1

ASHRAE WILL GIVE YOU

THE WORLD
Industrial Refrigeration
For Food Preservation
Dr. ApichitL. Pana(Ph.D.(Hon), ME)
Fellow – ASHRAE
Distinguish Lecturer (DL)

Na Mas Sa Tay ThisASHRAEDistinguishedLecturerisbroughttoyoubythe

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 5 6

Outlines
• Refrigeration System
• Freezing Technology
• Product Weight Lost
• Poultry
• Fishery REFRIGERATION SYSTEM
• Fruits & Vegetables

7 8

With Economizer (Screw Comp)

Single Stage
Without Economizer (Piston, Screw)
Refrigeration System
Liquid Injection Intercooler (LI)
• Typical using ammonia as an refrigerant
• For worker congestion area using secondary
System Selection

Liquid Injection Intercooler with Sub-cooler (LISC)

refrigerant such as P.G. or E.G.
Two Stage
Open Flash Intercooler with Sub-cooling Coil (FLSC)

Open Flash Intercooler (FL)

Ammonia – CO2
Cascade
HFC - R23
Cryogenic
9 10

11 12

Refrigeration System
• Falling film (Baudelot chiller) for chill water
 13 14

Flooded System for Falling Film Plate Chiller Refrigeration System

• Plate in frame or shell & tube for glycol system

Evap.
Cond.

Falling Film
Plate Chiller

Receiver
Compressor

15 16

Plate in frame or shell & tube for glycol

system Refrigeration System
• Two(2) stages system (HP+LP) as a
typical
Evap.
Cond.

Plate Heat Exchanger

Receiver
Compressor
 17 18

Two(2) stages system Liquid Injection Intercooler

To Evaporator Liquid From
1. Liquid Injection Intercooler (LI) Receiver

2. Liquid Injection Intercooler with Sub-cooler

(LISC)
TXV Solenoid
3. Open Flash Intercooler with Sub-cooling Coil
(FLSC)
4. Open Flash Intercooler (FL)

HP Comp. LP Comp.

19 20

Liquid Injection Intercooler with Open Flash Intercooler with

Sub-cooler Sub-cooling Coil
To Evaporator Liquid From
Receiver

Liquid From
Receiver
TXV Solenoid
Liq. Sub-cooler
To Low Side Sep.

Inter cooler

HP Comp. LP Comp. HP Comp. LP Comp.

 21

Comparing the Energy Usage

Open Flash Intercooler of Various Refrigeration Systems

Liquid From
Receiver

To Low Side Sep.

Intercooler

HP Comp. LP Comp. Differences are intercooler type

and liquid temperature. 22

23 24

Time Line for Refrigerants

REFRIGERATION SYSTEM
Cascade system
Typical CO2 (R744) refrigerant
 25

ODP & GWP of Some Refrigerants

Refrigerant Chemical Lifetime ODP GWP
(yrs) 100 yrs
HCFC R22 CHClF2 12 0.050 1810
HFC R134a CF3-CH2F 14 0 1430
R404a R143a/125/134a - 0 3900
R507A R143a/125 - 0 4000
R410A R32/125 - 0 2100
Natural R290 (Propane) CH3CH2CH3 0.041 0 20
R717 NH3 0.01 0 <1
R718 H2O - 0 <1
Triple Point (line):
R729 78%N2, 21%O2, 1%Ar - 0 0 -56.6qC [69.9qF]
5.2 bar [75.1 psi]
R744 CO2 >50 0 1

27 28

Trans-critical CO2 Cycle Sub-critical CO2 Cycle

Sub Critical
Refrigeration Process,
e.g.
• Cascade system
• DX systems
• Pump circulating
systems
Sub-critical Cycle
 29 30

+30 oC [+86 oF] Principal diagram

Ammonia in CO2 systems R717 - CO2 cascade system
R717
R717
R717
compressor
CO2 -R717 Heat exchanger
-20 oC [-4 oF] +30 oC (12 bar)
-15 oC [+5 oF]
+86 oF (171 psi)

CO2 -20 oC (1,9 bar)

compressor -4 oF (28 psi)

Enthalpy
-40 oC [-40 oF]
CO2 - receiver
CO2
• Ammonium Carbamate -15 oC (23 bar)
+5 oF (333 psi)
CO2
¾ Corrosive substance (white powder) -40 oC (10 bar)
-40 oF (135 psi)

