PROJECT |
INCORPORATING COLD CHAIN |
||||
|
We identified an opportunity to address inherent inefficiencies in the existing configuration that had previously negatively impacted service and maintenance access
handling massive volumes of fruit efficiently
and sustainably.
What sets the CCH Epping project apart
is its transformation from a conventional
freezer warehouse to a highly dynamic fruit
facility. This shift has dramatically increased
the daily volume of pallet movements,
transforming it from a typical 8-to-5
operation into a 24-hour-a-day operation
during the intense citrus season. The ability
to efficiently receive and cool massive
volumes of fruit arriving at all hours, ready
for immediate loading onto vessels, is a
significant operational achievement.
The extended citrus season itself is
a function of the diverse range of citrus
varieties – from soft citrus to navels,
oranges and grapefruit – each requiring
different handling temperatures and
|
protocols. This varied harvesting schedule ensures a continuous flow of produce, demanding the facility ' s constant readiness and adaptable cooling capabilities.
Cape Bulk Industrial Refrigeration was brought on board as construction managers and the primary refrigeration contractor for this ambitious project. Thomas O ' Connor, owner and manager at Cape Bulk, explains the scope: " We essentially kept the shell and stripped everything on the inside out, doing a rebuild specifically in the room areas."
The technical core of the revamp involved significant additions and upgrades. A total of 27 new cooling tunnels were installed. These tunnels offer flexible stacking options, accommodating pallets stacked three high in some configurations( up to 60 pallets) and two high in others( up to 44 pallets). Following the cooling process, produce is transferred to substantial holding areas which have been equipped with Barpro mobile racking systems, optimising storage density and efficiency.
On the refrigeration side, the project involved upgrading the existing system. While the compressors on site were reused, all coolers were replaced with new units. Product suppliers include HC Group and BAC( Baltimore Aircoil Company).
|
New offloading canopy.
“ We conducted a complete overhaul
of the plant room, including relocating
compressors and installing a new
electrical distribution system with updated
compressor and main panels. Extensive
changes were implemented to achieve
compliance with the new SANS regulations,”
says O’ Connor.
To accommodate the increased capacity
and new system design, new vessels
were added, including a high-stage vessel
alongside the existing low-stage vessel and
intercooler system. New GP 52 ammonia
pumps from Witt were also installed.
The facility now operates with two distinct
plant rooms. One is dedicated to the highstage
requirements of the fruit handling
area, while the other remains primarily
focused on the frozen products that the
facility continues to handle.
|
officer and a construction manager, to oversee activities. O ' Connor emphasises the critical nature of coordination, stating: " The coordination between the client, myself, project manager and the contractor, was extremely important." Constrained space for fabrication, material storage and site offices necessitated precise logistical management, relying on just-in-time material deliveries and immediate removal of excavated material. Furthermore, meticulous scheduling was essential, particularly around CCH ' s peak operational days. This often required planning potentially disruptive work, such as rigging and excavation, for weekends whenever feasible to avoid impacting core business activities, without incurring additional costs. |
|
Forced cooling tunnel being loaded. |
NAVIGATING CONSTRUCTION IN AN ACTIVE FACILITY
Executing a comprehensive renovation
within a continuously operational facility
posed significant logistical hurdles as
the project team managed the extensive
stripping, rebuilding and installation
" while their operations were still active ".
This constraint introduced considerable
complexity to the construction process
and required meticulous planning and
adaptation.
With numerous contractors across
civil, mechanical and steel erection
disciplines working concurrently,
minimising disruption to CCH ' s ongoing
|
operations was paramount. Cape Bulk
deployed dedicated site management,
including a permanent health and safety
|
Navigating these significant logistical hurdles, specifically the necessity of working around continuous operations, impacted the project ' s overall timeline but not its budget. The project, which commenced in October, saw its initial completion target of end-April adjusted. The programme logically shifted, resulting in a revised target date at the end of May. Despite the programme extension due to operational constraints, budgets were successfully managed.
Crucially, understanding the seasonal nature of fruit exports(" you can ' t tell the tree to stop producing "), the project team prioritised the completion of certain areas and rooms. This ensured that when the first fruit pallets began arriving from early April, CCH was ready.
|