One of the most significant changes in the refrigeration industry is the shift from HFCs ( hydrofluorocarbons ) to HC ( hydrocarbons ) gases . This transition is making waves across both cold rooms and display freezers .
FEATURE
INCORPORATING COLD CHAIN
The history , evolution and future of cold storage and freezer design
By Eamonn Ryan
One of the most significant changes in the refrigeration industry is the shift from HFCs ( hydrofluorocarbons ) to HC ( hydrocarbons ) gases . This transition is making waves across both cold rooms and display freezers .
Image by © Cold Link Africa Image by © Cold Link Africa
As businesses and retailers strive to meet stricter environmental regulations and enhance energy efficiency , the adoption of HC gases is becoming a gamechanger . Cold rooms , essential for preserving perishable goods , and display freezers , crucial for showcasing products , are both benefiting from this shift . HC gases not only offer a more sustainable alternative with lower global warming potential but also contribute to improved operational efficiency . As the industry embraces this transformation , the future of refrigeration looks both greener and more efficient .
The following presentation was delivered at the 2024 Cold Chain Refrigeration , Logistics and Technology Summit , by James Cunningham , CEO of Barpro on the topic ‘ Innovative cold storage solutions with racking systems ’.
“ Twenty-eight years ago , I gave a speech on mobile racking at a conference in South Africa , where it was generally described as being unsuitable for South Africa . At the end of the speech , one American cold store owner , affiliated with the Global Cold Chain Alliance ( GCCA ), told me I really needed to get a ‘ real ’ job as I wouldn ’ t make any money from mobile racking . Contrary to that early scepticism , that American is today installing mobile racking in his cold stores in the US , demonstrating a significant shift in industry attitudes .
“ Barpro has since installed over 400 mobile racking systems mostly in South Africa , each tailored for the conditions with various racking types . I would describe it as a ‘ good , qualified success ’,” says Cunningham .
“ IF YOU WANT TO LEARN COLD STORAGE , VISIT AUSTRALIA ”
Cunningham took a moment to honour past innovators in cold storage , particularly Fred Tudor ( born 1783 ). Tudor , from the east coast of the US , harvested ice from New England ponds , storing it in special houses and selling it to cities like Baltimore and Philadelphia where the people had a major problem with preserving fresh meat and fruit . He even exported ice to India , achieving the first commercial success with refrigeration .
James Cunningham , CEO of Barpro speaking on the topic ‘ Innovative cold storage solutions with racking systems ’
The Barpro stand at the conference .
He also mentioned Cape Town ' s first commercial cold store – the Imperial Cold Store and Supply Company building - built by David de Villiers Graaff . This was the first successful shipment of frozen mutton between Australia and England ( as well as the first mention of Australia which will be mentioned again ). “ This marked the beginning of South Africa ' s frozen beef exports – today a huge industry . De Villiers Graaff also built Cape Town ' s first electricity generator , highlighting the close relationship between cold storage and electricity .” The modern cold store has been shaped by numerous innovations , with Cunningham pointing out the development of pallets , which evolved from simple skips . “ Pallets became essential during World War II , facilitating the movement of military equipment . Following that , surplus pallets in Australia led to the formation of the Commonwealth Handling Equipment Pool ( CHEP ), which started renting them out standardising pallet sizes . This standardisation became crucial in designing cold storage spaces – and is the building block of racking we all still follow .”
“ Thereafter , Dexion steel racking was invented by Demetrio Comino in Australia in the late 1940s . This innovation allowed for vertical stacking of pallets , increasing storage capacity in cold stores . The reach truck , invented in the 1960s , further enhanced this capability by enabling the lifting of pallets to greater heights in narrower aisles .”
Cunningham noted how often wars spur innovation , citing the Vietnam War ' s role in advancing containerisation .
Then in the early 1960s Michael Rudnev , an innovator in cold storage in Brisbane , Australia , developed an insulated sandwich panel using chromadek sheeting glued on either side of a polystyrene core . These panels had better insulation properties than cork and were lightweight yet strong enough to support lengths exceeding 10 metres .
“ This panel , made from expanded polystyrene , replaced cork as an insulator in cold stores . The chromadek panel improved insulation and structural integrity , paving the way for modern cold storage construction .”
The advent of barcodes in 1974 marked the beginning of computerisation in cold storage . Cunningham shared anecdotes from his early career , including the challenges of real-time stock updates and the use of floppy disks for data transfer physically transported around by motorcycles .
Stressing the importance of affordable energy for cold storage facilities , he acknowledged the role of innovators like
Thomas Edison and George Westinghouse in the development of electrical systems that power these facilities .
“ Energy efficiency remains a critical issue in the industry , compounded by the dramatic rise in electricity costs in South Africa , which have increased by 500 % from 2014 to 2024 , and I believe will increase by another 500 %. Carbon taxes further complicate the situation , with a need for reliable and affordable energy sources to power cold storage facilities .”
He praised Frank Vale , who integrated various innovations into a model cold store in Dandenong , just outside Melbourne in Australia , in the early 1970s . “ That was the first modern cold store .”
Peter Spears , of the UK based Barpro Group was then one of the earlier innovators of mobile racking , along with Dexion . Cunningham explained why mobile racking has been successful : “ It maximises storage capacity while maintaining accessibility , is cost-effective and energy efficient . For instance , one British cold store manager reported that doubling storage capacity with mobile racking reduced electricity costs per pallet .
“ However , energy costs and reliability remain significant challenges given the high operational costs of running generators during power outages and the critical role of maintaining efficient door operations in cold stores . The industry consequently needs to adopt basic energy-saving measures and leverage available technologies to mitigate these challenges – and the biggest problem in cold storage is the doors , which when left open can typically cost R300 000 a year in energy costs .”
ENERGY INNOVATIONS AND EFFICIENT CASE PICKING IN COLD STORAGE
Cunningham discussed a promising innovation for maintaining cold storage temperatures during power outages : phase change materials . “ These materials can be installed under the ceiling of cold storage facilities without taking up valuable space . During normal operations , they freeze and store cold energy . When there ' s a power outage , they absorb heat , maintaining stable product temperatures until power is restored . This method could reduce the reliance on diesel generators , which are costly and inefficient . The US company Viking Cold Solutions has been a leader in this area , reporting energy cost savings of about 35 %. However , I believe the savings could be even more significant when compared to generator fuel costs
12 www . coldlinkafrica . co . za COLD LINK AFRICA • October 2024