For a number of reasons, cold storage solutions are essential to India’s expanding food sector. Due to urbanisation, shifting consumer tastes, rising demand for processed and packaged foods, and the expansion of organised retail, the Indian food business is undergoing major change. Within this changing environment, there are several difficulties and possibilities that cold storage systems address.
Cold storage facilities play a critical role in optimising the supply chain for perishable commodities. They let manufacturers and distributors keep items during periods of strong production and demand and gradually release them into the market during lean seasons. This helps stabilise prices and provides a consistent supply of food supplies throughout the year.
Beneficial Cold Storage System
Perishable Goods Preservation: India is a varied agricultural nation with a vast variety of climate conditions. Many agricultural goods are perishable and require precise temperature and humidity conditions to stay fresh and in good shape. Cold storage facilities offer the essential conditions for fruits, vegetables, dairy goods, meat, and seafood to increase their shelf life and reduce post-harvest losses.
Food Waste Reduction: Due to insufficient storage and transportation facilities, India suffers severe post-harvest losses. Cold storage systems assist in decreasing food waste by avoiding rotting, minimising losses during transit, and enabling improved inventory management. This helps to increase food security and availability.
Facilitating Food Processing: For processing, packaging, and delivery, many food items require precise temperature conditions. Cold storage systems allow food processors to operate with raw materials at ideal temperatures, ensuring food safety and product quality.
Promoting Agricultural Diversification: Cold storage facilities can allow farmers to diversify their crops and generate higher-value, perishable items, encouraging agricultural diversification. Cold storage facilities stimulate farmers to move beyond basic crops by offering a mechanism to keep and sell these items throughout the year, resulting in improved income and agricultural diversification.
Support for Export potential: As India’s agricultural industry grows, so does its food export potential. Cold storage systems are crucial for meeting international food safety and quality requirements, allowing Indian manufacturers to sell perishable goods in worldwide markets.
Facilitating Organised Retail Growth: Organised retail chains demand constant and dependable supplies of perishable commodities. Cold storage facilities offer the infrastructure required for these chains to keep fresh and high-quality items in their stores, boosting the expansion of organised retail and improving the entire shopping experience for customers.
Increasing Rural Employment: Establishing cold storage facilities in rural locations can create jobs and produce cash for local communities. It also helps agricultural goods keep their worth inside the region rather than spoiling due to a lack of storage alternatives.
Reduced Energy Consumption: As technology advances, contemporary cold storage facilities may be constructed to be more energy-efficient, lowering environmental impact and operational costs.
Changes in demography have increased demand for frozen goods, moving the cold storage business forward. This move has established a niche in food packaging, prompting Ice Cream Times to reach out to cold storage partners for further information.
To start with, we had a conversation with Sunil Bhat, the founder and director of Advance Agro Ripe Pvt. Ltd. from Pune, in reference to our inquiry about a cold storage facility.
“In every frozen food sector, the principal expense of their operation—whether it be processing or quick freezing and subsequent storage of final products—is spent on power bills, which account for roughly 60% or more of total costs”, asserted Sunil.
He further went on to say that, due to technological advancement, there are drastic improvements in energy efficiency in the latest refrigeration technologies. Unfortunately, only a small percentage of ice cream and frozen food firms do energy audits on their existing facilities.
“A huge quantum of energy is wasted in avoidable frosting and defrosting cycles. Either no anteroom or Ante rooms with no temperature and humidity control are in operation. This leads to the migration of moisture in the frozen zone, leading not only to excess energy consumption but also making floors slippery and accident-prone”, informed Sunil.
Giving more insight, he said, “Constant excess humidity leads to fungus development on PUF panel walls, rusting them rapidly. This is a critical risk for the storage facility’s integrity and durability. Fungus development not only jeopardizes the environment’s cleanliness and hygiene, but it also has the potential to infect stored food goods, jeopardizing their quality and safety. Rapid rusting of the PUF panel walls might compromise the facility’s structural integrity, posing possible risks and increasing maintenance expenses. Implementing appropriate humidity control methods and suitable ventilation systems are critical elements in mitigating these hazards and ensuring an optimum storage environment for the ice cream business and the food sector as a whole”.
