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Potato Post Harvest ManagementStorage Design
Content
• Storage Design• Smart Control• Groups case on challenges in storage design
• 1: Goals & Circumstances: local situation, background information;
• 2: Construction of building: quality, budget, preference;
• 3: Storage System: technical details: size of cells, storage capacity etc;
Based on these 3 pillars a storage facility is designed.
Storage design Scope of Supply
Storage Solution
Science
Local SituationLocal Situation
ResearchResearch
ExperienceExperience
Storage Solution
ScienceScience
Local SituationLocal Situation
Research
ExperienceExperience
Dynamic modelling of potato storage: PhD by NikGrubben
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Storage Solution
ScienceScience
Local SituationLocal Situation
ResearchResearch
Experience
Storage Solution
ScienceScience
Local Situation
ResearchResearch
ExperienceExperience
Your Supply Chain
Potato & Onion Supply Chain Storage Design
• Where to start?
• Goal: aim of client: minimize risks, minimize weight loss, control quality, control costs.
• Circumstances: location, climate, yield, capacity.
• Building: construction, budget, preference.
• Storage system: storage controls
• Minimize risks
• Minimize weight loss
• Control product quality
• Control costs
• Control sugar levels of product
• Defects & diseases prevention
– Pressure Bruises
– Rot
– Skin diseases
• Sprout Control
• Growth Vigour
Storage Design: Goal Storage Design: Circumstances
• What kind of crop (fresh, fries, crisps, starch)• Variety• Harvest method • Harvest conditions• Climate profile (rain, sun, snow, temperature, RH)• Transport organized (time and conditions field to store)• Quantity per day harvested• Temperature during loading • Outtake per day• Outtake period• Storage period• Available services (forklifts etc)• Power arrangement • kWh price• Onion/potato price
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• What are the onion/potato varieties?
• Under what weather conditions are the onions/potatoes harvested?
• What are the growing regions of the onions/potatoes?
• Can you describe how the logistics from the field to the store is organised? (means of transport, bags, bulk or big bags, how long does it take, maximum harvest rate per day in tons, etc).
• How is the onion/potato harvested?
• Under what conditions are the onions/potatoes harvested?
• What is the onion/potato temperature at harvest?
• Are the onions/potatoes short or long day (growing season)?
• How mature is the onion/potato?
• What is the soil type?
• Are disease an issue? If yes, what kind of diseases are an issue?
• Do you currently have a store? If yes, what kind of issues do you experience and how do you operate it at the moment?
– Do you experience issues during loading of the store? If yes, what kind?
– Do issues arise during the storage period? If yes, what kind?
• Where is the new to build store located?
• What temperature are you anticipating to store at, did you already consider this?
• What will be your desired delivery temperature to the market of the onions/potatoes?
• How many tons per day will you unload from the store to the market?
• In what kind of trucks will the onions/potatoes be transported to the market (reefer trucks?) and what is the transport time to the market? Where is the farm located?
• What is the kWh price
• What is the onion/potato price
Storage Design: Intake Existing‐ or new building
Global Agricultural Challenges Global Agricultural Challenges
Havest & Growing Conditions Europe Storage Design: Construction of building
• Construction type (preference client or personal advice)
• Insulation
• Storage System
• Construction of walls, roof, floor
• Dimensions cells
• Dimensions boxes
• Amount of cells
• Intake (receiving capacity)
• Product input temperature
• Storage lay‐out
• Orientation
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Storage Design: Insulation
• Insulating materials, e.g. mineral wool, foam polystyrene;– PIR
– PUR foam or panels
– The resultant product of PIR product gives greater heat stability, increased flame resistance, chemical resistance and dimensional stability, than that of a PUR foam.
• Minimal heat transfer: K‐ Value : 0.3W/m². K.
