTENTS >>

BUSINESS UPDATE

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15 08 Cover Story

Propelling cold storage capacity Industry leaders craft a comprehensive discussion on the trending investment and opportunities to bloom the cold chain infrastructure, and challenges faced by the cold chain industry in terms of transportation.

Industry Report 12 Energy-efficient cold store construction with fire rated panels 15 Co-efficient and sustainable refrigeration through TES 05

What’s New!

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Market Update

I-Tech Media Pvt Ltd, 604, 6th Floor, Surya House, Station Road, Vidyavihar East, Mumbai - 400077 (India) Tel.: +91-22-25018601

Let’s Talk 16 Low GWP refrigeration for practical environmental solutions 18 Recycling processed water for industrial rationale, a commitment

Facility 22 Conserving consolidated performance of cold room doors

ASSOCIATE EDITOR* Megha Iyer* Email: editor@thermalcontrolmagazine.com

EDITORIAL Liesha Tripathi

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22 Cover Credit: Tushar Kudale ADVERTISING Swati Mistry Email: swati@itmgroupmedia.com Call: +91-9821575178

SUBSCRIPTION Poonam Sukheja itm.subscribe@gmail.com Tel.: +91-22-25018601 *responsible for selection of news under PRB Act

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January 2020

Thermal Control Business Update

What’s new!

BEE sets new standards for Air-conditioners

Adani Group enters cold chain logistics

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n an attempt to bring down the energy consumption and promote energy efficiency, whilst keeping the environment cool, the central government and the Bureau of Energy Efficiency (BEE) have set new energy performance standards for room air conditioners and have mandated to have a default temperature at 24° Celsius (75.2° Fahrenheit).

The new default temperature setting is a mandate for all room air conditioners out of the factory under the scope of the BEE’s star-labeling program from January 1, 2020, as per the notification.

air conditioners was launched and was made mandatory with effect from January 1, 2018.

The latest notification states, “All brands and types of star-labeled room air conditioners, namely, multi-stage capacity air conditioners, unitary air conditioners and split air conditioners which are rated from one star to five star, based on their relative energy efficiencies up to a rated cooling capacity of 10,465 Watts (9,000 kcal/hour) and manufactured, commercially purchased or sold in India, should ensure default setting of temperature in the room air conditioners at twenty-four degrees Celsius with effect from the 1st January 2020.”

According to the new standards, the Indian Seasonal Energy Efficiency Ratio (ISEER), the energy performance index used for room air conditioners, is expected to range from 3.3 – 5 for split air conditioners and from 2.7- 3.5 for window air conditioners. This is also applicable from January 1, 2020. The ISEER and its assessment are based on the bin hours defined in ISO 16358.

Air conditioners consume large amounts of electricity to function and contribute to a significant chunk of the country’s energy consumption resulting in large amounts of carbon dioxide emissions every year. This new regulation is aimed at reducing power consumption and, thereby, the carbon footprint of air conditioners.

According to the government notification, the BEE launched the voluntary star labeling program for fixed-speed room air conditioners in 2006 that became mandatory from January 12, 2009. In 2015, a voluntary star labeling program for inverter room

Previously, the BEE and the Central Public Works Department (CPWD) signed a memorandum of understanding kick starting their cooperation to promote energy efficiency in buildings. The MoU will remain in force for five years unless rescinded by either party.

Thermal Control Business Update

illionaire Gautam Adani’s port-topower Adani Group has acquired majority stake in Snowman Logistics Ltd for 2.96 bln to foray into cold chain logistics. Adani Logistics Ltd, a whollyowned subsidiary of Adani Ports and SEZ Ltd, signed definitive agreements to acquire 40.25 percent stake in Snowman Logistics Ltd from Gateway Distriparks Ltd, the company said in a statement.

Snowman is market leader in cold chain logistics with over 30 percent of capacity amongst integrated organised cold chain service providers in India. The acquisition gives Adani Logistics platform to double its capacity in the next five years. The buyout is in line with the firm’s strategy to move from port gate to customer gate.

“The purchase price of `44 per share represents a 3.2 percent premium to the market price of December 27, 2019 and a 12 per cent premium to 60 day average,” it said. As part of the transaction, Adani Logistics will make a mandatory open offer as per the Substantial Acquisition of Shares and Takeover Guidelines, 2011 for a maximum 26 percent of the public shareholding in the Snowman Logistics.

Acquisition is subject to customary condition precedents and expected to close by March 31, 2020. The company is targeting 15-plus logistics parks, 200-plus rakes, 5 million sq ft of warehouse space, over 15,000 containers, 2.5 million tonnes of grain silos and 25 inland waterways vessels by 2025, the statement said.

Adani Ports Also, on Friday Adani Ports and Special Economic Zone said it would buy a 75 percent stake in Krishnapatnam Port Co Ltd for an enterprise value of ₹135.72 billion ($1.89 billion).

January 2020

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What’s new!

Johnson Controls to build digital platform for smart cities

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31.4 billion Ireland-based Johnson Controls, is witnessing increasing opportunities in India’s smart cities and smart buildings’ space. It is a global diversified technology company specialising in creating intelligent buildings, efficient energy solutions, integrated infrastructure and next-generation transportation systems.

Highlighting the opportunity, Visal Leng, president, Building Solutions, APAC, Johnson Controls, “Globally, smart cities have been a big focus area and opportunity for us.

Johnson strong in hardware capabilities but it is now strengthening its software capabilities. We are building digital platforms that have applications in smart cities and smart buildings. Smart cities in India offers a $27 billion opportunity and already about 5,000 projects in 100 smart cities are under implementation. We have contributed to smart cities globally and with the help of our engineers in India, we are actively engaged in smart city projects and will continue to seek more opportunities in future as well.”

Johnson Controls India primarily provides products, solutions and systems across heating, ventilation, and air conditioning (HVAC), building management system, fire suppression, industrial refrigeration, monitoring, adaptive traffic, retail and marine. The company has expertise across segments including industrial, commercial, retail, airports, metros, datacentres, smart city transportation and surveillance, hospitality and healthcare.

India market Shrikant Bapat, GM, Building Technologies and Solutions, Johnson Controls, India, said, “All our products are focused on ensuring energy efficiency. Cost of electricity is high in India and everyone wants to save on electricity. And the green concept and culture is fast picking up. The company operates five R&D facilities, eight manufacturing units, eight offices and over 40 branches across India. We have scope to expand our existing facilities, and wherever we have necessity, we will explore green-field facilities. If the

Hyderabad market continues to grow the way it is growing now, we could look at establishing a facility here. We cater to both domestic and export markets from our India units. We are currently exporting our products to Middle East and Africa.

Datacentres are a growing segment at present in India where we provide chillers, air distribution systems (ducting, diffusers, filters, grills, dampers and a whole suite of products), building management system products (sensors and server management solutions), and fire detection and separation.

Many datacentres in the country are using our solutions today. We also provide video surveillance and access.”

Major verticals for the company had been commercial buildings sector, followed by the residential space. Within the commercial building space- multi-use properties, datacentres, airports, retail, hotels and hospitals are the key sectors. The company sees double-digit growth in India across its offerings year-on-year and will continue to make significant investments in the country.

Indian team to study climate change in Antarctic Ocean

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team of Indian researchers are set to undertake a scientific expedition at Antarctic Ocean that aims at improving predictions of future climate by reducing uncertainties and increasing accuracies in climate models.

The expedition is slated to last for two month, starting from 9th January, with 34 researchers onboard of an oceanographic research vessel SA Agulhas navigating Mauritius and will sail close to the Antarctic coast. The team will amass samples of air and water samples from around 60 stations along the cruise track, which will provide vital information on

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the state of the ocean and atmosphere in this remote environment and help, understand its impacts on the climate.

According to the researchers representing 18 scientific institutions and universities, the agenda of the initiating this project is to try and understand the formation of the bottom waters in the Antarctic Ocean. “We need good quantification on how they form because these cold waters are one of the major drivers contributing to the global ocean current,” said Anoop Mahajan, who is leading the expedition and is a scientist at the Pune-based Indian Institute of Tropical Meteorology.

Further, team will collect few sediment samples that can aid in reconstructing paleo environmental conditions for select time during the last glacial-interglacial cycles to provide perspectives on future climate change. While some samples will be analysed onboard SA Agulhas, those requiring sophisticated instruments will be investigated on the team’s return to India. The Indian Southern Ocean Research Programme was initiated in 2004 by the ministry of earth sciences to understand how the Southern Ocean, the least sampled ocean in the world, is affected by climate change and how it affects climate change.

Thermal Control Business Update

What’s new!

Crops storage to be a huge concern in India

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ccording to official sources, FCI’s grain stocks (central pool stocks built up under a virtually open-ended procurement policy) is already close to its capacity of 76 million tonne (MT).

The Food Corporation of India (FCI) is badly hamstrung: even as its `1.95-lakhcrore bills to the government remain unhonoured and a debt crisis is looming, it hasn’t yet got the nod for liquidating its patently surplus grain stocks through massive open market operations (OMOs).

According to official sources, FCI’s grain stocks (central pool stocks built up under a virtually open-ended procurement policy) is already close to its capacity of 76 million tonne (MT). Given the expected (low) pace of off take under PDS and other government schemes, the requirement to shift the huge paddy stocks now lying with millers and the mandated rabi wheat purchases effective April, it may face a

Thermal Control Business Update

serious storage problem in a few weeks.

Even if the OMOs result in losses, it would still be a far better way for FCI to manage its operations as the realisations will ease its liquidity issues and enable it to retire part debt. Over three years in a row, the fiscally stressed Centre has made FCI take National Small Savings Fund (NSSF) loans under sovereign guarantee to ensure the corporation’s operations aren’t disrupted.

However, the Centre’s dues to the FCI have now touched an all-time high and FCI is being made to borrow more from NSSF. Sources said FCI had 56 MT of rice and wheat in its own and hired facilities and another 26 MT of paddy (rice equivalent of 17 MT) procured for the central pool lying with millers as of December 1. While the stocks with millers will need to be shifted to FCI warehouses by April, another 16-17 MT of kharif rice is likely to be bought by the corporation over the next four months as

part of kharif procurement. Add to this the rabi wheat purchases to start from April and the storage problem will get worse. According to official data, FCI has purchased 25.2 MT of rice between October and December 2019 in the current kharif season, which is more than half of the total quantity it bought in the whole of 2018-19 (October-September).

From Uttar Pradesh, India’s second-largest rice producer, the agency has procured 2.6 MT for this kharif season, as on December 30 against 1.4 MT in the year-ago period. If this trend continues, FCI will end up procuring about 46 MT of rice this year from across the country, against 34.4 MT in 2018-19.

It has to make room for wheat crop of around 35 MT to be procured in AprilMay out of its total storage capacity. Given that PDS off take from the central pool is expected to be less than 25 MT till April, FCI would have to grapple with a storage problem if OMOs aren’t quickly stepped up.

January 2020

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COVER STORY

Propelling cold storage capacity Industry leaders craft a comprehensive discussion on the trending investment and opportunities to bloom the cold chain infrastructure, and challenges faced by the cold chain industry in terms of transportation.

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he demand for cold chain logistics services in India is primarily driven by bulk agricultural commodities (predominantly potato storage), consumer segments such as frozen food, dairy, confectionery, highvalue fruits and vegetables, and pharmaceuticals segments.

There has always been a shortage of cold chain capacity, but sustained interest and increase in demand from new sectors such as Fruits and Vegetables, Meat, Seafood and bio-pharmaceuticals, which are pre-dominantly exported oriented, has resulted in an addition of about 4.5-5 million tonnes of cold-chain capacity in India.

Stringent US FDA norms have added an obligation for critical temperature monitoring, and hence the preference largely stays for organised players. There has been an increased focus by the government of India on developing farm to fork cold chain infrastructure as seen in the recently announced SAMPADA scheme. Setting up pack-houses is thus being seen as an emerging business opportunity with multi

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product cold stores within 50100 kms from the farm gates as collections centres and increased investment in refrigerated vehicles for Pan India distribution.

Current market trends The industry is growing day by day, and lots of commodities are moving through cold chain across the states. Consumers are flocking to fresh foods. Fresh fruits, food and perishable commodities that were transported through traditional trucks are now moving through cold chain, at a flexible and ambient temperature, further broadening their shelf-life as well as keep the nutrient value intact.

Divyansh Rathore, Business Head-Temperature Controlled Logistics, Future Supply Chain Solutions Ltd., mentions few key points including focus on maintaining temperature integrity of products across the value chain, investments in technology, temperature controlled supply chain, quality compliance, sustainable activities and initiatives by industry.“The industry is

estimated at `25,000 Cr in 2017, the cold chain industry is expected to grow at a rate of 13-15 per cent in the next 5 years thus taking the industry to `50,000 Cr by 2022. 3 key segments namely exports of meat, sea food and bio-pharma products are expected to buoy growth in the cold chain industry”, he adds.

According to Rahul Agarwal, Director, Kool-ex Integrated Cold Chain Solutions, “The current infrastructure is fragmented and there is also a need for creating larger warehouses to enable economies of scale. The next five years will see consolidation and emergence of larger capacity storage and transportation facilities”.

However, the demand for Cold Chain Logistics in India has been intensifying off-lately in both both in the Warehousing & Trucking segments. This is being driven both by Food and Perishable’s sector as well as the Pharmaceutical Sector. There is also a move by strategic players to acquire Cold Chain Assets.

Thermal Control Business Update

COVER STORY

Eason Cheng, Marketing Manager - Refrigeration, APAC, CAREL says that the Indian cold chain logistics market is estimated by recent marketing research to be in continuous and rapid growth for the next few years, and in this scenario, it’s easy to imagine how critical both quality goods preservation during transformation and transport processes and total energy consumption in refrigeration will be.“Remote management is also an important trend in India. With a boom in cold chain construction, however managing these cold chain infrastructures with limited skilled technicians may be a big problem in the near future. Remote management, such as remote alarms, data logs, system analysis and centralised monitoring systems with machine learning and system diagnostics will be the answer”, he adds.