¾ Dissolve @ temperature > 60 Deg. C -40 oC [-40 oF]

CO2-evaporator
Enthalpy

31 32

Controlling the pressure during

”stand still”
R717

FREEZING TECHNOLOGY

Saturated pressure CO2

CO2
 33 34

Freezing Technology Brine Freezer

• Brine Freezer
• Air Blast Freezer
• Contact Plate Freezer
• Spiral Freezer
• Tunnel Freezer
• Fluidized Bed Freezer
• Cryogenic Freezer

35 36

Brine Freezer Air Blast Freezer

 37 38

Contact Plate Freezer Spiral Freezer

39 40

Tunnel Freezer Fluidized Bed Freezer

 41 42

Cryogenic Freezer

PRODUCT WEIGHT LOST

43 44

Product Weight Lost Percentage of Weight (Moisture) Loss from Fruits and
Vegetable that Affects Produce Quality after Harvest
• Weight lost in storage and freezing Product Weight Loss (%)
Beans (broad, runner, snap) 6.0, 5.0, 41.0
• Chilling injury Broccoli 4.0
• Freezing injury Cabbage 8.0
Carrots (mature, young) 8.0, 4.0
• Ammonia injury Celery 10.0
Cucumbers 5
Lettuce 3.7
Onions 10.0
Potatoes 7.0
Spinach 3.0
Sweet Corn 7.0
Tomatoes 7.0
 45 46

Weight lost during storage Weight lost during freezing

Factors:- Factors:-
• Room temperature & temperature fluctuation • Type of freezer
• Humidity • Freezing time
• Air flow over the product • Type of product
• Radiation effects of lighting
• Air velocity
• Shape and size of the product
• Freezer operating conditions
• Type of wrapper

47 48

Weight lost during freezing Chilling Injury

Product Freezing Method %weight loss
IQF shrimp Air blast 2 to 2.5
IQF haddock Air blast 1.2
IQF haddock Cryogenic – CO2 0.6
IQF products Cryogenic – N2 0.3 to 0.8
Tray of fillets Air blast 1.0
Large fish or blocks Air blast 0.5
Contact freezer metal to
Blocks of fish 0
fish contact
 49 50

Freezing Injury Freezing Injury

Freezing Thawing
Large ice Cell wall has
crystals been ruptured
damage cell
wall

Slow Freezing

Freezing Thawing
Small ice Cell wall intact
crystals

Quick Freezing

51 52

Ammonia Injury

POULTRY
 53 54

Poultry Processing Plant Poultry Primary Factory Process

Receiving & Slaughter
Hanging Stunning
• Primary Factory (Slaughter) Weighing / bleeding

• Further Processing Plant (duck)

Plucking,
Washing defeather- Scalding

Singeing
ing

(duck) Oil
Eviscerat- Feather
Gland venting
ing
removal

Next (1), Giblet/ Feed Mill

(2) offal

55 56

Poultry Primary Factory Process Poultry Primary Factory Process

Chilling Air
Giblet/ By Product Giblet / offal
Chilling Inspect or Spin
offal (1) Processing (2)
Chiller

Metal Prime Meat De-

Freezing Packaging Debone
detector Holding(1) Contamination

Cold
store Chilled Store Further
Process
 57 58

Poultry Primary Factory Process Production Flow Chart

Prime Meat Holding(1)
Cut up Packing
Packing Metal detector Link Video

Metal detector Whole Chicken Chilled

Chill Freeze Frozen

Cold store

59 60

Design Parameter & Requirement

Design Parameter & • Chicken Portion Weight

• Design Parameter
Requirement
• Typical Utility Requirement
Poultry • Temperature for Poultry Plant
• Ventilation
• Typical Flow Movement Drawing
 61 62

Chicken Portion Weight Chicken Portion Weight

25

20

15

Target%
10

0
Carcas
Feathe
Intest Giblet BL/BIL Wing Wing Lean s
Blood rs Heads FeetC Hocks Bones BB Fillet MJHC
ines s * Sticks Tips Fat (Skele
(wet)
ton)
Target% 6.34 8.4 2.21 6.58 6.59 3.19 23.71 1.77 3.76 20 3.95 3.58 2.97 1.04 1.22 18.71

