Temperature-controlled containers are a neglected means of adding existing space and able to deliver high cooling capacity in combination with precise temperature control, says Ralph Howes, cold stores major account manager, ICS Cool Energy.
Increased demand for frozen foods translates to increased demand for cold storage facilities. Traditionally many big producers have used third party cold stores, where their logistics company picked up the frozen goods, stored them on behalf of the manufacturer and then distributed them to store. Now, with the increasing cost of energy, fuel and transport, the cost per pallet is higher as well.
Manufacturers are looking at more cost-efficient solutions across all their processes, consider installing modular, containerised Cold Stores within their production site, cutting down the movements, road miles and related costs because the product goes directly from the production line to the producer’s cold storage in the plant and then straight to the retailer.
Cold Stores
Cold Stores, in other words temperature-controlled containers, were originally designed for global – often in high ambient temperatures – marine transport of temperature sensitive perishables. Yet, the variety of applications is only limited by the end user’s imagination.
Cold Stores are available as 10′, 20′ and 40′ containers, which can add cold storage to existing space and deliver high cooling capacity in combination with precise temperature control from fresh to deep frozen, even in the most severe applications with high ambient temperatures, frequent door openings, long running hours etc. These solutions can be adapted to meet customer needs with options including telematics, remote monitoring, and Controlled Atmosphere.
Market-leading Cold Stores are equipped with proven refrigeration units designed for seagoing reefer applications they can naturally be used on land requiring just plugging in the 360-500 Volt 50 or 60 Hz power supply, creating cold or frozen temperatures in the container.
Cold Stores evolved from typical marine containers, but they are equipped with many features that make them suitable as static cold stores. They are washable with wash down drains, have man trapped person alarms, lighting inside emergency escape release and conform to BRC audit standards – these are features that by which customers can differentiate leading Cold Stores in the market.
These systems can be used for planned and unplanned cold storage requirements for super- and hypermarkets, manufacturing needing additional storage capacity, as well as by festival and large event organizers requiring storage to keep the food and refreshments cool. Typically used for food, perishables or pharmaceutical storage needing precise temp-control, Cold Stores can also be used in specific applications like R&D and pilot plants.
Modular Cold Store Structures
Bespoke cold storage solutions can overcome the unique challenges faced by businesses requiring low and very low temperature storage. Cold Store containers can be easily located in any part of the facility, outside and inside of the plant. Today, more and more customers start looking at modular Cold Stores as an extension to the building. When they run out of cold storage area in any part of the process, whether this is goods-in, goods-out or the production area, Cold Stores providers can help them make more of the existing facility by creating a modular build linking several containers. This is significantly more cost and time efficient than creating a new building.
Cold Stores linked together into one big modular unit can be then linked with the buildings. This doesn’t require time consuming engineering, ground works, or long drawn-out planning permission exercises. The off-site construction of modular cold stores also means less interruption to the business and much shorter lead times. Modular install’s typically taking days whereas conventional building methods can take months on site and take up large areas of space for materials and machinery relating to the build. Disruption is minimised and the customers production in the main can continue. This allows us to enhance the customer’s process capability within weeks compared to months required to build a new cold storage building.
The brewery case – steady temperature for fermentation vessels
Preventing spoilage, preservation of flavour and aroma, quality and consistency control were the main necessities for a leading international brewery when they were looking for a partner to create a temperature-controlled storage for their reactor vessels within their plant. Certain ingredients and reactor vessels can be highly sensitive to temperature fluctuations and need to be stored for a prolonged period of time. If exposed to temperatures that are too high or too low, they can become damaged and lead to spoiled beer.
Looking at more cost-efficient solutions across all their processes, the brewery wanted to install modular, containerised Cold Stores within their production site, cutting down the movements, road miles and related costs while ensuring the ingredients are stored as closely to the production line as possible. A reliable containerised solution was needed to enable them to keep their fermentation vessels at a specific temperature, in the middle of the plant. Additionally, the storage had to be easily accessible for a forklift or a motorised pallet truck to enter.
ICS Cool Energy responded with two customised, high-cube 40-feet refrigerated container units with heavy-duty ramp delivered as part of the Cold Store hire solutions.
By using containerised Cold Store units from ICS Cool Energy, the brewery avoided investments required to turn a part of their plant into a cold room. This also contributed to significantly lower energy consumption as cooling a container requires significantly less energy than cooling an entire room.
ICS Cold Stores project team were able to make more of the existing facility by creating a modular complex of several Cold Stores linked together to provide one large temperature-controlled area. This was significantly quicker than a traditional building and required no up-front expenditure.
As a rental product they are cash flow positive, allowing payback on projects from day one.
Finally, logistically, before installing the Cold Stores, the brewery had to deliver the ingredients to the production line from another location within the site. A route that would normally take around 15 minutes to cover, may times a day. Eliminating this can save them even a few hours a day and maximise the production process.
The success of the project was proven by the fact that following the initial 12-months hire contract and successful tests, the brewery decided to extend the hire and increase the number of cold stores for a further 5-year period.