“Over these few years, we have noticed a shift in focus towards an end to end cold chain from just storage.

Technology advancements have also been adopted to offer technology driven solutions specific to Cold Chain, with inclusion of better and more sophisticated machinery and equipment”, says Aditya Vazirani, CEO, Robinson Cold Chain Logistics.

Investments in cold chain infrastructure and uniform distribution of their assets across the country is a prerequisite.

Although cold chain construction is widening its base in India, but scarcity of skilled technicians management seems unyielding in future.

This sector is very quality and compliance conscious and would not like to store its medicines with other products, and regulations can add more quality constrains for product preservation.

Divyansh Rathore, Business Head-Temperature Controlled Logistics, Future Supply Chain Solutions Ltd.

Eason Cheng, Marketing Manager - Refrigeration, APAC, CAREL

Rahul Agarwal, Director, Kool-ex Integrated Cold Chain Solutions

about 20 percent of agricultural revenue in this country. Most of the facilities are located in Uttar Pradesh, Gujarat, West Bengal, and Punjab thus created a lack of storage options in the rest of the country. The lack of development of multi-commodity cold chain facilities can be attributed to multiple factors such as high real estate prices, lack

of clarity on changes in land use pattern and dependence on imported technology for refrigeration.

“The need of the hour is to increase the investments in cold chain infrastructure and to ensure uniform distribution of these assets across the country. There have been numerous

Higher demand and expectations of consumers for frozen and ready to eat food with the quality and hygienic products compel the intensive use of refrigerated rooms and transport means throughout the food supply chain, which improved the life cycle of the product and maintain the nutrition value and freshness of the product. According to Bhupender Singh, MD, Ravi integrated Logistics “New tools and technologies keep now the differentiation is the technology in maintaining the product at the right specifications like temperature, packing, handling, humidity etc., throughout the supply chain”.

Defying the storage challenges The development of cold chain warehouses in India has been skewed towards single product storage of potatoes since it also contributes to

Thermal Control Business Update

January 2020

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COVER STORY

Technology advancements, with inclusion of better and more sophisticated machinery and equipment are driving the Indian cold chain industry.

New tools and technologies add authencity the technology in maintaining the product at the right specifications throughout the supply chain.

Aditya Vazirani, CEO, Robinson Cold Chain Logistics

Bhupender Singh, MD, Ravi Integrated Logistics

state and central level subsidy schemes that provide up-to 35 percent support on the capital expenditure or support at the interest rates thus making ROCE of the investment more viable”, says Rathore. Such subsidies help in funding the viability gap which is a major concern for most investors. An estimated investment of more than USD 150 million has been put into cold chain companies by PE firms which are expected to improve the farm level infrastructure through the development of pack houses, ripening chambers and other allied transportation services. Focus of the industry will thus shift from single commodity storages to modern multi commodity facilities with the scope of consolidation and introduction of better technology thus optimising the entire supply chain Where as Agarwal doesn’t find single commodity storage a big concern. “There is a growing demand for Quality Warehousing in the Pharma Sector. This sector is very quality and compliance conscious and would not like to store its medicines with other

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products”, he adds. Moreover, stringent regulatory norms will further add constraint on having quality storage.

Talking about the storage concerns, Singh says, “Single commodity cold storage consumes more spaces then the multi-commodity cold storage. Cold storage cost will directly dependent on that product pricing.” He further adds that the cold storage used for single commodity doesn’t really fit into the quality requirement, hence are not equipped to handle the products mechanised. The products are handed in traditional ways and manually and are integrated with using old technologies and gases which are harmful to environment. Cold storage facilities are dealing with these challenges by moving in-to a multi-commodity cold storage facility. Interestingly, Mr. Kool is comes with first State of the art fully mechanised cold warehouse at Dadri, Ghaziabad having multi-user, multi-commodity and multi-temperature facilities.

On discussing the same, Vazirani highlights that around 30 percent of agricultural produce is wasted due to lack of available infrastructure in the supply chain. Apart from agriculture, other perishable food, including dairy, poultry, and processed food that require temperature control, go astray following inefficient cold chain. In such a scenario, cold storage warehouses designed to only accommodate single commodity storage, remains to be a challenge, as it hinders the optimisation of already scarce resources. Additionally, these set ups are also a huge burden on the energy and financial resources, which could have been optimised to generate better ROI.

Technological encumbrance in preserving fragile goods Since shelf life of perishable products is less, it is important to have good quality asset for long haul distribution, maintaining accurate temperature and humidity throughout transit.

Agarwal here highlights that cost being the cost of distribution; it becomes a challenge for perishable products which are low in value. Also, since the movement over longer distances is time consuming, the shelf life of the product can be impacted due to delays in transit. Another challenge is the maintaining of temperature in transit. It is crucial to continuously monitor the temperature in real time, as a small excursion can spoil/ damage the product.

Maintaining stable storage conditions both in terms of temperature and humidity is the key in these solutions. Making the total refrigeration system run smoothly to minimise the impact to stored products requires different levels of system control.

Electronic expansion valves, variable speed compressors and fans can maintain the evaporating temperature very stable, in some case, with a variation of just +-0.1, therefore reducing the temperature and humidity impact on the products.

This surely helps provide longer storage times and maintain the products in better condition.

Adding to the description, Cheng says, “Normally however, it means an increase in capital investments, and this will be the biggest challenge for these solutions. We at Carel, believe that energy saving to reduce operating costs and minimise product waste can help users understand how applying advanced technology is a wise investment in terms of both cost and food quality. We have

Thermal Control Business Update

COVER STORY

developed a specific algorithm for the cold room controller to avoid skipping defrosts. High/low voltage protection can also help ensure system reliability.”

Vazrani feel that staff training remains a major challenge. Although domestic freight transport is also one of the key challenges, but it is highly restricted.While railways used frequently, they are not as robust as required, waterways for domestic transport are yet to be developed, and air freight is highly expensive. Hence the most common and affordable mode of transport remains the roadways, which translates into higher time and thus higher risks for damage or inefficient temperature control for perishable goods.

Temperature controlled services, especially transportation, have the dual challenge of being time bound and temperature sensitive. Rathore mentions that ensuring their retention is one of the key challenges this industry faces. Skewed demand for temperature controlled vehicles in the long haul sector (loads concentrated in west and north) also results in reduced utilisation of vehicles since reverse haul movement becomes a challenge.

Most of the food products have a very short life span, and hence require intense temperature management to preserve their shelf life, so transporters’ key challenge is, return load. According to Singh, in India, road transportation is a primary and critical concern, following non-reliable condition of roads and traffic in different areas which increases the time of delivery and painful challenge for the transporters. Also limited time of entry to cities for transport vehicles makes the distribution cost more costly and delay in distributions.

Growth prospects for cold chain in F&B industry Currently most cold storages in India are smaller in size ranging from 5-12000 Pallets. We feel that multicommodity storage facilities with

Thermal Control Business Update

minimum size of 25000 Pallets will be ideal for the future needs and there is tremendous scope to build huge facilities which can cater to domestic as well as exim trading of commodities.

If the storage facility supports the logistics, both inbound and outbound, the service provider can move up the value chain and offer bundled services to the user, thereby ensuring stickiness of customer.

Noting the same, Rathore highlights “We are predominantly focused on the Pharmaceutical sector. However, for the Food & Beverage industry the opportunity lies in building large scale cold storages which will reduce the cost per pallet and a better understanding of product seasonality’s, thereby enabling better utilisation of space.” Consumer awareness towards quality and shelf like is also enforcing companies to use better storage and transportation conditions thereby leading to upgradation towards quality infrastructure.

Whereas according to Singh “Although the current business is passing through the difficult time in the current market scenario but demand is growing day by day but there is still scope of growth, which even can be observed from our growth.

Mr. Kool had started operations with 8

vehicles in March’15 and now we are having 250+ company owned reefer vehicle and our Newly build State of the Art Cold-Storage with 6,000 MT capacity at Ghaziabad location, while another 30,000 MT is in pipeline for the next financial year.”

Final note The F&B sector is expected to grow given the increase in purchasing power of consumers and the fact that consumers have become more conscious of ingredients and labeling as a result of recent scandals in this industry. Given the time bound nature of replenishment to F&B touch points and importance of maintaining quality at each link of the cold chain, focus of the industry will shift from single commodity storages to modern multi commodity facilities with multitemperature distribution options.

This will lead to a consolidation and introduction of better technology thus optimising the entire supply chain. With global sourcing, comes the challenge of managing a multicountry, multi-modal supply chains.

There is hence a growing demand for alternate solutions such as thermal covers / blankets, eutectic plates and non-fossil fuel based technologies that can sustain temperature under extreme conditions for longer durations of time.

January 2020

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INDUSTRY REPORT

Energy-efficient cold store construction with fire rated panels important and is defined as adequate density of the material to be selected.

In a cold store operation, a refrigeration system brings down the temperature initially during start-up, but thermal insulation continuously maintains the temperature later on.

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cold storage is a building or a group of buildings with thermal insulation and a refrigeration system where perishable food items can be stored for a longer period of time under particular temperature conditions, humidity, and appropriate environment to slow down deterioration and spoilage, which would occur in a natural environment. In some countries, cold stores are known as refrigerated warehouses.

Thermal insulation system is a combination of material and ancillaries for application and application methodology, which resists the flow of environment heat to the interior of a building or enclosure that is supposed to maintain a much lower temperature than the exterior (a typical Indian situation where ambient temperatures are higher during most of the year). Thermal insulation will resist the flow of heat by acting as a barrier. The most effective insulation will provide maximum resistance and will be defined by a particular “R” value which will depend upon its thermal conductivity value and thickness. The lower the thermal conductivity of an insulation material, the more effective it will be. Further, mass of the insulation material is also

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Cold stores nowadays are insulated with prefab panels — usually polyurethane foam sandwich panels comprising CFC-HCFC free closed cell polyurethane foam insulation of density 40–45 kg/m3, having thermal conductivity value of 0.023 W/mK, and faced with colour-coated galvanised steel sheet. The panels are manufactured from continuous line machine and finished with tongue and groove edges and typical width of 1.2 metres, length up to 13 metres and thickness ranging from 30–200 mm, though the international market has up to 300 mm.

A higher thickness provides improved energy conservation and extended time period of temperature maintenance during power failure/shutdown.

In addition, PIR is Class “O” rated as per BS:476 Parts 5 and 7. This makes PIR panel fire-safe. Further, PIR panels are tested for “1 Hour” fire rating as per BS EN 1364-1: 2015. This signifies that in the event of a fire inside a cold store, up to 1 hour fire will not affect the panels. This is important for evacuation or for the fire services to get into action.

During cold store construction, there can be instances of fire due to welding sparks coming in contact with foam or cables catching fire, but a fire rated panel will not get affected. There have been instances of cable burning, but only the portion where the cable passes the panel bears the burn marks.

The future trend of cold store construction will involve fire rated PIR panels.

Thermal insulation is not material alone; it is the complete system which includes how it is applied and finally finished or the cladding/covering arrangement which provides protection.

Proper application technique is equally crucial to its success.

In case of cold stores where a lower temperature is maintained, insulation has a major role to play. Insulation will resist the flow of heat from outside. If insulation does not perform effectively, cold loss from inside will take place and load on refrigeration will increase.

Now let us look into the functioning of cold storage and how insulation failure can be identified and what the causes are. Cold store comes under cold insulation. Cold insulation is also defined as anti-condensation insulation.

Whenever there is a situation of a cold body and humidity is present all around, heavy condensation deposition on the cold body will take place, which will make the entire area moist. A more severe situation can be icing formation.

Now, even if insulation is done over the cold body, condensation will still take place as water vapour will pass through the insulation joints. So a vapour barrier is used, which is a solid impervious membrane applied over the insulation joint on the warm side that avoids the water vapour or humidity to pass through it. Vapour barrier is very important in cold insulation. Along with vapour barrier, a proper adhesive and fixing of insulation within a holding framework is essential so that it remains in place for a longer period and performs effectively.

Existing conventional cold storage situation: Introduction Cold storage, primarily meant for potato storage, is an industry existing since independence. These cold storages, usually running from capacities of Thermal Control Business Update

INDUSTRY REPORT

2,000–6,000 tonnes, are found in the co-operative and private sectors. The usual height, on an average, is 40–50 feet, and the base is like a square of various dimensions, depending on the capacity. The main construction methodology involves erection of RCC columns on the periphery, thick brick walls, asbestos sheet roofing fixed over a steel structure or RCC roofing, and a false ceiling.

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The inside construction activities involves: Erection of steel or RCC columns/beams structural network for creating storage spaces of rectangular boxes. The vertical beams are erected first and then the cross horizontal beams are carried up to the walls forming 4–6 tiers. Wooden planks are placed over the horizontal beams, forming racks for holding the storage bags. In between the wooden planks, gaps are maintained for air circulation. Each rectangular box holds approx. 42 bags of 50 kg capacity.

Thermal insulation of usually expanded polystyrene or mineral wool/glass wool slabs in 100 mm is fixed over the walls with wooden battens, vapour barriers (over the plastered brick surface) and finally plastered. The floor is insulated with expanded polystyrene slabs having concrete or stone slab finish. There is a false ceiling of rigid board, and insulation is placed over the false ceiling, with usually rice husk spread uniformly.

Mineral wool/glass wool slabs stored in polythene bags are also used.

Refrigeration system is usually hung on the top or the sides. The temperature desired for potato storage is 2–5°C. Usually, it is a single chamber with no partition walls in between.

The staircase is usually at the centre in front of the door.

