APC_Ailgarh Seminar.pptx

SEMINAR ON ENERGY
CONSERVATION & ADVANCE
COLD CHAIN TECHNOLOGY
Ice Slurry Tech Widely used in Australia, Israel, Taiwan, China, Japan,
West indies, Thailand, Holland, Ireland, UK, México, Switzerland, US
Confidential APC Polycot Pvt Ltd
ALIGARH COLD STORAGE ASSOCIATION DATED 19/01/20

ABOUT US
 Managed by a group of experts with
engineering, manufacturing, research,
energy management and scientific
background.
 Member of associations / agencies
active in the field of energy
conservation like ASHRAE, ISHRAE,
AIACRA, NCCD, BEE, Global Cold
Chain Alliance (GGCA), Polyurethane
Association of India, Green Building
Council, All India Plastic Association
and BIS.

VISION & OBJECTIVES
 To acquire and use state of art technology to
manufacture pre-engineered masonry / metal dry
wall system for residential, commercial and industrial
buildings including cold storages, warehouses
requiring temperature, humidity and environmental
control, by using green energy.
 Actively associate in the implementation of latest
NBC, ECBC 2017 standards and codes for
Government, Public sector and Corporate buildings.
 Participate in Government’s initiative of Mega Food
Park projects by way of providing assistance in
design, installation and application of energy
efficient building systems and processing of food .
 Contribute towards the making of Green India.

BACKGROUND
 Designing, planning and constructing
environment friendly buildings/
structures solutions since 1996.
 High end cooling, refrigeration and
environment control.
 State of art solutions to cooling
technologies by employing green
technology.
 Waterproofing, sealing and thermal /
acoustic insulation and HVAC
systems.

WHAT WE DO
 Energy-efficient building / cold chain solution
using solar technologies and storing cooling and
heating energy in greenest way.
 Implementation of cooling technologies based
on low temperature (upto -35 degree) by
employing flowable Ice slurry as green
refrigerant .
 Key customers - Parliament Library, Rashtrapati
Bhawan, Airport Authority of India, National
Horticulture Board, CPWD, Transco, CWC,
Ordnance factory and Delhi Metro.
 Consultation to NHB and associated agencies in
the field of Cold Chain, thermal insulation and
water proofing.

Business Units of APC
a. Diagnostics Division- Energy Audits of cold storages,
industries & building HVAC application
b. Renovation & Modernization (R&M) of cold
storages- R&M of cold storages based on old & inefficient
technologies. Our ice slurry technology integration with
present system improves the efficiency of cold storages
c. New Projects- New cold storages
d. New Products- We offer two products in this segment-
i. Portable Cold Storages- These cold storages can be
installed in field (dimension 10’X10’X20’/30’/40’). This will
purely run on solar power with ice slurry tech. This product
will be beneficial for farmers / traders to stock the fruits &
vegetables for short period of time till they fetch good rates
in the market.
ii. Ripening Chambers & Pack houses- Portable
Ripening Chambers & Pack houses can be installed in field
for ripening the fruits & later on can be used as pack houses
for sorting, cleaning & packaging fruits vegetables.

COLD STORAGE R&M
 Old insulation system replacement with
energy efficient APC insulation.
 Sealing / reducing the energy leakage points
 Refrigeration system augmentation with
APC ice slurry technology
 State of art automation system with load
balance technology
 Conversion of single commodity to multiple
commodity
 Replacement of required electrical &
mechanical system with less economical
impact & more efficiency impact
 APC recommended best practices & SOP’s
introduction for cold storage O&M
APC Polycot Pvt Ltd
Confidential

NEW COLD STORAGE
 Design & consultancy of new energy
efficient cold storage.
 Most energy efficient technology
selection for electrical & mechanical
components
 Energy efficient refrigeration system
coupled with APC ice slurry technology
 State of art automation system with
load balance technology
 Energy efficient APC Isoflex insulation
 APC recommended best practices &
SOP’s introduction for cold storage
O&M
APC Polycot Pvt Ltd
Confidential

MINI COLD STORAGE / PACK HOUSE
 Ice Slurry based energy efficient
Mini Cold Storage/Pack House
 Standard Size- 20X10X10,
30X10X10, 40X10X10
 Power Source- 3-5 kVA Solar
Panels
 Portable System, can be
transported to other location
with ease.
 Modular Design with state of
art automation system.
APC Polycot Pvt Ltd
Confidential

FOCUS AREA
 To improve energy efficiency and enable
greater use of renewable energy so as to
achieve reduction in greenhouse gas
emissions.
 Creating a “GREEN UMBRELLA” in
our ecosystem.
 Fighting concrete cancer, concrete -
ferrous and non ferrous corrosion
widely prevalent in urban areas by
employing affordable, advanced green
energy technologies.
 Manufacturers of insulation and
waterproofing polyurethane based
products, which comply with global
standards.