Storage Design: Insulation
• It is all about the details: – Material (wood or steel)
– Thickness construction ( walls, ceiling)
• Possibility of condensation, dew point;
• Importance of proper insulation: CO₂ levels , energy consumption (heat‐cold exchange)
Storage Design: Insulation Storage Design: Insulation
Storage Design: Insulation Storage Design: Insulation
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Insulation
Storage Design: Insulation
Insulation
Storage Design: Insulation
Insulation
Storage Design: Insulation
Insulation
Storage Design: Insulation
Insulation
Storage Design: Insulation SolidWorks Flow SimulationAir distribution Bulk Storage
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SolidWorks Flow SimulationAir distribution box storage
Two choices:
Bulk storage
Box storage
Ventilation Systems
Fully ventilated floor
Underground ducts
Above ground ductsHalf round (steel)
Triangle ducts (wood)
Bulk Storage Bulk Storage: Fully ventilated floor
Bulk Storage: Underground Ducts Bulk Storage: Above ground Ducts
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Bulk Storage: Above ground Ducts
AdvantagesRelative low investment
Quick loading
Flexible on set‐up
DisadvantagesLess flexible during outtake
Bulksystem (pressure bruising)
Quality loss
Bulk Storage: Ad & Disadvantages
Drying Walls 1‐layer 2‐layer
Suction system
Blowing system
Room ventilation / Overhead Throw
Box Storage: Options Box Storage: Letterbox wall
Advantages • Equal distribution of the air • Flexibility: ventilation per row and layer per layer is one of the big advantages of the system.• Forced system with high air capacity • Relatively low running hours
Constraints• Limited box lenght (10 for potatoes, 8 for onions) • Special boxes required • For optimal efficiency, design, condition and uniformity of the boxes is crucial • High investment per ton
Box Storage: Drying wall – 1 layer Box Storage: Drying wall – 2 layer
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Box Storage: Drying wall Box Storage: Suction wall
Advantages:• Long box rows (max 20)• High efficiency for drying and storage with minimal storage losses
• Even air distribution ‐‐> low delta temp. and running hours Easy installation on site with prefab units
Constrains:• Limited acces to system• Equal row length required• In‐ and outlet hatches in same wall• put on and off the suction sheet (can beautomated but has extra investment)• Needs a separate room to function properly
Box Storage: Suction wall Box Storage: Suction wall
Box Storage: Suction wall Box Storage: Blowing wall
Advantages:• Longer box rows (max 16) • High efficiency for drying and storage with minimal storage losses
• Even air distribution ‐‐> low delta temp. and running hours Easy installation on site with prefab units
• Easy operation, manual coverage of pressure duct not required• Can be used in an open area or packing bayConstrains:• Limited acces to system• Equal row length & height required
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Box Storage: Blowing wall Box Storage: Blowing wall
Box Storage: Blowing wall
Advantages:• Equal distribution of the air • Flexibility: no adjust boxes required • Low investment per ton • Easy to implement in existing buildings • Minimal additional requirements for
adjustment of buildingConstrains: • Not suitable for drying• Stacking pattern important for product quality
• More running hours
Box Storage: Room ventilation/Overhead Throw
Box Storage: Room ventilation/Overhead Throw Box Storage: Room ventilation/Overhead Throw
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• Most effective, efficient and flexible storagesystem is the suction system
• Most flexible is drying wall system
• Alternative for suction when in need of otherhatch arrangement or not willing to put covers on or off is the blowing system
• Room ventilation/Overhead throw is not a drying system but a storage/cooling system
Storage Systems: Conclusions Storage Design: Lay‐out
Storage Design: Lay‐out Storage Design: Lay‐out
Storage Systems
Bulk Drying Wall Suction/Blowing Room ventilation
• Designing a potato store, based on the following details:
• Intake, information client:
• Store capacity: 20.000 ton (1.920 boxes)
• Suction system
• 8 cells: 2.500 ton per cell
• New‐building
Group Case
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Storage Design: System
• Air Quantity
– Quality demands
– Harvest circumstances
– Climate profile
– Speed Control
• Refrigeration
– Direct
– Indirect (natural or chemical)
• Heating
• Humidification
• CO2 control
• Control on temperature & quality
• Limited temperature variations
• Efficiency using cold outside air
• Reducing risk on rot development
• Control on sugar development
• Control on respiration
Air Quantity
£‐
£200
£400
£600
£800
£1,000
£1,200
£1,400
£1,600
0 7 30 280 300
Days
Cost development
Costs Inverter
Costs Normal
Return on Investment: Speed Control
• Factors influencing quality
• Delta temperature of system
• Influences dehydration losses
• Direct or indirect system
• Assistance of supporting ventilation system
Refrigeration
• Thermera chiller cooling machines
• Compact turn key coolers
• DX cooling installations (Direct Expansion)
Refrigeration Solutions
• Thermera cold transfer fluid• Low dehydration by controlling DT1
max delta Temperature of 7 degrees• 100% food safe• Environmentally friendly• Higher thermal performance than propylene glycol• Not corrosive• High efficiency• Easy installation• Low maintenance
Refrigeration Solutions: Indirect
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Low to no drying effect
Return on Investment: Heating
Fosil Fuels, Central Heating or Electric: Cold and Wet climates
Low drying effect
High drying effect
Return on Investment: Heating
Fosil Fuels, Central Heating or Electric: Cold and Wet climates
Return on Investment: OmniRecup
CO2 heat exchanger (tropical and sub tropical climates)
Cold inside air
(exhaust from
storagecells)
Exhaust: (warm air is
removed from storage)
Inlet(fresh air)
Inlet (cooled air through storage)
ENERGY RECOVERING CO2 EXTRACTION SYSTEM (OMNIRECUP)
Storage
Green Energy
Reductionnoise levels
Environmentallyfriedly sprout control
EMS
Track & TraceBenchmarking
Wireless sensors
Modulair hardware
Intelligent “Predictive” control
Monitor & Control 24/7
Innovation: Smart Control
• Modern simulation technologies: visualise analytical mathematical equations.‐ Computational Fluid dynamics
Smart Control: concept idea
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• Design quality model
?
Smart Control: concept idea
• Validation
Smart Control: Implementation
• Strategy, moisture losses and running costs
Smart Control: Result
Research
Smart Control: Result
Net bulk value = (bulk mass – dehydration) . market valueVentilation cost = energy consumption . energy costNet profit = net bulk value – ventilation cost
Smart Control: Result Smart Control: Result
• Return on Investment
• Less Defects
• Reducing running costs
• Reducing weight losses
• Increase Efficiency of Store
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• Which challenges do you face concerning your climate when it comes to ventilation technology?
• How do you see the future of storage technology in 10 years time?
• How can you be more effective in your Sales and how can we (Omnivent) be of assistance in this?
• What is positive in our partnership?
• What can be improved and what can we do better?
Group Case
Thank you
Any Questions?