Of late, these conventional cold storages have become ineffective and inefficient mainly due to failure of the insulation and refrigeration system. The insulation wears away because of continuous moisture ingress through the plastered surface, leading to the surface becoming wet, loose and chipping off. This exposes the insulation and the wooden battens, which are then attacked by moisture that gradually destabilises the system and makes it ineffective. In cold storages, mice are very common and they destroy expanded polystyrene. In case Thermal Control Business Update

of mineral wool, moisture gets trapped between the fibres, making them heavier and ineffective. The vapour barrier which is on the warmer side of the insulation and fixed over the plastered brick wall slowly and gradually gets exposed to the moisture ingress and gets dislodged from its place.

This results into the inner cold environment coming in direct contact with the outer brick wall. This situation leads to moisture deposition from the outer environment to the wall due to formation of cold spots. So finally, the insulation system is under attack both from the inside and outside. This makes the insulation wet, rendering it ineffective with the passage of time. One percent moisture ingress reduces insulation value by five percent. So at a point of time, insulation loses its resistance property and outside heat ingress increases.

This leads to more running of refrigeration compressor and load on the refrigeration machinery, which in turn increases electricity consumption. With regular power cuts, the interior of the cold storage becomes warmer, leading to product deterioration. So it is a cyclic effect starting from construction methodology or system to improper running and finally attack on product storage life and losses.

Usually, most of the conventional cold stores have single, large chambers, so even when the storage is half filled, the entire refrigeration machinery has to be in operation, making the cold storage operating cost higher and making it a loss-making venture.

Insulation is meant to maintain a desired temperature for some time even when the refrigeration compressor is not functioning. It should not allow heat from the outside to penetrate through the walls and ceiling into the cold storage, thereby ensuring energy conservation. So, the slower the heat passage through the walls and ceiling, the slower would be the gain in temperature inside the cold storage when the compressor is not running.

Consequently, in case of power failure, the inside temperature will remain congenial for a longer period of time. Otherwise, the moment the power goes off, the temperature will rise fast and the products inside will start to decay.

Insulation also helps in the running cycles of the compressor. The compressor can be switched off after reaching a lower or stable temperature and switched on when the temperature rises. The time gap between the “Off and On” function will depend on the efficiency of the insulation system.

In the present situation, almost all the old cold storages in India have faced or are facing inefficient insulation function, leading to refrigeration system failure. The insulation system was found to have lagged or deteriorated partially with the plaster or water soaked, making it ineffective. This leads to formation of cold spots on the walls. The continuous presence of moisture leads to algae formation, making the inside atmosphere filthy and leading to faster deterioration of products. So product decays, higher energy costs, and failure of the refrigeration system have led to many cold storages being closed down.

New insulation system A thorough analysis was done of the existing cold storage problem in India, and it was found that the insulation system needs a complete revamp. The present insulation materials like expanded polystyrene and glass wool/mineral wool that are of open cell structure allow moisture ingress and deposition. The most appropriate modern insulation material for cold storage is a closed cell material like polyurethane foam.

In Indian conditions, both in terms of techno-commercial factors and availability, polyurethane foam has much better insulation properties and higher thermal efficiency in comparison to the materials being used presently (expanded polystyrene/ mineral wool/glass wool). Further, it has a density almost double that of expanded polystyrene. Because of its lower thermal January 2020

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INDUSTRY REPORT

conductivity value, the thickness required for polyurethane foam will be less, thus allowing more storing space inside. Moreover, PUF is not eaten by rats and insects. Another alternative is polyisocyanurate foam, which is an advanced fire safe insulation material.

These two are also closed cell insulation materials with lower conductivity values and higher densities.

While selecting insulation for cold storage, one should differentiate it from an air-conditioned building. A building is a situation where the various occupants including human beings and electronic gadgets generate continuous heat. Further, there are windows and doors through which heat or cold comes in. So the design has to take care of all these aspects and has an effect on the insulation material and thickness, whereas in a cold storage the number of openings are limited and mostly closed and the products once stored will release humidity (whereas in an office building, human beings and electronic gadgets release only heat). Further, the product once cooled will act as a cold body emitting cold.

The problem with a conventional insulation system was not only the material but also the application procedure. Cold storage insulation is different from building insulation. In a normal insulation system, vapour barrier is applied on the warmer side of insulation. But in the case of cold stores, vapour pressure is from both sides, that is the outside environment as well as the inside of the storage while vapour barrier on the warmer side prevents vapour from the outside environment, and there is no system in place to stop the moisture ingress from inside. Since the inside cover or finish over the insulation is plaster, which is again a porous material, it will allow moisture deposition and absorption. So we need an insulation application where the insulation is covered with an impervious cover or

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membrane from both sides. This cover should be non-porous and mechanically stronger.

for RH 85 percent, adequate thickness can be followed.

Another problem was the insulation form.

Insulation is applied in slab form, allowing numerous joints to be properly covered with adhesive. Multiple layers with adhered joints have to be sealed properly, along with the vapour barrier. Presently, all these are highly labour-oriented and any lapse at any step will result into leakage and cold spot formation. Finally, while applying plaster, a reinforcement of wire netting is required above that has a high chance of puncturing the insulation. Plaster is porous and moisture from inside is gradually absorbed by it. So the moisture slowly kills the insulation system from inside.

In terms of vapour barrier, the same can be applied on both sides. Insulation can be laminated on the facing side; similarly, vapour barrier can be applied on the wall. The first layer will be applied on top of a brick wall and then insulation laminated with aluminium foil on one side will act as a vapour barrier on the product storage side. Finally, colour-coated galvanised steel sheet (1 m wide and any length) must be fixed vertically or horizontally onto the supporting structure and the joints sealed with sealants and 75mm wide tape.

Insulation thickness is an important tool for effective performance. If thickness is inadequate, there will be heat ingress continuously. In thickness calculation, humidity is an input. One should take care of considering the maximum RH happening in that area or remaining for sometime during the rainy season. Say, if average taken is 70 percent, then during the peak monsoon period when RH remains 85–90 percent, there will be cold spot formation. So it is advisable to factor in at least 85 percent during design.

Existing insulation system is highly labour-oriented, cumbersome and a basic drawback in terms of application methodology. Continuous supervision is required during construction.

Next comes the basic insulation material, which has a defined property with respect to the water/moisture ingress. An open cell structure material like a fibrous material or steamed, compressed, bead-filled insulation like expanded polystyrene will have the tendency to absorb moisture and retain it throughout. So once moisture enters the material, it will remain there, thereby reducing its efficiency. Ultimately, ice formation also takes place.

Now let us analyse which are the possible controllable factors. These are material, design, and procedure. Material can be changed to closed cell materials like polyurethane foam, polyisocyanurate foam, and extruded polystyrene foam. By opting

Repair of existing cold stores walls and roof insulation The most efficient and latest technology application will be externally fixing of closed cell polyurethane foam insulation slabs with special water-based adhesive onto the walls and then applying polymerised plaster 4–6 mm thick in 2 layers, with synthetic reinforcement superimposed between both layers. The plaster after drying will have a natural finish (white colour). One can alternatively apply 2 coats of proper grade painting over the dried plaster. For the roof, polyurethane foam insulation shall be sprayed to form a uniform homogenous cover over the RCC roof, followed by plaster and suitable waterproofing treatment.

In this way, the wall and roof can be revamped.

Proper application procedure can be formulated, but the extent of control can only be determined during construction.

The application procedure remains labourintensive, requiring a lot of supervision and control. But it has to be seen how well the application is implemented. So changing or shifting to an efficient system is not the final solution — it is only a partial solution.

The total construction time for a typical 5,000-tonne cold storage will remain to be around 9–10 months. So, if the harvesting time is February, construction needs to start by around May–June the previous year factoring in monsoon. So the basic system needs a correction.

For more details, visit: www.lloydinsulation.com Email: kk.mitra@lloydinsulation.com

Thermal Control Business Update

INDUSTRY REPORT

Co-efficient and sustainable refrigeration through TES transferring to the cold storage. It is currently being done through cooling directly via air or liquid loops, which have lower cooling rates and higher pinch point temperature across the TES and cold storage (at the best 7C). The primary drawback is the utilization of sensible capacity of heat transfer medium. An advanced approach is to utilize latent capacity of heat transfer medium such as 2 phase cooling mechanisms.

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he future trends in TES for cold storages are primarily towards an efficient way of transferring the cold from TES to the cold storage units.

Cold thermal energy storage (CTES) systems can be classified according to the type of thermal storage medium. Cool storage media include chilled water, aqueous or non-aqueous fluids, ice, and phase change materials. Energy can be stored in two forms – either sensible or latent.

Thermal energy can be stored in the latent heat of fusion of water (ice) or other materials. Water has the highest latent heat of fusion of all common materials (334kJ/ kg), high density, safety, appropriate fusion temperature and insignificant cost. Although sensible cold thermal storages are simple and costeffective, the size of these devices is quite large when compared to ice storage.

Further classification of this system can be done based on the mechanisms utilized to extract cooling from CTES and thereby Thermal Control Business Update

Ensuring safety of perishable food products Latent energy based CTES systems can reduce the risk of spoilage of perishable commodities in following ways: • CTES can dump large amount of energy in a short period which helps in effective precooling.

The lesser time it takes to bring the core temperature of perishable commodity from ambient to storage temperature, better is the quality/preserved freshness of it. Large scale deployment of such systems at the source of production will result in better quality and higher shelf life of the perishables.

• Traditional cold coupled with CTES can prevent the spoilage of perishable commoditiesby providing cooling during extended power cuts.

• Solar powered CTES based offgrid cold storage systems can even be used in remote areas to prevent spoilage of perishable commodities.

Field of application CTES based cooling systems have following applications: • Using grid powered CTES instead of Diesel based cooling systems. For example,

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refrigerated trucks, tourism boats, ships, etc. If CTES based cooling systems (where ice formation was done on grid) are used instead of diesel-powered alternators on these systems, operational cost decreases and the carbon reductions help in reducing environmental pollution.

Remote areas in developing countries with no or less availability of grid power can utilize solar power to be stored within CTES to provide 24 X 7 cooling.

In developed countries, CTES systems can help in shifting of peak load to an off-peak period.

Future Trends Elucidating on the future trends that can give a face lift to India’s cold, Nitin Goel, CEO, Inficold India Pvt. Ltd., says “It is traditionally accomplished through air or water cooling. However, the parameters associated towards effective heat transfer such as heat transfer area, heat transfer coefficient and sensible heat capacity of air/ water cooling is limited resulting in very low cooling rates. Such a challenge is currently circumvented through the utilisation of lower temperature phase change material instead of water.” However, there is an additional penalty of lower efficiency from electrical energy to storage and later from storage to cooling. A future trend is to utilise two phase cooling medium such as refrigerant, which enables 10x increased heat transfer coefficients and lower parasitic electrical power for pumping the heat transfer fluid.

There are few companies across world such as Inficold, which are working on such next generation technologies.

January 2020

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LET’S TALK

Low GWP refrigeration for practical environmental solutions We view the deployment of smart IoT applications in refrigeration to be the best way to gain an edge in the market – both in view of process and profits

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iscussing about the trends taking over the cold chain industry, Anurag Chandra, Head – Cooling Sales, India Region, Danfoss Industries Pvt. Ltd, mention of having a sustainable future with the adoption of energy efficient refrigerants to develop an ecologically balanced environment in the sector.

How do you see the domestic manufacturing momentum in the refrigeration industry?

What are the market trends?

The current Industry market landscape throws up a few broad issues – lack of skilled labour in the cooling industry, lack of awareness and knowledge about the benefits of using natural refrigerants and a resultant industry wide reluctance to adopt it. Chlorofluorocarbon (CFC), hydrofluorocarbon (HCF) and hydrochlorofluorocarbon (HCFC) are traditional refrigerants that are still widely used across the industry. Natural refrigerants like ammonia, also known as gennext or alternate refrigerants are an environmentally safer and responsible alternative to the traditional refrigerants as they have significantly low ozone depletion potential (ODP) and global warming potential (GWP).

How do you define the role of HFOs compared with natural refrigerants for the industry, in terms of overall environmental impact, energy efficiency and cost?

Hydrofluroolefins and natural

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Anurag Chandra, Head – Cooling Sales, India Region, Danfoss Industries Pvt. Ltd

refrigerants both come under what are called next-gen or alternate refrigerants. They are the more favourable options owing to their low global warming potential (GWP) as well as ozone depletion potential (ODP). The shift towards adoption of energy efficient technologies and the usage of natural refrigerants in the place of HFCs also highlights the responsibility that individuals and industries have undertaken towards a sustainable future.

Moreover, we are committed to facilitating innovations that have minimum economic and environmental costs but faster ROIs, thereby ensuring a better tomorrow for our future generations. Regarding this, we are focused on proactively developing products that operate on low-GWP refrigerants to fulfil the industries’ demands for practical and safe solutions, without compromising on energy efficiency.

How do you view the deployment of smart IoT applications in refrigeration?

Over the last decade, digitalisation

and IoT have transformed the nature of energy consumption and contributed to an increasing scope of energy efficiency and sustainability in the industry. We view the deployment of smart IoT applications in refrigeration to be the best way to gain an edge in the market – both in view of process and profits. It can boost the overall efficiency of manufacturing and industrial processes as it means better connectivity and communication between systems enabling processing of vast amounts of data, in different formats, at high speeds.

As an industry leader in the forefront of digitalisation, Danfoss is working on low-cost and energy efficient solutions that allow for the remote monitoring of cold storages in order to build efficiency across the cold chain infrastructure value chain; which means you can monitor what is happening in your cold room sitting in your office or while on travel, tracking the same on your mobile phone. We are in store for some exciting smart solutions in coming days.

What are the latest innovations (products) you unfolded for the refrigeration industry?

Danfoss India has recently unveiled six new innovative products in the cooling and refrigeration segments. These products were launched by Arvind Surange, Consultant for Cold Chain, at the RefCold India

Thermal Control Business Update

LET’S TALK

2019. Danfoss representatives and several other industry dignitaries.

These new products are set to change the standard of applications for the industrial refrigeration and cooling industry. The products are: The Danfoss Intelligent Purging System (IPS), The Danfoss Gas Detectors, Danfoss Plate Heat Exchanger, The EKE 400, The ICFD and the ICH 2 Step Solenoid Valve. Each of these products emphasizes energy efficiency, ease of use and maintenance and cost effectiveness.