“Ideal cold storage is defined by the absence of ice layers on the walls and floors. There is no water dripping from the ceilings. There is little frost on the evaporators, and there is no significant temperature difference within the storage. Products are piled more scientifically to allow cold air to reach the centre of boxes or products.
An AI-based temperature controller providing hour-by-hour energy reports would be ideal for a cold storage facility. This assists in assessing each machine set’s performance separately and alerting you well in advance of any significant failure. Prevention is always preferable to unanticipated breakdowns.
Ideal cold storage facilities should have proper thermal wear sets for operating personnel. Door safety alarms should be installed to prevent unintentional entrapment and tragic incidents.
Ideal cold storage should have high energy efficiency for lower carbon footprints and use eco-friendly refrigerants in their systems to safeguard the environment.
Ideal cold storage facilities should follow GMP (Good Manufacturing Practise) norms like plant building hygiene, personal hygiene, and equipment hygiene for the welfare of society”, Sunil concluded his words.
“As the Director of Cold Star Solutions Pvt. Ltd., I find it imperative to address the pressing issue of cold storage facilities in the context of India’s rapidly expanding population and its subsequent impact on food demand and storage requirements,” Madhu Sudan Sharma stated.
With our country’s population nearing a staggering 1.4 billion, it’s clear that the need for food is on an upward trend. This increase in demand translates directly into the requirement for effective and expansive storage solutions. Cold room storage emerges as a critical pillar in our efforts to maintain food security and reduce waste.
The ice cream industry’s remarkable rise is of particular importance. We estimate a multifold increase in this area by 2025, driven by shifting customer preferences. As we prepare for this seismic transition, we must also recognise the problem of servicing rising demand. It’s worth mentioning that the ice cream market is expected to produce a whopping 177.15 billion in sales revenue by 2025. Premium ice cream companies are at the forefront of influencing eating trends, making storage and distribution important.
Given these constraints and possibilities, the careful location of cold storage facilities is crucial. A well-located facility, adjacent to production and distribution centres, is the foundation of a smooth supply chain. This positioning’s economic feasibility guarantees that items may be effectively moved from production to distribution sites while retaining their quality and integrity.
Cold Star Solutions Pvt. Ltd. is unwaveringly devoted to meeting India’s expanding cold storage needs. Our continued relationships with restaurants and ice cream companies demonstrate our commitment. As we move forward, we hope to extend our clientele and bring additional well-known celebrities under our wing.
The future of India’s food business is inextricably linked to the effectiveness of its storage systems. We understand the importance of cold storage in protecting our food supply and supporting sectors such as ice cream. Our commitment is unwavering, and we look forward to making a substantial contribution to this paradigm change”, were some of the devoted sentences by Madhu Sudan.
Krunal Makwana from Gayatri Engineering Co. Pvt. Ltd., Ahmedabad, regulated his reply: “The ideal design of cold rooms or cold storage has become an important topic in the ice cream business, mainly because of the increased need for energy-efficient solutions. Maintaining the quality, safety, and shelf life of ice cream products depend on achieving the necessary chilling while requiring the least amount of electricity”.
“Important factors in the design process include choosing energy-efficient cooling systems and compressors, installing heat recovery mechanisms, controlling airflow for consistent temperature distribution, and making sure doors are airtight to avoid heat infiltration. In order to maximize cold room efficiency and advance sustainability in the ice cream sector, accurate temperature and humidity management, thermal load analysis, monitoring and automation systems, and regular maintenance are also crucial. Ice cream producers may improve their operational effectiveness, cut expenses, and support ecologically friendly practises by taking these elements into consideration”, here Krunal shared his notable words.
Shifting our attention to Sanjay Sharma, COO from COLDMAN Warehousing & Distribution, Navi Mumbai, he replied, “An ideal storage facility in the ice cream industry and the food sector in general would encompass a range of features and considerations to ensure the safety, quality, integrity, and efficiency of food storage. Some crucial key aspects are Temperature and Climate control, Advanced refrigeration systems, Hygiene and Sanitation, Inventory Management Software, Traceability, Product Security, compliance, etc.”
Adding further, “Maintaining a consistent and appropriate temperature is crucial to prevent spoilage and maintain product quality. For ice cream, temperatures below -20°C (-4°F) are typically required to prevent melting and texture degradation. Utilizing modern refrigeration systems that offer precise temperature control, energy efficiency, and backup capabilities in case of power outages is essential. Many Cold chain service providers employ smart technology for real-time monitoring”, Sanjay explained.