* BL/BIL is 20.43%/27% average

Prime meat will be appx. : 35~40%

By product will be appx. : 50~55%

63 64

Temperature for Poultry Plant “Typical Temperature Range”

Domestic chilled room : 0~+2qC In Food Processing Plant
Giblet & offal chilled rm. : 0 ~ +2qC Room Application Room Evaporating
Carcass store room : +10 ~ +15qC Temperature (qC) Temperature
Spin chiller room : +10 ~+12qC (qC)
Ante, Loading, Boxing +5 ~ +15qC +5 ~ -5qC
Cut up & debone room : +10 ~+12qC
Cut up, Processing Are +10 ~ +12qC +5 ~ -5qC
Air blast freezer/tunnel freezer : Ş35qC
Chilled Room +5 ~ +0qC -10qC
Cold storage room : Ş20 ~Ş25qC
Ante room : +5 ~ +15qC Cold Storage -20 ~ -25qC -30 ~ -35qC
Loading room : +10 ~+15qC Freezing -35 ~ -40qC -40 ~ -45qC
Boxing room : +10 ~+12qC
 65 66

Ventilation
• Air flow from clean zone to dirty zone
• From cut up to spin chiller to evisceration
and other Further Processing
Poultry

67 68

Product Coating Air Sock Distribution System

(Reduce wind chill effect)
 69 70

Multiple Head
Weighing System

Cooking Outfeed Area Spiral Freezer Infeed Area

71 72

Cooling House (Cold Storage)

Product Boxing Area
 73 74

Cooling House (Cold Storage) Ventilation

OFFU OFFU OACU

OACU

+++ ++ +
Cartoning HighRiskArea+15OC MediumRiskArea LowRiskArea
Area+15OC
(Freezing) (Frying) +15OC(Soaking,
Selecting,
Feeding)
EFU EFU
EFU

IAQ:IndoorAirQuality OFFU:OutdoorAirFilterFanUnit
EFU:ExhaustFanUnit OACU:OutdoorAirCoolingUnit

75 76

Ventilation Ventilation
Medium HEPA
Medium Filter Evaporator Coil Medium Evaporator
Pre Filter Pre Filter Filter
Coil Filter
Pre Filter OACU HEPA Filter EFU Filter HEPA Filter
OA OA OA
OACU OFFU

+25OC
+++ ++ +
+++ ++
Medium Risk Area (Frying)
High Risk Area +15OC (Ambient Temp. ~38OC)
(Freezing)
OA : Outdoor Air OFFU : Outdoor Air Filter Fan Unit
OA : Outdoor Air OACU : Outdoor Air Cooling Unit
EFU : Exhaust Fan Unit OACU : Outdoor Air Cooling Unit
 77 78

Ventilation Typical Flow Movement Drawing

Evaporator Coil
Medium Filter
EFU HEPA Filter OACU Pre Filter

OA

+
Low Risk Area +15OC
(Soaking, Selecting, Feeding)

OA:OutdoorAir,EFU:ExhaustFanUnit,
OACU:OutdoorAirCoolingUnit Clicklinktopdf file

79 80

Typical Flow Movement Drawing

FISHERY

Click here to link pdf

 81 82

Frozen fish Freezer Trawler

Max. transit Opt. transit Highest Recomm. %RH Air Change Ethylene
container temp.
& Shelf life temp. (qC) freezing (cfm) Produc-tion
setpoint
(Days) temp. (qC) Rate
(qC)

Fatty (carp, 120-140 -23.3 to -23.3 to Vents None

salmon, -20.5 -20.5 closed
sardine,
tuna)
Lean (cod, 240-300 -23.3 to -23.3 to Vents None
pollock, -20.5 -20.5 closed
perch)
Shrimp, 120-360 -23.3 to -23.3 to Vents None
Scallops -20.5 -20.5 closed

Crab, lobster 120-360 -23.3 to -23.3 to Vents None

-20.5 -20.5 closed

83 84

Freezer Trawler Fish Processing

Ice Machine for trawler
• chip ice from freshwater
• chip ice from fresh or seawater
• liquid ice from seawater
 85 86

Fish Processing By-product

Receiving (Fresh or Frozen Fish)
Fish Processing
Unpacking Rejected fish By-product
material
Thawing (in water)