How do you view the RefCold platform for the emerging refrigeration industry?

The RefCold India Expo is a platform for the refrigeration industry to engage in B2B networking and education. This year, we saw that it brought together the key players from the food retail,

food service, processing, and other industries pertaining to food.

The advantage of having events such as these is that it not only brings major players under one roofbut ensures active engagement and exchange of knowledge with one another. This kind of exchange has the potential to change the landscape of the cooling and refrigeration industry, especially where there is an industry wide effort to move in the direction of sustainability and energy efficiency.

At Danfoss, we espouse the values of environmental responsibility and sustainability in all our applications.

This platform has given Danfoss a great opportunity, not only to launch our latest innovations, but also to engage in discussions and disseminate knowledge

about the benefits of using natural over traditional refrigerants, which hasn’t found industry-wide adoption yet in our view.

What are your growth expectations for coming years?

With the launch of our six new products, we have brought forward newer, energy efficient products which will help the industrial refrigeration and cooling industry across the globe and further the scope for sustainable growth for many companies. The promise of increased safety and reliability as well as easy and cost-efficient installation and maintenance of these products will hopefully be incentive for a wider adoption of these products, thereby driving new business for Danfoss in the upcoming year.

Optimising storage facility at varied temperature

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he beginning of every New Year users and varied temperature facilities. brings with it the opportunity and Which was inaugurated on 3rd of Jan’20. the excuse to make a new start. Part We want Mr Kool as a single window of the exhilaration that accompanies solution for all the services related to every January is the optimism that supply chain, logistics and transportation. starting over is possible and the belief of new theandart fully that new beginningsState can create Let mechanized me take opportunity cold to invite you successful outcomes. the Inauguration ceremony of our new warehouse at LalonKuan – Dadri Road, store on 3rd of Jan’2020.

It would be Ghaziabad havingCold Multi-user and Multi So, with the beginning of New year great if you please take out some time for temperature facilities Mr Kool is delighted to announce the the visit, out of your tight schedule. opening of our first State of the art fully Cold Chain Warehousing mechanised cold warehouse at Lal Kuan – Dadri Road, Ghaziabad having multiple This facility is well equipped with state

Pvt Ltd

Thermal Control Business Update

of art Infrastructure and team of experts having plentiful experience in handling wide variety of products & having following facilities: • 6000 pallet positions multicommodity cold Warehouse Temperature ranges from +25 to -25 Degrees • G+4 racking 5 docks for loading & unloading Fully Mechanized State of art Cold storage • 3 tier monitoring system • Online temperature monitoring • ERP based system to enable FEFO/ FIFO • Barcode tracking Facility • Highly reliable reefer machines • Thermograph cold storage to detect any type of leakage • Total 14 chambers for the storage for your valuable goods which enables separate chambers for separate commodities For more information, visit: www.mrkool.in

January 2020

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LET’S TALK

Recycling processed water for industrial rationale, a commitment We have made a commitment at the UN that we will initiate possible measures to comply with the climate change and contribute in building a healthy environment.

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anjeev Sirsi, Associate Vice President - Water Utility, Grundfos India in an interaction with Megha Iyer, talks about their commitment to resent water wastage and elucidates their offerings that can minimise the same at industrial level.

Implementing wastewater management at plant level I think earlier, there were no methods to measure your requirement, usage and wastage of water at your industry or plant level, which further led to wasting water. The moment the industries found ways to measure the water utility, they started realising the importance of making measured use of available water in terms of quality and quantity. That’s when one starts thinking on what’s to be done with this quality. How do I get to know about it, as the pollution control board is making their respective norms stringent every other day? Following to which, every single person, every single body, at the industrial level, municipality level has to ensure on delivering the prescribed quality output. This realisation made it quite simple for Grundfos to understand your expectations and create a workflow pattern by drawing to design that will gratify your needs.

For instance, when you have an air-conditioner in a building, with chiller and pumps; of which, the chiller makes the water cold and the pumps further circulates it throughout. Now the process will run throughout the day,

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and focus on them. Climate change is nothing but scarcity, in terms of unavailability of water, poor access to water, and floods among the others. Why is the water scarcity happening? There is water scarcity because we are mercilessly taking our water from the ground, without realising the consequences.

Sanjeev Sirsi, Associate Vice President - Water Utility, Grundfos India

without realising the requirement.

Hence they started monitoring the parameters, which included user requirement, user interface, being efficient in terms of deliverables with superior quality.

We don’t just deliver consumes unnecessary power, excess water and other natural things that can be controlled and preserved according to the uses. We first study the process, define it for a better understanding and proceed accordingly.

Fighting the environmental challenges Grundfos is completely related to SDG 6 and 13. We have made a commitment at the UN that we will initiate possible measures to comply with the climate change and contribute in building a healthy environment. We also mentioned few points in the SDG that we’re looking at, and pledged on providing safe drinking water to millions of people. So we have certain parameters which are built in into Grundfo’s preamble. This makes things more open to access and drill down the critical aspects

Following a few incidents that shattered several cities, we as a company are involved in programs and plans for rejuvenation of lakes; not as a part of CSR but an attempt to make things more accessible. Grundfos is more conscious on developing solutions to make better water for everybody. We also believe in investing in factories and investing in our people. So, the whole idea is about give it back to the people and to the nature.

So, keeping that in mind when we started off actually, when I started their operations here in India, 20 years back, and with the kind of service profile we hold amidst our customers, today, we are platinum rated organisation.

So there is not a single drop of water which goes out of her factory. It says at LD, what they call the zero liquid discharge, okay. So we get back whatever is the enemy planted back all the trees which were taken out from the compound back into the same place, ensuring that we don’t disturb the ecosystem. Grundfos revolves around our concepts on developing solutions for the user, solutions that are environment friendly.

Thermal Control Business Update

LET’S TALK

We are working with government, smart cities, and stake holders by giving them a direction to pursue the same.

By collaborating with the government and industries, we are being able to save the two essential commodities, water and power. Our whole mantra stands on our operations.

Look at the smart SDG 613 are embedded into our 2025 Action Plan, every decision was to take every product or every solution or we try and see we’ll link it through those.

We were a part of one of crucial projects, where we created flood control stations for one of our clients. We developed a solution for them which can pump out around 48,000 litres of water per second. Apart from setting up a pump for them, we also installed the control units and SCADA. It took 8 years for us to complete the O&M and delivered a final product recently.

Implementing wastewater management in Smart Cities Water conservation is one of the basic agenda in smart cities, as the NRW (non-revenue water) is a grave concern in all the cities. We are collaboratively working with a couple of companies helping them in water conservation and apt utilisation.

In a pumping process, the non-revenue water is ranging between 40 to 50 percent, which means, if I pump hundred litres of water from point ‘A’ but point ‘B’ receive only 45 litres to 50 litres, and the rest is lost. This further makes me clueless about the water loss.

Non-revenue water is basically something that cannot be commercialised. So we are looking at we’re talking to various people saying that Thermal Control Business Update

how can you identify this non revenue water the water which is not being used to make money which means leakages is the main thing and the second portion is a commercial problems and metering problems as a but that’s very less that can be sorted out.

Now what if I can use that power and give you the same, through your DMA (district metered area) and to reuse the additional waste or power. It means, when my system reaches its maximum capacity for the day (10 hours) uninterrupted, it will send signals, an alarm indicating that there might be a problem. This is possible due as we have sensors installed in those pumps; we can locate the problem / leakage area and repair it instantly. I think people won’t mind paying for water meters, so as to make appropriate and controlled utilisation of available water, especially when these water meters are technologically advanced. Consumers today are smart, they know importance of controlled water consumption, and this it can drive the

consumption pattern among the consumer themselves, and further modifies their overall routine consumptions.

Defying infiltration and thefts in water supply There are various techniques to identify water theft or infiltration in water supply, which usually comes along with the installation of pipes and pumps. But it’s all about interest in adopting these technologies and applying them for efficient results. And I think measuring and metering is something which will actually drive your habits. If your habits are in the right way, the water scarcity will get reduced eventually, following which you can push the climate change problems.

There has been a delay in implementing these technologies amidst the consumers as nobody was aware of the importance of metering and analysing the amount of water being utilised and wasted in the process. These issue were never been addressed earlier; January 2020

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LET’S TALK

but ever since several states have started contemplating graphical representation of water consumption, water wasted at different levels, pollution among others, issues related to water and air have gained the momentum at national and international level.

Here, Grundfos comes in with solutions to integrate pumps, chillers and valves. So, precisely, all three of the installed products will work according to the receivable pressure at required density. We not only provide integrated pumps but we also make them smarter.

Automated and integrated pumps for HVAC sector Yes, there. We call it a distributed computing network of the college. So we look at the chiller and valves, take inputs from piping lines and optimise the whole thing so that you don’t use much water. Even if a rupee saved in my power and rupee saved in water for them, it’s a huge cost reduction for them. So, government is not there because they’re not bothered, but today they are under huge pressure.

Why is government coming up with solar scheme because they know they cannot deliver the power and farmers consume 80 percent of the water in India, and the power dependency will be minimised eventually with the application of solar. So the power which is which they were given to the farmer now they can give it to the industry and actually earn revenues. Now if they own revenues, they will come from red to green.

According to the PCB (Pollution Control Board) norms, factories should become ZLD (zero liquid discharge), which means, the factories cannot discharge the used water, but reuse it for various processes. The norms further restrain the industry to discharge

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the industrial waste water to the rivers, as the river water is utilised by the municipalities, and treat them for further distribution to the residential areas. So there are various parameters and depending upon the bandwidth of the company itself was deciding whether or legal ways to discharge it, that’s a different issue altogether, but the norms are becoming citizens are ensuring that we will pollute water.

Latest products and innovations in your basket We are not just product oriented, but are equally keen in providing better solutions for our customers.

Being a pump manufacturer, we don’t just manufacture pumps, but we also create solutions that fit best for the environment and the surrounding where our product will be installed and utilised. And this is where technologies like, AI, smart pumps and smart products comes into the picture. These technologies help you conduct a preventive maintenance on your products before it breaks down.

So we have sensors installed in our pumps that indicate a sign whenever it reaches its exhaust level require a maintenance.

Solutions to be expected in coming years Every day is a discovery. We keep learning new things every day. It’s all about the user expectations and our consumer’s demand, which keeps changing every day. Like, we have implemented AI in most of our functions. When a service

executive couldn’t solve an error or an issue, he use Helo lenses through which he can transmit the system’s data to someone who can bring a solution by considering the required parameters. It’s all about reaching fast to your customers, and provides best fit solutions at the earliest, whilst reducing the machines downtime. Since Helo is quite expensive, so we are looking at plug-in sensors.

Grundfos solutions for Smart factories The idea behind becoming a platinum rated building was, we wanted to walk the talk, we said we will increase efficiency in every product; like treating the water being used in kitchen and reuse the for gardening and related purpose. We have a solar farm counted down which you hardly use because we are using ZLD, we had the air conditioning for the complete office and the factory’s empty office areas. If you actually go by the theoretical means, we required approximately 120 tons of chiller. Instead of going for 120 ton chiller, we went for 80-90 tons chiller, during the night time when the power charges are less, we convert water into ice and remaining 30 tons we take from the melted ice. This is driving my power consumption down.

These are some of the smart things that we have added to our factories. On the water usage, we use pumps to boost the water directly instead of running the pipes and pumps round the clock.

Thermal Control Business Update

FACILITY

Safety measures for handling electrical equipment in HVAC unit The copper or plastic tubing carries the control signals around the building, which is relatively inexpensive. The pneumatic system is very durable, safe in hazardous areas where electrical sparks must be avoided, and most importantly, capable of modulation or operation at part load condition.

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lectric controlled devices are vital in an HVAC unit to monitor and control the overall health of the unit. These devices provide ON/OFF option or a twoposition control to the unit. Low voltage electrical controls are most common n residential and small commercial applications. This voltage signal is controlled by thermostats, and can open gas solenoid valves, energise oil burners or solenoid valves on the DX cooling, control electric heat, operate two position valves and dampers, or turn on-off fans and pumps. A relay or contactor is used to switch line voltage equipment with the low voltage control signal.

The advantage of an electric system is that it eliminates the personnel safety and fire risk associated with line voltage, and allows these control wires to be installed by a non-electrician without requiring conduit and other safety measures.

However, these systems are generally limited to providing on/off control only: they cannot operate at half capacity.

Pneumatic Systems Compressed air with an input pressure can be regulated by thermostats and humidistat. By varying the discharge air pressure from these devices, the signal can be used directly to open valves, close dampers, and energise other equipment.

Thermal Control Business Update

Pneumatic controls use clean, dry and oil free compressed air, both as the control signal medium and to drive the valve stem with the use of diaphragms. It is important that dirt, moisture and oil are absent from the compressed air supply. Instrument quality of compressed air is more suitable for controls rather than industrial quality and requires drying to a dew-point low enough to satisfy the application. The main disadvantages are less reliability and more noise when compared to electronic systems.

Types of Sensors Sensors are an extremely important part of the control system and can be a weak link in the chain of control. A sensortransducer assembly is called a transmitter.

Some electronic sensors use an inherent attribute of their material (e.g., wire resistance) to provide a signal and can be directly connected to the electronic controller. Some sensors may measure other temperatures, time of day, electrical demand condition, or other variables that affect the controller logic. Other sensors input data that influence the control logic or safety including airflow, water flow, current, fire, smoke, or high/low temperature limits.

Electronic Sensors The electronic temperature sensors are classified in following categories: Resistance Temperature Devices (RTD): Resistance Temperature Detectors (RTD) operates on the principle that the electrical resistance of a metal changes predictably and in an essentially linear and repeatable manner with changes in temperature. The resistance of the element

at a base temperature is proportional to the length of the element and the inverse of the cross sectional area.

