The Lusaka Commercial Cold Store project is a significant greenfield initiative undertaken with the goal of improving the cold chain infrastructure in Africa .
INCORPORATING COLD CHAIN
PROJECT
Zambia ’ s first mobile racking state-of-the-art cold store
By Eamonn Ryan with technical input from Jan Eagar ( JAE Cooling Solutions ) and Shawn Gray ( Acrow )
The Lusaka Commercial Cold Store project is a significant greenfield initiative undertaken with the goal of improving the cold chain infrastructure in Africa .
Commencing in 2021 and completed in 2022 , this state-of-the-art facility was designed to enhance the region ’ s ability to store and transport temperature-sensitive goods , such as meat products , across the continent . Located in Lusaka , Zambia , the cold storage facility spans 4 000m 2 with an internal ceiling height of 12m , making it one of the largest of its kind in the area .
In terms of project specifications , the client had clear objectives for the cold storage facility . The Lusaka Commercial Cold Store ( LCCS ) was designed to accommodate 5 400 pallet positions in Phase One , ensuring sufficient capacity for the initial operational requirements . Based on return on investment projections , the land was acquired and the facility designed with future expansion in mind , with provisions made to add additional compressors and refrigeration units as needed without disrupting ongoing operations . This flexibility was essential for the long-term viability and scalability of the project .
Shawn Gray , senior sales executive at Acrow , says it is the first mobile racking installation in Zambia , to the best of his knowledge .
The project was therefore a pioneering effort to create a modern cold storage solution from the ground up . Unlike retrofits or replacements , this greenfield development was built on a fresh plot of land specifically chosen . The LCCS project sought to address the logistical challenges faced by African countries , where efficient cold storage facilities have historically been limited . The goal was to create a facility that could support the growing demand for refrigerated storage of perishable goods , ultimately enhancing trade and food security .
Jan Eagar , owner of JAE Cooling Solutions , overviews the project : One of the key technical features of the LCCS is its refrigeration system . The facility uses an economised single-stage ammonia system with a combination of pumped and DX evaporation coils with full redundancy . This application of ammonia as refrigerant simplifies the installation , which uses one compressor to maintain various temperature regimes and is consequently highly efficient and effective for small to medium scale cold
Supplied by JAE Cooling Solutions storage operations such as this . This facility operates across a temperature range of -25 ° C for the deep-freeze area and for the two other cold rooms which can operate at any temperature from ambient to -25 ° C , as well as maintain the receiving areas at + 10 ° C degrees utilising DX from the high-pressure liquid ammonia supply – allowing for versatile storage solutions .
The use of GEA compressors and Evapco condensers , as well as coolers from HC Heating Centre in combination with a dehumidifier supplied and installed by CFW , all contribute to the effectiveness of the refrigeration plant . Acrow supplied the mobile racking systems with rails from Kredit Industrie – all of which ensures that the cold storage environment remains optimal and flexible , adapting to the various types of goods stored . Importantly to note that without a properly installed insulated box to ensure the cold stays inside the building , IDS , a Cape Town based insulated panel manufacturer and installer , was responsible to ensure vapour barriers were perfectly installed . In addition to the refrigeration
Freezer floor under construction - strip footings cast for first stage of mobile racking rail installation .
Supplied by JAE Cooling Solutions Supplied by JAE Cooling Solutions
Completed facility highlighting refrigeration plantroom and ground-based pods for maintaining -25 ° C inside the building .
equipment , the facility was equipped with reliable power generators from Namib Diesel to address any potential interruptions to the local power supply given unreliable power supply in Zambia , and ensuring the facility could continue to operate smoothly .
Dessicant dehumidification technology implemented to control and minimise ice formation in freezer – internal view of de-humidifier .
Gray says that the success of the project is demonstrated by the fact that the facility has experienced zero significant downtime over the past two years , a testament to the reliability and robustness of the systems installed .
Stefanutti Stocks was the overall contractor , with Cape Town-based JAE Cooling Solutions contracted for the design of refrigeration system , racking and panelling installations . GEA Africa , IDS and Acrow were contracted by Stefanutti Stocks and responsible for the installation of refrigeration , insulated panelling and the racking respectively . Eagar attributes the success of the LCCS project to the well-coordinated efforts of the professional team involved . “ From the outset , the project team used a sophisticated design platform , including 3D modelling or building information modelling ( BIM ) tools , to pre-plan and resolve potential issues before construction began . This forward-thinking approach allowed for smoother execution during the construction phase .” Eagar attributed the success to Stefanutti Stocks ’ insistence to ensure that a fully coordinated model of the building and services be in place before the commencement of construction .
“ The weather conditions - especially the threat of the rainy season - were taken into account early in the planning stages , ensuring that key construction milestones were completed before adverse weather could disrupt progress . The pre-manufacturing of
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