Port Elizabeth identified a significant need for an independent cold room to serve as a vital link for local fruit farmers throughout much of the year. This facility plays a crucial role in mitigating the impact of wind conditions in the region and supports the growing volume of fruit exports. Additionally, from a frozen storage perspective, the cold room will benefit import-export customers by alleviating congestion at the Durban and Cape Town harbours.

Equity and debt funders encountered challenges in securing financing for the project due to its greenfield nature. Many potential customers were only willing to commit to short-term contracts, a common practice in the cold and freezer storage market. Additionally, the site development plan approval process complicated progress, particularly as the three properties involved had not yet been transferred from the seller or consolidated for building plan approval. These factors created significant hurdles for funders looking to invest in the project.

The facility ' s requirements were based on projected and future off-take in the region. To effectively serve a larger market with a diverse range of services, the design specifications called for multiple rooms capable of operating at either cold temperatures( around 0 ° C) or freezer temperatures( approximately-18 ° C). Initially, each room was designed to function at one of these temperatures. However, during construction, this approach was revised to allow all rooms to accommodate both temperature settings. To manage capital investment, the sterile rooms were initially excluded from the development plan, with plans to add them later. Ultimately, these rooms were reintegrated into the design to meet the industry ' s growing sterilisation demands.

At the outset of the project, a decision was made to implement a CO 2

-based refrigerant system, utilising technology

already in use in several large-scale facilities across South Africa. This choice aligns with the global trend towards adopting CO 2 refrigeration systems, which are recognised for their environmental benefits. CO 2 is a natural refrigerant with low global warming potential and ozone depletion potential, making it an attractive option for businesses focused on sustainability.

The transcritical CO 2 systems are particularly well-suited for warm climates, offering energy savings and operational efficiency. These systems incorporate advanced design features such as adiabatic gas coolers and sophisticated control systems to ensure reliable performance even in high ambient temperatures. As industries increasingly prioritise eco-friendly solutions, the adoption of CO 2 refrigeration technology is expected to grow, positioning it as a leading choice for future refrigeration needs.

CO 2 refrigeration systems are increasingly recognised for their energy efficiency and sustainability, making them an attractive alternative to traditional refrigerants.

ENERGY EFFICIENCY

CO 2 systems offer superior energy efficiency, particularly in cooler climates where they can achieve high Coefficient of Performance( COP) values. These systems are designed to operate effectively even at higher ambient temperatures; however, their efficiency may decline in extreme heat due to CO 2

’ s critical temperature of 31 ° C( 87.8 ° F). Innovative technologies, such as pressure exchangers, have been developed to enhance system efficiency, especially in warmer conditions, by improving stability and reducing energy costs.

ENVIRONMENTAL BENEFITS

• Low global warming potential( GWP):

CO 2 has a GWP of 1, significantly lower than many synthetic refrigerants, which can have GWPs in the thousands. This feature helps mitigate climate change impacts associated with refrigerant leaks.

• Non-toxic and non-flammable: CO 2 poses minimal health risks and is safe for use in various applications, including food storage.

• Ozone depletion potential( ODP): CO 2 has an ODP of 0, meaning it does not contribute to ozone layer depletion.

These attributes make CO 2 a preferred

choice under regulations aimed at

phasing out harmful refrigerants. CO 2 refrigeration systems represent a significant

advancement in sustainable cooling

technology. Their energy efficiency and

environmentally friendly characteristics

position them as viable solutions for

reducing the carbon footprint of refrigeration

processes. However, careful attention to

design and climate-specific performance is

necessary to maximise their benefits across

different applications. As industries move

toward decarbonisation, CO 2 refrigeration

systems are expected to play a growing

role in achieving these goals while ensuring

operational efficiency.

The cold room is designed for flexibility, operating independently to serve dual purposes as both a freezer and a chilled storage area. It is equipped with eight sterile rooms and eight dock levellers, ensuring efficient loading operations. The facility is built to accommodate high demand, particularly during peak seasons such as citrus harvests, when it operates 24 / 7. This adaptability and continuous operation during critical periods make the system and installation particularly unique and well-suited to meet the fluctuating needs of the industry.

MATADOR’ S ENGINEERED DESIGN, TECHNOLOGICAL FLEXIBILITY AND ADVANCED CONTROL SYSTEMS

By Eamonn Ryan, with technical input from Brent Duffield and Chris Vorster of Matador Refrigeration

The Port Elizabeth cold storage facility is a prime example of how modern refrigeration technology and adaptive design by Matador Refrigeration can reshape the food storage industry. Designed with operational flexibility in mind, the facility employs a sophisticated transcritical CO 2 refrigeration system, allowing it to toggle seamlessly between different temperature ranges to accommodate a variety of storage needs.

Brent Duffield, Matador Refrigeration managing director, says:“ The project initially began as a simple cold storage solution but quickly evolved as the needs of the business evolved. The facility’ s design was adjusted to include both medium and low-temperature storage capabilities – changeable at the flick of a switch. This change required engineering ingenuity to ensure that the system could be reconfigured to serve multiple temperature zones, depending on the type of produce being stored at any given time.”

The CCH cold store incorporates four large rooms capable of switching between medium and low temperatures, making it a versatile solution for handling a range of products. The flip of a switch can change the operational mode, adjusting multiple controllers and parameters in the system to deliver either cold or freezing temperatures. This adaptability allows for dynamic response to varying storage needs, whether handling fresh produce or frozen goods.

HOT GAS DEFROST AND EFFICIENT COLD STORAGE

Chris Vorster, Matador’ s engineering manager, adds:“ One of the standout features of this facility is its advanced hot gas defrost system, which is used for low-temperature applications. This system allows the cold storage rooms to maintain consistent temperatures by preventing the build-up of ice on the evaporators, ensuring continuous performance even in the most demanding conditions. The hot gas defrost process is controlled through a central system that ensures rapid and efficient defrosting, minimising energy consumption and downtime during the defrost cycle.”

Additionally, the facility features eight‘ steri-rooms’, designed specifically for the critical drop temperature process. When produce enters the facility, it’ s placed in these rooms, where the temperature is gradually reduced over 72 hours from a starting temperature of + 20 ° C to reach an optimal storage condition. This slow cooling process is crucial for maintaining the quality of the produce, especially for export markets with stringent quality requirements. The gradual cooling is managed by a peripheral control board( PCB), ensuring that the temperature drop is uniform and within the specified protocols required for certification in different global markets.

The rooms can also double as storage rooms when necessary.

REMOTE MONITORING AND AUTOMATION

Ongoing maintenance and monitoring are also key components of the facility ' s operations. It is equipped with an advanced remote monitoring system that ensures optimal operation. Using a centralised control platform, operators can monitor and adjust the refrigeration system remotely, making it possible to respond to real-time conditions without needing to be physically present on-site. The monitoring system