Common materials used in RTD sensors are BALCO wire, Copper, Platinum, 10K Thermistors, and 30K Thermistors.

• BALCO - A sensor constructed using a BALCO wire is an annealed resistance alloy with a nominal composition of 70 percent nickel and 30 percent iron. A BALCO 500ohm resistance element provides a relatively linear resistance variation from -40 to 250°F. The sensor is a low-mass device and responds quickly to changes in temperature.

When 1000 ohms is measured across the BALCO element, the temperature is approximately 70°F. As the temperature increases, the resistance changes 2.2 ohms per 1°F. • Platinum - RTD sensors using platinum material exhibit linear response and stability over time. In some applications a short length of wire is used to provide a nominal resistance of 100 ohms A platinum film sensor on an insulating base provides high resistance to the tune of 1000 ohms at 74°F. With this high resistance, the sensor is relatively immune to self-heating and responds quickly to changes in temperature. RTD elements of this type are common.

However, having linear resistance with temperature, good stability, and wide range of operating temperature, interchangeable over wide temperature range is one of the advantages.

But a minor resistance change with temperature may decrease the response time, subject to self heating.

For more details, visit, www.cedengineering.com AH Bhatia Email: info@cedengineering.com January 2020

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FACILITY

Kartik Gandhi, Director, Gandhi Automations Pvt Ltd.

Conserving consolidated performance of cold room doors High-speed doors endow rapid access further contributing to the efficiency of a low temp operation through dynamic thermal performance characteristics.

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old storage industry equipment from commercial refrigeration units to the tight-sealing freezer doors that keep cool air in.

Maintaining a chilled ambience is highly essential in industries including pharmaceuticals, food petrochemicals and even fresh flowers. Maintaining your systems performance keeping refrigerated goods fresh and preventing other hazards, such as piled-up of melt water rely on these elements, along with the appropriate handling of these cold storage doors.

The ideal door for chilled areas allows incessant internal airflow. It further ensures that the goods are placed at the right temperature without overtaxing refrigeration systems, whilst reducing the energy cost. Whether it’s a slide door or a foldable door, it needs

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to function consistently at a high level. Facility owners, who neglect to install and maintain high-quality doors, may face complications in maintaining the cold storage temperatures.

Prime Freeze High Speed Doors are perfect solution where cold storage with negative temperatures to of as low as – 22°F is required. The curtain is made of reinforced PVC vinyl with heated side guides. Optionally, a special and innovative insulated flexible curtain is also available.

High Speed Freezer Doors are the solution when temperature control is critical and where forklift traffic is high.

As a facility equipment partner, Gandhi Automation will look into the complete functional operations of your system and will take care of the assembly and maintenance

right from the installation time to the on-going maintenance.

Identifying and managing drips in cold storage doors Always remember that these doors have to get out of the way of traffic.

So here is the dilemma for facility cold storage areas/food processing/ handling facility managers – Do you cover the doorway with a thick panel door and slow down material handling, or compromise the environment to enable fast traffic flow?

Never do it to your doors. This can have extended risk factors when your product has to face an increasing temperature. Moreover, if you want to maintain spec temperature, chillers have to work harder, start up more often further utilising additional energy and cut down the products performance.

Thermal Control Business Update

FACILITY

Recent research from the Door and Access System Manufacturers Association (DASMA) provides some help in making this choice. The study, “High-Speed Doors and Thermal Performance,” finds that today’s industrial and commercial buildings can deliver high door speed and save energy simultaneously, depending on doorway factors.

The DASMA research took into consideration common U-factor, air leakage, and motor horsepower values in a comparison of high-speed doors to conventionally operating insulated doors. Turns out high-speed doors become more energy efficient when cycled 55 or more times per day, according to this analysis. As you may know, in a busy facility, doors can be cycled hundreds and even thousands of times a day.

This new approach views the doors as dynamic parts of the building. Highspeed doors, in addition to providing rapid access, also contribute to the efficiency of a low temp operation through dynamic thermal performance characteristics when the door is not closed.

air is limited and less energy is used.

Minimised temperature variations limit icing in your freezer room. An optional insulating curtain on the warm side reduces condensation and icing. This means fewer requirements for ice and frost removal, no menace of slipping and no indemnity to your refrigeration devices.

Reaping benefits At the GSF DC, 52 dock doors receives product and keeps 460 McDonald’s restaurants supplied with everything from buns to burger patties.

While 55 cycles is the minimum, high-speed doors are typically specified for applications requiring well over hundreds of cycles daily. Thus, the doors studied demonstrate superior overall energy efficiency when meeting the demand for high-cycle operation in a building.

Cold Room Door comprises of wide variety of doors used in various types of cold rooms such as blast freezer door, chiller room door, clean room door, freezer room door among the others. These doors are built with heavy duty and thermally insulated material to keep required temperature maintained, offered range is extensively demanded by clients from allied industries. Technically equipped with smart features that speaks for the versatile performance and long life, this range is tested on quality norms as defined by industry.

The core principle of doors for a cold room is thermal insulation of the doorway through which the products are loaded and unloaded. Gandhi automation’s flexible high speed freezer doors help to meet important cold storage requirements like, unwavering cold temperatures, nominal energy consumption, deference for the cold chain and the deterrence of icing.

The exceptional seal and fast cycle of our high speed freezer doors takes in the cold and dry air, and throw out the hot and moist air out of your freezer room. The loss of conditioned

Thermal Control Business Update

In order to prevent accumulation of ice in the side guides, our cold storage high speed roll up doors are equipped with low consumption electric heating cables in the side posts.

Save energy The fast door cycle and the tight seal reduce transfer of air

Increase refrigeration efficiency Automatic and fast opening and closing improves efficiency of your freezer room

Optimise your cold storage operation Optional insulating curtain and heated side posts reduce icing

Save costs Self-re-inserting door curtain avoids down-time and reduces maintenance

Extremely safe The flexible door curtain is free of rigid components

Long lifetime Gandhi Automations prime high performance doors contain very few wearing parts

January 2020

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FACILITY

Cold store construction technology with pre-fabricated panels Pre-fabricated cold storages panels can ensure high thermal efficiency and low heat transmission, further minimising the overall load in a refrigeration unit.

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doption of new modern technology concept where a complete study of existing construction system is done from basic civil infrastructure to insulation system can take care of existing problems. The massive civil construction involving RCC and brick works also needs to be given a thought. Suppose the brick wall and insulation system is replaced by a system which will serve the purpose of a permanent wall and insulation as a composite system then it becomes very convenient.

This is exactly where modern technology comes. Now we have prefabricated panels that can be permanent walls and insulation, which can further be used for roofs. These panels have closed cell insulation (PUF) and faced on both sides with colour coated steel. These metal sheet bi-facial panels act as vapour barrier and resist flow of moisture from both sides. These steel panels provide mechanical strength and sturdiness in harsh environmental conditions, and do not have any thermal bridge in between to allow heat conduction.

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January 2020

Panel construction The panel system consists of basic pre-fabricated panels made to very tight specification and the full range of accessories required, including insulated doors, pressure relief valves, sealants, mastics, PVC and aluminum profiles, ceiling suspensions and plastic components.

The inner and outer surface of each pre-fabricated panel is made of a 0.5 / 0.6mm thick hot dipped galvanized steel sheet and sandwiched between them is a 40+2 kg/m3 layer of rigid CFC free close cell and also HCFC free and zero ODP Polyurethane foam. Each panel is furnished with a tongue and groove joint and is optionally provided with cam locks jointing arrangements to ensure rigid interlocking between panels.

Each panel is painted with a colour coating of 20-25 microns of architectural polyester on a minimum 175 gms/m2 base of zinc coating.

PVC and plastisol coatings of 200 micron thickness are also available as an option. The standard colour is off-white and the surface of the steel sheets has light- cutting grooves

both to enhance their strength as well as to provide an aesthetic appearance. Plain panels are also available. Panels are usually approx.

1M wide and transportable length up to 12-13 meters.

The pre-fabricated panels are built with a wide variety of doors, hatches and see-through glasses.

Moreover, these doors can be hinged or sliding, manually operated or mechanised.

Usually, standard mechanised doors are designed with a dimension of 1300mm x 2300mm and have electrical heat tracers to prevent freezing of gaskets. Manual sliding doors are designed at a size of 2200mm x 3000mm and normal hinged door of 1220mm x 2010mm.

These panels are manufactured in a semi automated or fully automated continuous machines, with total quality control. The panels are indigenously manufactured and easily available in the country (approx. mfg. capacity 20 million sqm. per annum).

Installation of panels These panels can be directly bolted Thermal Control Business Update

FACILITY

to the RCC columns with apposite binding arrangements. It can be of two kinds:

welding function at site. This makes construction faster without having site welding.

In one method, after fixing the panels horizontally the joints on the column is covered by a flashing.

The roofing arrangement here is a 2-tier system. A false ceiling, with pre-fabricated PUF panels is hung from the roof structure. An insulated „T‟ arrangement is through, on to which panels are placed. Over the steel structure, profile colour coated steel sheet is provided, which stops direct heat or rain to come in contact with the panels below. Exhaust fans are provided to blow out the heat accumulated in between the roof and panels. Chilled water pipes can be carried in this space.

In other type the panels are fixed with a hidden fastening arrangement, which makes an absolute flushed finish. In both case, panels are fixed horizontally and the columns are inside visible only.

Outside an absolute smooth wall will be noticed.

The RCC columns can further be replaced by steel columns, rafters and purlins. This technology of steel is also termed as Pre- engineered Building concept. The entire RCC framework is replaced by structural steel components (vertical-columns, horizontal – rafters). The columns are usually placed at 4-5 meters.

These steel structures are lighter than conventional steel structure.

The steel columns and rafters are tapered reducing the steel consumption. Wall panels are fixed vertically to these purlins. Wall panels can have a maximum length of 12-13m length. Here, horizontal purlins will be on top and bottom, fixed to the columns. The entire steel fabrication is done at the factory and brought to site in knock-down condition, thereby reducing any

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• The construction time required for a typical 5000 tons cold storage with steel PEB structure can be approximately of 90 days. Since time period is short, construction can be taken up 2-3 months before the harvesting time and save interest period.

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Main features of the Panel system are: •

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Thermal Control Business Update

•

A high strength to weight ratio, with significant savings in steel work and load bearing foundations, allowing large spans to be constructed with no intermediate columns Dimensional stability Maintenance-free surface High thermal efficiency ensures low heat transmission, resulting in lower refrigeration load No deterioration of thermal efficiency overtime Panels can be furnished in single jointless height / Length up to 12 meters. Partition wall can be easily erected as the panels are

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self-supporting Panel system incorporates special “L” shaped single piece panels for CORNERS. This avoids wall to wall direct jointing provides additional stability, strength, aesthetical appearance, easy housekeeping etc.

To arrest thermal leakage, joints are finished in tongue and groove configuration which in combination with cam-locks (optional) ensures a foam to foam joint rather than a metal to metal joint.

For additional reinforcement “U/L” shaped flashing are provided at wall to ceiling joints.

Basic advantages of modular construction of cold storage It provides the best possible Thermal Insulation value achievable.

Overall construction period is reduced to a great extent.

With Modern Cold Storage Construction with PU Panels, the internal atmosphere becomes complete hygienic and resistant to fungal attacks. According to available data, this accounts to 30 percent savings of stored products.

The deposition of any kind of impurities over the panels or holes being created by fungus / rats is entirely ruled out.

Are maintenance free, and trouble-free cleaning and washing.

Such systems are in use in the country for more than ten years now.

For more details, visit: www.lloydinsulation.com Email: kk.mitra@lloydinsulation.com January 2020

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HVAC&R SAFETY

Increase in refrigerator’s reliability with safety Dry Rubber Gloves and insulated tools should be used when working on electrical circuits to prevent electrical shock. The floor where you are standing should be insulated and dry. Better still, wear a rubber safety shoes. It is important to note that water is a relatively good conductor of electricity hence ensuring the ground is not wet or damp is a necessity. If you need to climb to access the circuits, use a wooden ladder instead of aluminium ladder as aluminium can conduct electricity easily. Do not contact pipes, water, damp floor or other electrical wires when handling live circuits.

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ou must have some basic knowledge of electricity to ensure safety for yourself and the equipment under repair. Electricity has made our life easier but at the same time it can also injure or kill a person if it is manhandled.

A current of a few milliampere can cause serious injury to our organs even though the voltage is as low as 30V-40V. Higher current flowing through our bodies can even cause death.

now totally disconnected from the mains. If this is not possible, go to the distribution box and trip the appropriate circuit breakers to OFF position. Place a tag to indicate that no one is supposed to ON the circuit breakers as repair work is in progress. Better still, use a lock to lock the distribution box to ensure no one is able to access it.

Instruments such as voltmeter or test pens should be used to check that the wire is not live before you proceed to work with it. When measuring voltages and currents, you must be aware of the maximum readings and set the tool range accordingly. This is to ensure no damage is done to the instrument.

Lighting must be sufficient to see all the circuits under repair. Do not grapple in the dark.

When in dry condition, human skin has a skin resistance of about 400k ohm to 800k ohm but when in wet condition, the resistance can go down to 50k ohm. Therefore, it is a must to ensure your hands are not wet when handling electrical works.

Safety Precaution Disconnect Power to the equipment under repair by pulling the plug out from the electrical socket. This is the best practice as the equipment is

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January 2020

Thermal Control Business Update

HVAC&R SAFETY

Working Alone is not recommended as you may need help from another person in the event of emergency. Always work in pairs to take care of one another.

Safety Glasses should be wore if you are doing drilling work or in areas where debris is present.

Bare Conductors should not be touched with your bare hands unless absolutely necessary. This is also after ensuring that the conductors have been isolated from the mains. Sometimes, there is still some charge left on the capacitor which means you may get electrical shock when you touch the bare wires connected to the capacitor. Capacitor with charge should be discharged by using a resistor before attempting to work on them.