“The facility should adhere to regulations regarding food storage, safety, and hygiene. Regular inspections and audits can help ensure compliance. Strict cleanliness and sanitation protocols are critical to preventing contamination. The facility should have proper ventilation, pest control measures, and easy-to-clean surfaces to meet food safety standards.
“Efficient rack systems with the right choice of Material Handling equipment should be in place to allow storage and stock rotation. Utilizing inventory management software can help track product quantities, expiration dates, and other relevant information. Such software can optimize restocking, reduce waste, and improve overall efficiency. Given the value of food products, especially in large-scale operations, security systems, including surveillance cameras, access controls, and alarms, are crucial to preventing theft and unauthorized access. Facilities should have contingency plans for power outages, equipment failures, and other emergencies. Backup power sources and protocols for handling unexpected situations should be in place.
“Well-trained employees are essential for proper food handling, storage, and inventory management. Regular training sessions on food safety and handling procedures are crucial. Establishing systems to quickly trace the origin and distribution of food products is important in cases of product recalls or quality issues. This can minimize the impact on consumers and the company’s reputation.
“The facility should be designed with flexibility and scalability in mind, allowing for changes in storage needs as the business grows or market demands shift”, concluded Sanjay .
Blue Star Refrigeration’s All-India Sales Head for Cold Storage recommends a palletized multilevel storage system for ice cream and food storage. This method ensures product traceability, real-time temperature monitoring, and an inventory first-in, first-out model.
The palletized multilevel storage system is a crucial component of efficient inventory management and successful food storage. It allows for the implementation of the first-in-first-out (FIFO) model, ensuring product retrieval and distribution in the order received, minimizing wastage, and ensuring freshness.
Space optimization is also a critical aspect of this system, maximizing available storage space while maintaining efficient access to stored products. By adopting this system, operational efficiency can be enhanced, and commitment to product quality, safety, and customer satisfaction can be enhanced.
Such system aligns with the industry’s demands, ensuring accurate tracking throughout the supply chain. Traceability is crucial for maintaining product quality and safety in the ice cream industry.
The recommended storage solution also incorporates advanced temperature monitoring technology, ensuring temperature-sensitive products remain within optimal temperature ranges, safeguarding their quality, and extending shelf life.
Instant alerts for deviations allow for prompt resolution of potential issues, preventing costly losses. This system aligns perfectly with the industry’s demands, making it an indispensable asset.
At Blue Star Refrigeration, we recognize the importance of cost-effective, space-efficient, and sustainable cold room options that align with industry trends and requirements.
The adoption of small and medium-sized cold rooms for distribution within city limits is a strategic choice that not only reduces real estate costs but also offers practical solutions for businesses managing real estate expenses. These rooms efficiently utilize available space, optimize costs, and maintain storage capacity. Operating compact cold rooms within city limits brings perishable goods closer to consumer markets, reducing transportation times and costs and ensuring the optimal condition and freshness of products.
In the context of refrigeration technology, the use of freon-based systems remains a practical choice for smaller cold rooms. The current industry trend favours the utilization of scroll compressor technology within these systems. Scroll compressors are known for their energy efficiency, reliability, and quiet operation, making them an ideal fit for cold room environments.
Blue Star Refrigeration recommends the use of multi-compressor rack systems for larger storage needs and extended durations. These systems offer superior efficiency and flexibility, ensuring optimal performance across varying load conditions. They enable precise temperature control while minimizing energy consumption and operational costs.
Final Note:
Cold storage solutions emerge as a critical bridge between changing consumer needs, supply chain optimisation, and decreasing food waste in India’s dynamic food environment. The growth of organised retail, increasing consumer tastes, and rising demand for processed foods highlight the importance of effective cold storage systems.
Cold storage facilities help solve problems by preserving perishable items, decreasing food waste, boosting agricultural diversity, and assisting with food processing and exports. Technological improvements, energy efficiency, and adherence to hygiene requirements are all important factors in optimal cold storage architecture. As India’s population grows and demand for food items rises, cold storage facilities become not just a need but also a critical component of food security and economic prosperity. The sector has enormous potential, with chances to improve the whole food ecosystem while maintaining a steady supply of high-quality products for customers.