Washing & Grading Rejected fish

Fish meal &
Skinning Skin fish oil Fish Fillet
Process
Evisceration & removal
of valuable by products Guts, head
(liver, milt)
Dehydrating
Filleting

Washing Bones, off-cuts reject Surimi

Chilling, freezing, salting, drying packing
QC reject
Fish Finger
External Packing

87 88

Shrimp Processing Shrimp Processing

Harvest
Store
De-head
Grade
Peel Weigh
Weigh
Dust- Batter Cook
Bread Place in block tray
Tray pack I.Q.F.
Fry Block freeze
Glaze
Freeze Knock out
I.Q.F. Weigh

Overwrap Pack Glaze

Store
Ship
 89 90

Fruits Postharvest General Flow at Packinghouse

Fresh fruits

Load into wax m/c

Load to Load into
Pre-cooler Water spray cleaning ripening room
Inspection

Pre-cooling @ Water spray brushing

Ripening @ desired
desired condition condition
Surface water removal
FRUITS & VEGETABLES Wax emulsion coating with brush & spray
Unload from Pre-
cooler Drying with fan & heater Unload from
Pre-cooling Methods Grading by size
ripening room

& Control Atmosphere (CA) Packing Packing

Cold storage Packing

Transport

91 92

Fruits & Vegetables Fruits & Vegetables

Commodity Max. Opt. Highest Recomm. %RH Air Change Ethylene Commodity Max. Opt. Highest Recomm. %RH Air Change Ethylene
container temp. container temp.
transit & transit freezing (cfm) transit & transit freezing (cfm) Produc- Sensi-
setpoint (qC) Produc- Sensi- setpoint (qC)
Shelf life temp. (qC) temp. (qC) tion Rate tivity Shelf life temp. (qC) temp. (qC) tion Rate tivity
(Days) (Days)
Beans, Green 10-14 7.2 -0.7 5.0-7.2 90-95 45 (H) Low M
Lettuce 8-12 0 - 0-1.1 90-95 45 (H) Low M
Broccoli 10-14 0 -0.6 0-1.1 90-95 20 (M) VL High (butterhead)
Onions, Green 7-10 0 -0.9 0-1.1 95-100 20 (M) VL Low
Cabbage 90-180 0 -1.4 0-1.1 95-100 45 (H) VL High
(White) Onions, 30-180 0 -0.8 0-1.1 65-75 20 (M) M M
Cantaloupes 10-14 3.3 -1.2 2.2-5.0 85-90 45 (H) High M Dry
Spinach 10-14 0 -0.3 0-1.1 95-100 45 (H) VL High
Carrot, 28-180 0 -1.4 0-1.1 95-100 15 (L) VL Low
Strawberries 5-10 -0.5 -0.8 0-1.1 90-95 20 (M) Low Low
Topped
Celery 14-28 0 -0.5 0-1.1 90-95 45 (H) VL M Sweet Corn 4-6 0 -0.6 0-1.1 90-95 15 (L) VL Low
Cucumbers 10-14 10.0 -0.5 10.0-11.1 90-95 45 (H) Low High Tomatoes, 7-14 10.0 -0.5 10.0-11.1 90-95 45 (H) M High
breaker to
Eggplant 10-14 10.0 -0.8 10.0-12.2 90-95 15 (L) Low Low light pink
 93 94

Pre-cooling Methods for Fresh Produce

• Top Icing
• Hydro Cooling
• Hydrair Cooling (air + cold water spray), Wet
PRE-COOLING METHODS Air Cooling
• Air Cooling
™ Room Cooling
For Fruits & Vegetables
™ Force Air Cooling
• Vacuum cooling

95 96

Top Icing Hydro Cooling

Evaporator

Cooled Water Distribution Pan

Product Out

Water Reservoir

Continuous Flow Shower Type Hydrocooler

 97 98

Hydrair Cooling System, Wet Air Cooling

Hydro Cooling
System
Cooled Wet Air Cooler
Product Out
Flighted
Conveyor Cold, Humid Air

Ice Water
Evaporative
Condenser
Immersion Tank

Evaporator Produce

Continuous Flow Immersion Type Hydrocooler Compressor Ice Chiller & Water
Tank Cold Room

99 100

Hydro-Force Cooler (HAC) Hydro-Force Cooler (HAC)