Use One Hand when working with live circuits. Most power systems engineers that work with high voltage transmission and sub-stations will place one hand in their pockets. This is to prevent a complete electrical circuit around your chest in the event of electrical leakage.

Always use measuring instruments such as multi-meter with proper probes to check the presence of electrical power.

Do not touch the live circuits with any part of your body.

Below are nine tips to keep refrigeration system users safe.

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Implement a refrigeration system maintenance program that addresses: wear-out / endof-life; resources, approval and accountability.

Provide refrigeration system, maintenance program and worker

Thermal Control Business Update

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qualification/skill awareness training to all employees and representatives responsible or involved with approving arena maintenance related activities or expenses.

Implement clear procedures that provide guidance and instructions to employees regarding the hazards associated with leaking chillers and required actions.

Implement training and procedures for refrigeration system managers to identify the limitations of different technical qualifications associated with refrigeration systems and engage independent advisors for items considered a cause for concern.

Incorporate safety risk assessments into asset management planning activities for all arena and curling refrigeration systems and mechanical rooms.

Conduct an assessment of the organisational design and assigned resourcing for positions that are accountable for technical system management.

Conduct an assessment and test of ventilation systems to evaluate effective internal ventilation of the mechanical room and external discharge in a manner that minimises risk of exposure.

Inspect all emergency discharge piping and confirm that steering does not enter any spaces that present a risk to public safety.

Make publicly available the following information associated with management and oversight of regulated refrigeration systems, if you manage public assembly facilities (such as arenas): 1. Refrigeration system maintenance programs for regulated equipment; 2. Related capital budgeting plans for supporting maintenance programs; 3. Assessment and audit criteria; 4. Results of assessments and audits; 5. Independent recommendations relating to the condition of equipment, including

recommendations from maintenance contractors for repair or replacement; and, 6. Any other information relevant to the assessment, audits and overall safety of the technical equipment and its management programs.

Servicing Compressors Electrical Safety Tips In some compressors, there are electrical supplies to the compressors even though the compressors are not running. For instance, crankcase heater is sometimes installed to prevent refrigerant from accumulated in the compressor housing.

Hence, it is important to ensure that the main circuit breaker is switched off before you attempt to open up the compressor for servicing.

These are some of the electrical safety tips that you must consider before attempting to do your own repair work.

Always get a qualified technician to do it. Note that the presence of electricity cannot be seen with our naked eye but can only be detected by using appropriate instruments.

Safety being a major concern among all industries, for refrigeration it is electrical safety that puts light on safety requirements. Air Conditioning system and Technical safety BC have given few tips and opinions as mentioned above, on how electrical safety of refrigeration should be taken care of. By following these simple guidelines one can increase the refrigerator’s life.

January 2020

27

CASE STUDY

Lower-GWP enhanced range of condensing units provides cooling for hospital cold rooms

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hen a busy hospital needed to relocate its cold room condensing units, Consultant Neil Garnett knew it was time to upgrade to F-Gas compliant refrigerants.

He chose OptymaTM Plus units, running with R134a and, crucially, R452A. The Danfoss OptymaTM outdoor condensing unit ranges provide high energy efficiency, reliability and low noise operation. Easy to install service and maintain, they all use lower-GWP refrigerants and are Eco-design and F-Gas compliant.

For an efficient system control and reliability, Danfoss has a wide range of components, such as thermostatic and electronic expansion valves, and a brand new enhanced range of solenoid valves - EVR. All these components are qualified for use with lower-GWP refrigerants.

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Background When a hospital in the East of England decided to create a new service building, it also meant relocating seven roof mounted condensing units that were cooling the hospital’s mortuary.

The hospital turned to its framework consultant, Johns Slater and Haward (JSH) and as senior mechanical engineer Neil Garnett points out, it was no easy task. “The hospital can’t just stop working and you can’t predict a quiet period,” Neil explains. “I needed to come up with a design that would let the contractors work fast and at relatively short notice when the opportunity arose.”

The need Transition to lower-GWP refrigerants A recent survey revealed that the condensing units were due for replacement, but this presented Neil with an additional challenge of

convincing a cost-conscious hospital to move away from the ozone-depleting refrigerant R22 to a lower-GWP (Global Warming Potential) alternative, thereby complying with F-Gas regulation.

He says: “I wanted to provide a solution which was fully compliant with F-Gas regulation and the 2020 phase down of higher GWP refrigerants whilst at the same time, ensuring that the new installation met all the operational requirements. “Capital expenditure and life cycle costs, are a priority at any hospital, but they could see it was in their interest to have a unit they could rely on in the future – without having to replace it again. We worked with the maintenance contractor on the specification, and everyone agreed we’re getting what’s best for the hospital.”

Danfoss’ intervention R452A: A like-for-like replacement

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CASE STUDY

Knowing that Danfoss offers a range of lower-GWP cooling solutions, Neil discussed his options with the company’s commercial consultant, Mark Fiddy. Neil recalls: “I knew Danfoss and the OptymaTM range very well. I met with Mark and when I heard about his experience, I felt reassured.

I didn’t realise Danfoss had R452A Optyma TM units and I liked the sound of it.” With Mark’s support, Neil specified seven New Generation Optyma TM Plus condensing units, five MBP units running R134a plus two LBP versions using R452A allowing the mortuary staff the ability to rapidly drop the temperature in two smaller cold roomsto -18 °C. Both R134a and R452A have a GWP level below 2500 and are therefore fully compliant with the F-Gas regulation. “With its lowerGWP refrigerants strategy, Danfoss was clearly the way forward,” says Neil. “The backup support has been good, and the fact that OptymaTM is a packaged unit makes it so much easier for the contractors to work quickly.”

Neil selected the following Danfoss equipment: •

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5 x Optyma TM Plus condensing units with R134a for MBP application 2 x Optyma TM Plus condensing units with R452A for LBP application 7 x T2 thermostatic expansion valves 7 x EVR solenoid valves

Its plug and play and that reduces downtime.

Another fan of the OptymaTM plus condensing units is Les Mitchell, branch manager at Pitkin and Ruddock Ltd, Bury St Edmunds branch, who installed the new system. “We need to make sure the design is right,” he remarks.

“When we see Optyma TM outdoor units specified, it’s always a relief.” “We use Optyma TM ranges wherever possible, anywhere from small cold rooms to large freezer rooms. Everything is in there – filter drier and sight glass – it’s

Thermal Control Business Update

already housed and easy to install.

It’s plug and play - and that reduces downtime. “The units are very quiet so you can use them without disruption or complaints.” Les was also impressed by the timing of the decision to switch to lower-GWP – echoing Neil’s view that it is in his customer’s best interests.

He says: “Given the short lifespan of R404A, the number of those units still being sold seems strange. We’ve been trying to phase out R404A for the last twelve months so it’s helpful that Danfoss are providing clear advice on a compliant replacement.”

The Danfoss Solution The longevity of the product Despite unseasonable weather interrupting installation, the easyto-use nature of the Optyma TM units meant Les and his team could meet the challenging schedule. He says: “The hospital is really pleased. We didn’t cause too much disruption and were able to decide on a day-to-day basis whether we could go ahead.

Even with those gaps, we were still

able to complete the job on time.”

Eight months from the time that the first units were commissioned, there have been no reported issues, and the condensing units are performing well.

“Danfoss condensing units are really efficient,” says Neil. “But it was the longevity of the product that appealed the most. You can’t put in something that’s only going to last for two or three years.”

Very straightforward Importantly, the choice of R452A – and the support from Mark at Danfoss – meant switching to lower-GWP refrigerant was no more difficult than any other job. Les says: “R452A was a new refrigerant for us, but it was really easy. Its wide temperature scale made it a good like-for-like replacement for R404A. As far as possible, everything we install now will be either R452A or R449A.” Neil agrees: “The Danfoss technology is ready and available now, making selection simple and straightforward.”

January 2020

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CASE STUDY

Sustainable Techniques in Refrigerated Space

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ustainability and high performance of refrigerated space used for the preservation of perishable product capitalises on conservation techniques which reduce environmental impact.

The concept embraces a variety of techniques including the exchange, or supplementation of mechanical refrigeration systems

by Thermal Energy Storage (TES) that incorporate Phase Change Materials (PCM), and advanced refrigeration control. By using TES as a part of an integrated system, overall efficiency can be improved resulting in lower energy costs.

Introduction The Latent Energy Cycle To properly understand the way TES can be used in a refrigerated environment, it is important to understand the difference between sensible and

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latent heat. When thermal energy is transferred into or out of a perishable product, that product becomes measurably warmer or colder. This is called sensible heat, and can be measured using conventional temperature measurement devices. Latent heat in this case occurs when a material is going through a phase change from solid to liquid and that material is capable of absorbing thermal energy without becoming measurably warmer or colder for the duration of the phase change process. Once the phase change is complete, the product heat becomes sensible (and measurable) again.

TES modules containing PCM are placed above the storage racking so that they are above the product and are also placed inside the air stream of the evaporator

fans. This allows heat to flow via convection to the TES when the air units are off. Once the TES reach their thermal capacity absorbing heat, the air flow from the evaporator fans can efficiently and directly cool the cells back to the solid state.

The phase change materials in the TES system provide latent heat capacity to the refrigerated environment, allowing the TES to absorb a large amount of thermal energy from the surrounding environment while remaining at the same temperature. This functions to allow the refrigerated environment to maintain a cold operating temperature for an extended time period without running the mechanical system(s).

The freezer TES systems operate on a continuous 24-hour cycle.

The latent heat capacity of the system reduces the frequency of compressor cycling by providing a larger heat sink on which the compressor can now work on while operating a t a higher, more efficient, suction pressure.

Effects on Operating Efficiency By employing TES in a refrigerated space, measurable improvements in equipment and system efficiency can be realised. By managing the existing refrigeration equipment to leverage the thermal capacitance of the TES, existing refrigeration equipment is able to operate at peak design efficiency, often exceeding typical performance.

This effectively improves the coefficient of performance of the equipment, EER of the compressor and the SEER of t he system.

Thermal Control Business Update

CASE STUDY

Higher Suction Pressure Compressors for refrigeration systems are designed for peak conditions.

Operation is typically at partial load conditions for the majority of the life of the compressor. By imposing an additional load (TES) on the system, the compressor will operate at higher suctions and improved horse power/ ton, EER and SEER. The relationship of BHP/ TR as pressure goes up and down. These are actual ratings of industrial large bore and stroke reciprocating compressors pumping R -22. This shows a 2.7 percent improvement in BHP/ TR for a 1 degree rise in suction temperature.

In small bore hermetic compressors this is more dramatic due to the small bore and higher operating speeds. By increasing the run time at higher suction temperatures the net or SEER efficiency is improved significantly.

As air unit coils lose their load, the ΔT becomes small, the liquid flow is shutoff by the expansion valve, so the long circuits boil off the liquid refrigerant and the rest of the circuit superheats the gas returning to the compressor. This is one of the built in inefficiencies of DX systems because expansion valves are designed to operate as a function of superheat. Unlike industrial coils, a re-circulated system where liquid is over fed to maximise coil heat transfer, DX coils leave about 30 percent of the coils surface to make sure t he DX valve can provide superheat with which to regulate its DX valve.

The superheat is a menace for several reasons. It forces the compressor to operate less efficiently by pumping superheated gas instead of saturated gas and it tends to wire draw the parts inside the DX valves. The compressor itself suffers because it now operates at higher outlet temperature s, higher compression ratios and with less efficiency. More blow-by is experienced which causes wear, breakdown of oil, etc. By forcing the compressor to operate at higher and more efficient suction conditions, the system operates at a lower horsepower

Thermal Control Business Update

per t on (better coefficient of performance, EER, SEER, etc.).

expense, extended equipment life, and a reduction in maintenance costs.

Reduced Runtime and Capacity The increased thermal capacity offered

by TES can allow for refrigeration equipment sizing to be skewed towards average load rather than peak load, because the additional thermal mass allows the room to warm more slowly, and the TES absorbs heat more efficiently than stored product both in rate of transfer and in its heat capacity.

Effective Envelope Improvement By utilising TES, the room envelope efficiency is effectively improved by limiting the impact of infiltration.

Placing TES above product, near doorways, along ceilings, and other sources of infiltration, the impact of infiltration on stored product quality can be reduced as the TES will absorb infiltration more efficiently than the stored product.

Otherwise, the compressor would cycle repeatedly from high down to low pressure when at lower than peak load condition. This is necessary the keep product temperatures within their range. TES prevents the short cycling and permits the compressor to operate for longer periods then turn off for extended periods while the TES cool the room.

Intelligent Defrost Coolers with temperatures at or near 35 °F require defrosting to melt the ice formation during operation. Less ice and moisture is extracted with the TES system because the coil has been forced to operate more time at higher temperatures. While system designs vary, those with greater coil surface can operate at higher temperatures.

Repeated cycling is mechanically detrimental to the fans and compressors. Compressor runtimes have been effectively reduced by as much as 50 percent, using the TES system.

Traditional defrost cycles: • 45-60 minutes per defrost, 3 -4 defrosts per day.

• Surface temperature of heating element over 250 F degrees for duration. Coil can reach 100F. • Results in steam blown into space which will condense and freeze as frost on any surface.

Also, TES can mitigate the need for backup refrigeration capacity in certain situations. This can lead to a reduction of refrigeration equipment capacity and runtime required to condition the space, resulting in lower up-front

TES defrost cycles: • 20-25 minutes per defrost, only as

January 2020

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CASE STUDY

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needed; in freezers 1-2 defrosts per day, some coolers much less frequent (once per week) Temperature terminated defrost Demand defrost based on coil efficiency Heaters not operated for entire duration of defrost Observation of a proper drip-down time to let the coils dry before initiating fans

By optimising cooling heat transfer temperatures in both the TES and in the evaporator, the infiltration air load is shifted and less moisture extracted.

By managing the defrost process, less moisture from the evaporator coils blown back into the room after defrost.

Fewer defrost cycles lead to more uniform product temperatures, leading to less product shrinkage in open, unwrapped product.

Dynamic System A refrigerated storage environment changes over time. The amount and type of product can change, as well as daily operations. By employing a cohesive control strategy involving the use of TES, the refrigerated system can adjust to both daily and general use fluctuations while protecting stored product and improving energy efficiency. The system can dynamically adjust control strategy to reflect real world conditions.

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For example, if a controlled space is in a shifted demand period, but enough heat is introduced into the room via infiltration t hat product integrity is threatened, the system will take steps t o protect the stored product even if that means a slight increase in energy consumption. This can be accomplished while maintaining a desirable demand profile. By measuring product temperature directly, the control system can leverage the thermal capacity of the TES while adequately protecting stored product.

Changes to the room envelope, such as door openings, are incorporated so that pending defrost cycles can be initiated a t an advantageous time. For example, the room can be allowed to recover from an extended door opening before a defrost cycle is initiated that could further increase temperature.

Other Benefits The application of the TES system can improve the operating efficiency of the existing refrigeration equipment without costly replacement, While improving the shelf life and quality of perishable foods and other products: • Refrigeration equipment can operate longer at higher suction pressures and higher coil delta temperatures, where it is more efficient.

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Refrigeration equipment can operate at lower condensing pressures, reducing compressor KW. Reduction of refrigeration equipment total runtime required to condition the space, resulting in extended equipment life and a reduction in maintenance costs.

TES has the ability to shift load throughout the day by leveraging the thermal energy storage capacity of the TES to match the utility rate structure and operational needs of the electric utility with Demand Response and Smart Grid Integration capability.

Incorporation of intelligent defrost capability, reducing the energy impact of defrost.

Ability to respond dynamically to real world usage scenarios, including product loading and power outages.

Pre-emptive detection of need for service, including service preclassification.

Effective management of moisture (relative humidity) in the room, to improve safety and equipment efficiency.

Improve quality of product through the reduction of product temperature fluctuation and open product shrinkage, while minimising low temperature suction pressure (temperature) which extracts excessive moisture.

Refrigeration equipment sizing could target average load rather than peak load, leading to lower initial cost.

The following discussion relates to the operation and use of commercial refrigeration equipment for operating freezer and cooler perishable product storage space. The system employs the use of Thermal Energy Storage cells (TES) installed in the ceiling areas of refrigerated rooms combined with intelligent controls, and a 24/7 remote monitoring package.

For more details, contact: Viking Cold Solutions, Inc. vikingcold.com/resources

Thermal Control Business Update

MARKET REPORT

Strengthning the base of India’s supply chain management to allow professionals to handle retail distribution and returns, which is expected to increase in the year 2020.

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Brands/companies opting for floating lease space for warehousing: According to property consultant CBRE, 31 per cent more companies opted for floating lease space for warehousing reaching over 13 million sq ft in the first half of 2019.

Going forward, it is expected that more companies will lease space for warehousing owing to expansion and consolidation.

echnological advancements in AI, Machine Learning and Data Analytics have revolutionised the operations of logistics and the SCM sector through improvements in efficiency, and a prime focus on customer centricity. Government policies such as ‘Make in India’, the recently acquired ‘infrastructure’ status to logistics sector, including cold chain and warehousing facilities, and the relaxation in FDI policies that have strengthened the growth of the sector in India.

sensors to ensure extreme accuracy not just on the warehouse floor but also in ERPs and external software, with the help Robotic Process Automation (RPA).

Increasing Investment: According to a report by Your story, the logistics sector in India invested $6.25 billion in the second half of 2019 alone. The interest of investors is expected to increase further in 2020 to allow innovation and serve the customers better.

International trade and infrastructure status to logistics: The logistics sector was given the international trade and infrastructure status in the year 2017. The impact of the tag is likely to positively affect the performance of the sector in 2020. The status will help the sector to avail credit at cheaper and competitive rates to ensure uninterrupted growth and increased market presence.

According to a report by ‘Make in India’, the Indian logistics and SCM sector is currently valued at $165 billion, with growth expected to reach $215 billion by the end of 2020. Furthermore, the sector has employed more than 22 million people and pushed the rank of India from 54 to 44 in the World Bank’s Logistics Performance Index (LPI) 2018, in terms of overall logistics performance.

Supply Chain Visibility: SCV is increasing exponentially as more customers are demanding customised logistic services based on real-time data. In 2020, more logistics and supply chain companies will invest in SCV technologies to ensure a quick real-time response to change based on data such as weather, traffic and city conditions.

Rise of dedicated logistics parks and SEZs: Logistics parks and Special Economic Zones are gaining increased attention from both public and private players. Mumbai has been deemed the most sought after location for dedicated Logistic Parks and SEZs; the year 2020 will see an increase and the quality will cater the demand of the ever changing customer.

Internet of Things: IoT is making the logistics and supply chain smarter by integrating various software and machines to create a unique, manageable system.

IoT provides, the management of the supply chain increased efficiencies through integrations across platforms that will lead to a higher adoption rate amongst service providers and customers alike.

A study by the India Brand Equity Foundation (IBEF) determined the investments in the logistics and supply chain management sector to reach $500 billion by 2025. With growth driving trends affecting the logistics and SC sector in 2020, `50,000 crore is expected to be invested by 2020 to establish the sector as one of the fastest-growing in India. As the end-users are expected to increase by a hefty margin, the logistics and SCM sector is poised to employ 40 million people by the end of 2020.

The trends for the sector is 2020 seem favorable for the expansion of various companies to meet growing warehousing needs.

Logistics and SCM sector has seen a steady growth throughout 2019, thanks to the rising demand from customers encompassing industries like retail, pharmaceuticals, telecom, automobiles, etc.

Some key trends that are going to drive the sector in 2020 can be listed as follows: Robotics: According to the Global Customer Report 2019, numerous manual tasks in the warehouse are being automated through robots, leading to an increase of 18 per cent year-over-year, in warehouse robotics. In 2020, warehouse robotics is likely to pick up the pace by integrating advanced technology and Thermal Control Business Update

3PL and warehouse integration: According to a KPMG report, the number of startups in India has grown to 50,000 from 7,000 in a decade, which has spiked the need for storage and warehousing.

Most companies are partnering with thirdparty logistics and warehousing companies

January 2020

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PRODUCT REPORT

Next generation of efficient and compact pumping solutions drive. The compact CME design is now available with up to 2.2 kW with many new features which enable tailor-made operation and customer benefits. The new design is more reliable, offering IP68, if needed.

CM and CME pumps cover a wide range of applications, from small installations in homes to large industrial systems.

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rundfos CM and CME pumps range redefine compact efficiency for any industrial applications. These horizontal, multi-stage pumps are driven by Grundfos’ innovation-led approach. These pumps are primarily used as a built-in pump in industrial solutions. Its compactness and flexibility make it an optimal solution for installations and interactions with other components in a larger product.

CM and CME pumps are close coupled and comprise a series of interchangeable modules designed to work together seamlessly. The key differentiator between a CM and CME pump is its motor. While the CM pumps are fitted with a mains operated motor, CME pumps represent the new era of pumps with an integrated frequency driver and PI controller.

All CM and CME pumps are capable of pumping liquids at temperatures from -30 degree Celsius to +120 degree Celsius, respectively. These pumps are available in various sizes and the number of stages to meet customer requirements, in terms of flow and pressure.

magnet motors and its high frequency variable frequency drive has one of the highest energy efficiency ratings worldwide.

Their highly reliable nature ensures that there is minimal downtime with low maintenance costs.

Compactness: The CM/CME pumps design offers 30 percent reduction in pump size compared to similar pumps for the given application without compromising the overall pump performance. These reductions are possible due to the use of advanced processes and technologies of these CM/CME pumps.

Reliability: Grundfos CM/CME has high built-in reliability. A well-defined and rock-solid clamping of the pump impellers combined with a NORD-LOCK washer at the other end of the pump stack creates a robust and reliable design.

Features and benefits

Flexible range of connections: A flexible range of connections ensures that the customer can utilise the connection systems in end-user’s solution at ease.

This provides an excellent flexibility and simplicity, creating a customised solution without the normal waiting time.

Like all other Grundfos solutions, these pumps are designed to conserve energy and use water optimally during its entire lifetime. CME pumps fitted with permanent

New E-motors: CME now with the state-of-the-art E-drive, featuring IE5 efficiency including a variable frequency

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January 2020

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Washing and cleaning: Pumps are used to wash and clean with soap and other cleaning components.

Other applications in these processes include degreasing or washing of industrial equipment, vehicle washing tunnels, washing machines and mobile washing units.

Water treatment processes: A CM or a CME pump can be used in multiple stages of water treatment process as a feeding/booster pump. They are also used in RO plants filtration systems and swimming pool recirculation system.

Temperature control applications: These pumps are used to circulate a liquid in a closed loop with heating or a cooling application. This is typically found in the F&B industry for refrigeration, heating and cooling of industrial equipment and for medical products. The capability of the pump to operate at extremely low and high temperatures gives it an added benefit.

Pressure boosting: CM and CME pumps can be used in pressure boosting applications anddeliver the right pressure after understanding flow requirements of the end user or its applications.

Chemical and Pharmaceutical industries: Flexible nature of CM and CME pumps finds its applications in also distilling systems, dosing/mixing, evaporation, liquid boosting and transfer.

For more information, visit: www.grundfos.in

Thermal Control Business Update

MARKET UPDATE

Gandhi Automations received WASME Award for warehouse and logistic innovation

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orld Association for Small and Medium Enterprises (WASME) is a global non-profit organisation that has been spearheading the cause and development of small and medium enterprises (SMEs) the world over since its inception in 1980.

Warehousing and logistics are crucial factors for companies to gain a competitive edge. With the advent of modern manufacturing, which combines smart and effective products with advanced and innovative technologies, the very definition of warehousing and logistics has evolved to a much larger and integral concept.

As the logistics and manufacturing sectors move beyond the rudimentary manual operations in the supply chain, Gandhi Automations’ range of entrance automation and loading bay range of products has revolutionised traditional warehousing powered by advanced engineering technology, thereby not only impacting logistics but the supply chain as a whole. For its advanced tech innovation, Gandhi Automations Pvt Ltd once again bagged the WASME Award of Warehouse & Logistic Innovation Award, which was presented by the Hon’ble Minister of State for Health and Family Welfare, Ashwini Kumar Choubey.

Thermal Control Business Update

Gandhi Automations has successfully evolved into an innovative company catering to all kinds of needs. It has an extremely talented in-house research and development team which designs customised solutions for its customers.

Its product engineering team uses the latest software in combination with technologically advanced machinery to provide customers with an unmatched experience in entrance automation and loading bay equipment.

Gandhi Automations has made significant improvisations and innovations to its loading bay equipment range of products as well as high-speed doors.

The new Forklift Roll-off Barrier lip Dock Leveler, Prime Cold Reset, High Speed Doors - Prime Reset, High Speed Doors Prime Internal Doors, Industrial Sectional Overhead Doors, Dock Levelers, and Isotherm Rolling Shutters are some of the fast-moving innovations and products that have changed the landscape of logistics and warehousing automation.

Quality is a key driver of progress for Gandhi Automations and is an integral part of every process it undertakes, from R&D to product delivery. Its quality policies are constantly upgraded to exceed customers’ requirements and expectations. Gandhi Automations is committed to delivering

high-quality products and services to its customers and continuously strives to improve in all aspects. Its products and services are geared towards ensuring that every delivery to the client passes through its stringent quality measures. This policy has engendered a work culture that exhibits a no-compromise attitude towards quality.

Gandhi Automations is known for its research and development, quality and commitment towards customers. The material handling industry is responding with new equipment, technology, and systems that enable complete supply chain visibility, thus allowing customers to see how their investments are impacting their overall operation. The demand for material handling automation and equipment has increased exponentially over the past few years because of increasing production capacity, reducing manhours, and meeting deadlines. Now, with more and more companies streamlining their processes, use of material handling equipment for any industry is a must.

Demand for such automation is the need of the hour, even to deliver faster, hassle-free loading/unloading functions to reduce supply chain operating costs.

To know more about Gandhi Automations products, visit: www.geapl.co.in

January 2020

35

MARKET UPDATE

WING air curtain to redefine Bangaluru Airport air quality

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ING Air Curtain is the new generation device created from a passion for a light and modern design representing characteristics of gliders. WING combines the unique design and excellent efficiency to redefine the air curtain image.

Bangalore Metro Rail Corporation WING air curtains was delivered to Namma Metro, the Kempegowda interchange station, Bangalore. Air curtains will secure clean and fresh air inside the second-largest metro station in Asia currently. The air curtains not only help in maintaining the air quality but also are energy efficient for places having maximum ridership, walk-ins, visits etc.

Delhi Indira Gandhi International Airport With 65.69 million passenger traffic, Delhi International Airport Limited has a total of three operational Terminals.

VTS was chosen as the reliable HVAC partner for maintaining adequate indoor air quality at Terminal 3. Completed in 5 different levels, each level is divided into international and domestic service areas.

Situated in a 5.4 million square feet area, Terminal 3 has 34 million passengers per annum capacity.

WING air curtain has occupied multiple doorways of this terminal at Delhi International Airport. More than 60

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January 2020

WING air curtains have been delivered to the building and will facilitate different entrance areas, lounge and food sections.

This will be first airport and one of the very few buildings in India to VTS units installed horizontally and vertically to obtain the max possible comfort for the customers.

Daxing Airport in Beijing Beijing Daxing Airport will become world’s biggest airport along with being the most progressive and modern transportation centre. The new airport will act as a second international airport for Beijing to relieve pressure from Beijing’s Capital International Airport.

With unpredictable and quickly changing weather caused by the high amplitude of temperature and infamous Beijing’s smog, designers of Daxing Airport have decided to facilitate air curtains which can maintain very comfortable environment inside the complex. By using the air stream air curtains, one can prevent insects and impure air mixing with the inside air of the premise keeping the chilled air inside at its utmost purity.