High Humidity Air Supply

Water
Drift Eliminator Spray
Evaporator

Air
In

Circulate Pump
 101 102

Room Cooling Recommended Temperature (TD) for Four Classes

of Foods (Forced Air Unit Coolers)
Class TD RH Suitable for
1 7-9qF 90% Fruits, vegetables, flowers, unpacked
(~5qC) ice, chill room
2 10-12qF 80 - 85% General cool room, packed products
(~7qC)
3 12-16qF 65 - 80% Beer, wine, pharmaceuticals, short
(~9qC) term packaged products, tomatoes,
onions, and tough skin fruits e.g.
melons
4 17-22qF 50 - 65% Processing rooms, cutting rooms,
(~12qC) candies, loading docks

103 104

Forced-Air Cooling Force Air Cooling

Cold-wall

Fan

Evaporator
Cold-wall
Fans

Cold Room Air

In
Produce Produce

vent open when pallet is pushed against bumper

Canvas System
Canvas System
Tunnel type FAC using cold-wall system
 105 106

Force Air Cooling Force Air Cooling

Canvas Free System Air Bag (Vertical Air Circulation)

107 108

Vacuum Cooling Vacuum Cooling

Typical schematic of a vacuum cooler

Condenser
Evaporator
Produce

Condensate

Compressor Vacuum Pump

Vacuum Chamber
 109 110

Vacuum Cooling Compare Cooling Methods for Fruits and Vegetables

Some vegetables that can be vacuum cooled:- Room Vacuum FAC Hydro Top/Liquid
Cooling Cooling Cooling icing
• All leafy vegetables • Green peas Typical cooling time 20 to 100 0.3 to 2.0 1 to 10 0.1 to 1.0 0.1 to 0.3
• Any type of lettuce • Leeks (hr)

• Asparagus • Mushrooms Product moisture 0.1 to 2.0 2.0 to 4.0 0.1 to 2.0 0 to 0.5 No data
loss (%)
• Bell pepper • Parsley Water contact with No No No Yes Yes, unless
• Bok choy • Radishes product
bagged
• Brussel sprouts • Romaine Potential for decay Low none Low High Low
• Cabbage • Snap beans contamination

• Carrots • Spinach Capital cost Low Medium Low Low High

• Cauliflower • Squash Energy efficiency Low High Low High Low
• Celery • Oriental vegetables Water-resistant No No No Yes Yes
packing needed
• Cucumbers • Prepack coleslaw Portable No Common Sometimes Rarely done Common
• Endive • Prepack spinach
Feasibility of No No Rarely done Yes Rarely done
• Escarole in-line cooling

111 112

Recommended Cooling Methods Recommended Cooling Methods

for Fruits and Vegetables for Fruits and Vegetables
Commodity Vacuum Room Forced Air Hydro Top/ Commodity Vacuum Room Forced Air Hydro Top/
Cooling Cooling Cooling Cooling liquid icing Cooling Cooling Cooling Cooling liquid icing

Beans/snap Y Y Y Y
Broccoli Y Y Lettuce Y Y
Cabbage Y Y Potatoes Y Y
Cantaloupe Y Y Spinach Y Y Y
Carrot Y Y Strawberries Y Y
Celery Y Y Y
Sweet-corn Y Y
Cucumbers Y Y
Egg Plant Y Y Sweet-potatoes Y
Green Onions Y Y
Tomatoes Y
 113 114

Control atmosphere (CA)

CONTROL ATMOSPHERE
(CA)

115 116

Control atmosphere (CA) Control atmosphere (CA)

Membrane type PSA type VPSA type Carbon Dioxide

Nitrogen Generator Nitrogen Generator Oxygen Adsorbers Adsorbers
 117 118

Control atmosphere (CA) Control atmosphere (CA)

CA Door
Ethylene Scrubber

119 120

Control atmosphere (CA) Control atmosphere (CA)

Air bags to equilibrate pressure in

Analyzer
controlled atmosphere rooms
 121 122

Industrial Refrigeration
Industrial Refrigeration For Food Preservation
For Food Preservation Thank You
For Your Attention.
Q&A
For more information please email to
apichit.lpana@itc-group.co.th Su Gree Kob
Ya Khun Ka
Tel: +66-2374-4640