Designers decided to establish cooperation with VTS Group. VTS’ WING air curtains were chosen due to its high efficiency and quality. 298 sets of WING air curtains, which are a lookalike of airplane wings, will protect the facility.

Coca Cola Arena in Dubai 46 WING air curtains was delivered to Coca Cola Arena – sports and entertainment hall. Inside 50,000 m2 hall, there are 20,000 seats. Cold curtains, equipped with energy saving EC motors and automation that enables cooperation with BMS in the building, will be working in the facility.

The investor chose WING air curtains not only due to their excellent technical parameters, but also due to the quality of the workmanship – the best on the market and unique design.

Royal quality, wild price The use of VTS air curtains in such prestigious facilities undeniably confirms that VTS is currently a leader on the HVAC market. Air curtain may perform according to door opening sensors. Smart door protection gives user not only permanent temperature comfort but also secure interior from dust, pollution, insects and unpleasant scents.

Highest quality and most efficient WING Air Curtains are now available with two motor types AC motor & EC motor.

Both solutions are available in Indian Market.

For more information, visit: www.vtsgroup.in Thermal Control Business Update

MARKET UPDATE

Samsung launches new range of premium room air conditioners to choose the wind direction.

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he split AC line-up includes classleading Wind-Free, Triple Inverter, Eco Inverter, and On/Off Samsung, one of India’s largest and most trusted consumer electronics and mobile phones brand, today launched an exciting new range of air conditioners that includes Wind-Free AC 2.0 with Wi-Fi capability, human detection and green R32 gas, premium Triple Inverter Series, Eco Inverter, and On/Off split ACs. The new line-up of 40 models, aesthetically designed and priced to suit every home, comes with attractive floral patterns and premium strip design.

Samsung has also expanded its copper condenser range to 32 models to match customer demand across the country, in each tonnage and star rating segment.

“Samsung is a consumer-centric company. We believe in meaningful innovations that transform lives.

Our research showed that durability, affordability and energy efficiency are the primary concerns of AC consumers in India. With our new range, we have ensured all those expectations are met. In addition, consumers also get Samsung’s best-in-class technology and the most trusted brand,” said Rajeev Bhutani, Senior Vice President, HVAC division, Consumer Electronics Business, Samsung India.

The new range will be available in stores from January 2020. Samsung has

Thermal Control Business Update

The product comes with 10 years of warranty on the compressor and features an energy-efficient Digital Inverter, which can maintain the desired temperature without frequently shutting off and on, thus consuming less energy. With the Wind-Free 2.0 the Energy Saving Mode helps conserve up to 77 percent energy as compared to the Fast Cooling Mode. over 2,000 brand stores – the highest in the country, and has a footprint of 200,000 stores in India. Samsung also has the biggest network of customer service, which is available both offline and online. Customers opting for Wind-Free 2.0 Series will get an express installation service wherein the AC installation will be done within 4 hours from time of delivery.

Wind-Free 2.0 Series Samsung’s Wind-Free™ 2.0 system uses 23,000 micro-holes to gently spread air evenly throughout the room, maintaining a comfortable level of coolness without any draft. Once the desired temperature is reached, the system disperses fresh air uniformly.

The design has been upgraded to rectangular from the previous triangle design and with this change the microholes have been increased to 23,000 from 21,000 in the previous version.

The Wind-Free 2.0 enables users to control their ACs using the Smart Home App through Wi-Fi. These ACs allows the user to remotely control the functions and schedule operations along with live feedback. Users can also monitor and limit power usage as per their needs.

The latest Wind-Free ACs is equipped with Motion Detect sensors (MDS) and automatically go into an energy saving mode if it does not detect any human presence for 60 minutes. Another option which users get through this feature is

The Samsung Wind-Free ACs has easy filters that can eliminate dust, contaminants, allergens, bacteria and viruses. The new series is also equipped with R32, an eco-friendly refrigerant that efficiently transfers heat and has a lower environmental impact while ensuring substantial drop in electricity consumption.

Triple inverter series The Samsung Triple Inverter Series comes with plethora of features along with host of benefits across models. The range comes with a convertible mode as an option where customer can convert its 2 Ton AC to 1.5 Ton, 1.5 Ton to 1 Ton and 1 Ton AC to 0.8T. The Convertible Mode uses less compressor capacity, thereby reducing power consumption.

The Triple Inverter Series models are powered with World’s First 8-Pole Inverter Technology which helps in energy saving and has immensely low vibration while in operation.

Catering to consumers looking for energy efficient ACs, Samsung has lined up an extensive range of high energy efficient models – the 5-star 1 Ton and 5-star 1.5 Ton which are a part of Samsung’s most appreciated Maldives Split AC series. The series comes with bigger indoor unit size, available with copper condenser in 3-star 1.5 Ton configuration. Continuing its design expertise, Samsung has

January 2020

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MARKET UPDATE

introduced a new variant with floral pattern – Paradise Bloom – as part of the 2020 Triple Inverter Series. The new contemporary and stylish pattern blend well with the aesthetics of a room. The latest design will be available in two models – 3-star 1 Ton and 3-star 1.5 Ton. eco inverter series As part of the 2020 expansion plan and addressability across price points, Samsung has also launched its first range of Eco Inverter Series of ACs in India. The new ACs have been designed carefully keeping in mind the consumers’ needs and expectations. The latest ACs comes with four different strip designs and have 100 percent copper condenser models.

The unique Hidden Backlit Display and Crystal Design in selected models gives a contemporary and minimalist

look. The range has 10 Year Warranty on Digital Inverter Compressor and comes with Turbo Cooling, Anti Dust and Bacteria Filter.

On/off series Samsung has re-entered the On/Off AC segment with freshly designed Split AC in 1 Ton and 1.5 Ton 3-star AC configurations. Samsung will be launching 4 new models in On/ Off series across 2 different design platforms. The latest range will come with 5-year warranty on compressor and has features like Turbo Cooling mode.

Price and Benefits: Samsung’s 2020 AC line-up will include 40 ACs across Wind-Free 2.0, Premium Triple Inverter Series Inverter, Eco Inverter and On/Off ACs. The new split AC range will start from a price point of `35,990 and will go up to `73,990.

Samsung has planned a strong durability proposition across line up along with its Digital Inverter Compressor range that will come with a 10 Year Warranty.

Copper condenser models of Premium Triple Inverter series and Wind-Free 2.0 will come with 5 years condenser warranty and a 5 years warranty on PCB Controller as well to give customers complete peace of mind. In order to drive affordability in the market, Samsung has also introduced attractive EMI options where customer can own a Samsung AC at zero down payments. Customers can also avail various installations offers like free installation or installation at ₹499. Along with this they can also avail 10 percent cash back on Wind-Free models and 5percent cash back on the premium Triple Inverter Series through various banks and formats.

For more information, visit: www.samsung.com

FanGrid solutions for high air performance

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o achieve high air performance in ventilation technology, several smaller fans are combined to create a FanGrid. ebm-papst now has FanGrid modules with RadiPac centrifugal fans in its product range – with automatic resonance detection for more operating reliability. Many applications require high air performance. Data centers, large industrial building complexes, hotels, residential complexes and hospitals are all typical examples.

Cubes prevent installation loss At ebm-papst, fans for a FanGrid are installed in a support structure. The cube has extra-generous dimensions to prevent the undesirable installation loss that

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January 2020

arises when fans are positioned too close together and can influence each other.

Automatic resonance detection for more operating reliability Depending on the installation situation, resonance can cause vibrations within specific speed ranges. Such vibrations can damage the bearing system of electric motors and lead to fan failure. This is why ebm-papst has developed automatic resonance detection that minimises the effects of vibration – vibration velocity – for its RadiPac centrifugal fans.

Energy-efficient EC technology with convenient closed-loop control The driving force behind the fans installed

in the fan grid are modern EC motors, which are highly energy efficient in both full- and partial load operation. The FanGrid line is rounded out by a new controller that easily activates fans operated in parallel. It requires minimal wiring work. ebm-papst FanGrid modules are available as plug and play compatible units or as complete kits consisting of the fans, air inlet grill, support plate, corner connectors and spacer profiles for direct installation on site.

Smaller, lighter, better FanGrid In practice, FanGrids have many benefits.

The individual fans can be arranged next to or above each other to save space.

They significantly improve air distribution and ensure a more even airflow through upstream or downstream components such as filters or heat exchangers. Their redundancy also increases operating reliability, since the other fans compensate for missing air performance. The relevant redundancy requirements can be taken into account during the selection process.

For more information, visit: www.ebmpapst.com Thermal Control Business Update

MARKET UPDATE

Danfoss qualified DSH scroll compressors for use with R454B and R452B Matthieu Stoll, Director of A/C Marketing at Danfoss Cooling, said: “Around the world, refrigerant transition is happening at different speeds. By using Danfoss DSH scroll compressors with IDVs, OEMs can now respond to market changes more easily – whether that’s new efficiency requirements or the GWP phase down. That’s ultimate flexibility. And with a GWP level of 466, R454B in particular can be viewed as a potential long-term solution.”

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lready a popular option for commercial chillers and rooftop systems using R410A, with Intermediate Discharge Valve (IDV) technology to enhance seasonal part-load cooling efficiency, the DSH scroll compressors now support R454B and R452B refrigerants. The option to use new, lower-GWP refrigerants was prompted by the EU’s ongoing phase-down of high GWP refrigerants, limiting availability and increasing the price of R410A.

Benefits of the new, enhanced compressor range include: • Drop-in multi-refrigerant support for R454B and R452B, offering late line customisation and reduced inventory with minimal redesign effort, • Danfoss IDV technology to enable higher partload efficiency, • 10 models from 7.5 to 40 TR and a wide range of manifold options, • Operating maps to fit a wide range of applications, both reversible and cooling only, including chillers and rooftop units.

R454B and R452B refrigerants are classified as A2L (mildly flammable) and are regulated under EN378 and IEC60335-2-40. OEMs therefore need to take the appropriate compliance measures in certain applications.

For more information, visit: www.danfoss.com

Meanwhile, in countries where refrigerant GWP is already taxed, switching to R454B or R452B will provide savings on the tax value up to 78 and 67 percent respectively.

The compressors’ multi-refrigerant compatibility, along with similar drop-in performance versus R410A, is designed to make refrigerant transition as easy as possible for OEMs without the need to make radical system alterations, thus accelerating time to market, both for cooling and reversible systems altogether.

The changes also enable OEMs to make late line customisations and reduce stock inventories, which increases overall flexibility and ease of stock management.

Thermal Control Business Update

January 2020

39

MARKET UPDATE

Ventilation on demand for underground mines the fan starts according to a pre-set ventilation demand for that type of vehicle. That means a smaller vehicle will automatically trigger less airflow than a larger vechicle might. All depending on what is needed to maintain good air quality.

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rctic Vent Control is ventilation on demand system that provides full control over air flow within the mining site. This advanced mine ventilation system has vehicle detection, gas detection, air quality sensors and scheduling possibilities that optimises the airflow underground.

The ventilation system works independently and does not require any infrastructure in the form of Wifi or other IT solutions.

Because of its independency, Arctic Vent Control is easy to install and requires low initial costs. The system is also scalable, and each fan control unit is autonomous, that means the ventilation system can be installed and tested in one small part before continuing with installations throughout the mine.

In some underground mines you have blasting at the same time every day.

Arctic Vent Control will then schedule the control of the fan(s) to that exact time of day to help clear the air and maintain good air quality after blasting. This means that no manual control of the ventilation system is required for patterns within your workflow that reoccurs every day.

Controlling the air flow and being able to schedule the mine ventilation fans to your operation will help you keep good air quality in the mine and reduce costs.

Ventilation on demand optimised with pressure and air flow It is easy to connect sensors for pressure, gases, flow and other metrics to Arctic Vent Control to enable further optimisations for extended Ventilation on Demand.

We can also connect sensors for temperature, CO and NO (among many other types of sensors like dust, flow or pressure) to the control system underground. These sensors can inform the PLC how to adjust the fan(s) to maintain air quality.

Vehicle detection helps control the airflow in underground mines and optimise the use of the ventilation system based on when there are vehicles in certain areas. This will help with maintaining good air quality underground and at the same time reduce costs and emissions.

Benefits of Arctic Vent Control

A receiver is connected to the control system and a transmitter is installed in the vehicles. When a vehicle is detected,

Safe work environment Use of scheduled operation of the fans to flush out toxic gases after blasting etc.

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January 2020

Save money – reduce costs Because Arctic Vent Control will control the fans to only run when needed (using vehicle detection and other sensors) you will use less power and your fans will have a longer service life and less damage.

Compatible with most fans and ventilation systems If existing ventilation systems and fans are already installed in the mine, Arctic Vent Control will integrate via common bus protocols.

Low initial investment Each fan control unit is autonomous, that makes Arctic Vent Control highly scalable. It can be tested in one area before full or progressive installation throughout the mine.

Autonomous operation Each fan control unit can operate on its own if communication does not exist or fails. Arctic Vent Control can be controlled via local HMI underground and/or remote from above ground.

Portable control units As your mine changes, so does Arctic Vent Control. By being modular you can easily move control units to the new mining areas.

Quick and easy support Since Arctic Vent Control can be controlled remotely from above ground, we can offer support, in most cases, without having to leave or home office.

That means support becomes cheaper and faster and makes the downtime minimal.

HMI Our demand controlled ventilation system comes with local human machine interface (HMI) installed nearby the fans underground to ensure access for operators or technicians. With the HMI attached underground you can see how and why certain fans operate, sensor data, alarms and do basic setups.

The local HMI can be set up with authorisation to avoid unauthorised access.

For more information, visit: www.gefasystem.se Thermal Control Business Update

604, 6TH FLOOR, SURYA HOUSE, STATION ROAD, VIDYAVIHAR EAST MUMBAI - 40077 | TEL: 022-25018601

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