FOCUS: CONTD.
 Creation of employment opportunities
connected with the implementation of these
green initiatives.
 Research has proved that by introduction of
these new technologies, a saving of 30 to 40 %
of the present energy requirement can be
achieved.
 Building energy-efficient homes, installing
solar technologies, using and storing cooling
and heating energy in greenest way.
 Implementation of cooling technologies based
on low temperature (upto minus 35 degree) by
employing flowable Ice slurry as green
refrigerant .
 Pioneers in installing ISOFLEX Super
Insulated multi function panel system for
building envelope using external and internal
insulation finishing system.

INSULATION
TECHNOLOGY

IMPORTANT PARAMETER OF INSULATION
 The R-value of the material selected
(per unit thickness of insulation
material)
 The method of insulation.
 To hold insulation air tight and firm
enough to withstand the movement
and deflection.
 The insulation should also not allow
entry of moisture from outside and
should have a strong vapor barrier.

MOST COMMON MATERIALS INSULATION
Fibre glass
EPS(expanded polystyrene)
XPS (extruded polystyrene)
Expanded Polyethylene (EPE)
Puff (polyurethane foam)
Radiant barrier
 Use of fibre glass in low temp insulation is
not encouraged due to its poor moisture
permeability. If used should be enclosed in
panels or batted.
 XPS/PUF is most hi-tech product with
100% closed cell structure and high
compressive strength and very low water
permeability specially designed as most
efficient insulating material.

INSULATION SELECTION
Since purpose of insulation is to preserve energy which has become very
expensive ASHARE recommendation should be followed to specify minimum
R value. It is good practice to select higher R value as in most of Indian region
summer ambient temperatures are very high then specified in ASHRAE Hand
book.
Most of insulation supplier underplay R value and try to justify based on past
practices. Since higher thickness means higher insulation cost to achieve
desired R value it is neglected most of times to reduce expenses. Most of time
right funds are not allocated. While selection of right insulation material
important, installation by trained and experienced contractor is must.
Insulation must be airtight, thermal bridges should be minimized, vapor
barrier should installed .
COMPOSITE INSULATION SYSTEM
To provide high R value by increasing thickness abnormally is not a optimum
solution specially in tropical climate with hot and humid or dry climate. The
use of radiant barrier and cooling has to be incorporated with conventional
insulation material with proper controlled air gap.

BASIC PARAMETERS OF COLD STORAGES
Sl. No. Particulars Units Values
1 Volume of cooling space to weight conversion m3/t 2.2-3.4
2 Air circulation before set point is reached m3/h/t of product 160-170
3 Air circulation after set point is reached % of design capacity 20.0-40.0
4 Cooling capacity TR/1000 m3 2.80-4.0
5 Margin in design cooling load % 10.0-30.0
6 Ventilation air changes per day before set point is reached no./day 6.0-8.0
7 Ventilation air changes per day after set point is reached no./day 1.8-2.0
8 Operating period before set point is reached h 16.0-18.0
9 Operating period after set point is reached h 8.0-10.0
10 loading rate of new product for cold % of total capacity 4.0-6.0

EXTERNAL INSULATION & FINISHING
SYSTEM WITH ISOFLEX EIFS
 EIFS stands for Exterior Insulation & Finishing
System.
 For residential & commercial, conditioned
warehouse building envelope for all type of
buildings
 Most versatile & durable (long life) system,
 In use in Europe ( 1940), in USA, (1970) Canada,
Australia, Asia Pacific (China, Dubai etc).
 Extensively tested & evaluated by world
authorities EPA, IOTA etc.
(An efficient way to save energy by 30-80%)
EXTERNAL INSULATION WITH FINISHING
SYSTEM (EIFS)
CONDITIONED BUILDING ENVELOPE

RADIANT COOLING OF ROOF, FLOOR AND
WALLS
 Under concept of radiant cooling the temp. of
building envelope comprising ceiling, floor, walls
are maintained at above condensing temp. through
circulation of water between the two insulating
surfaces. A very high insulation on external warm
facing and moderate insulation at inside the room.
The wall temp is controlled through simple
mechanism of varying the temp. and flow of water
 If properly designed the cost of radiant cooling will
not be more than 10-15% of the conventional
construction cost of building. However the
operating cost of electricity will be around 15-20%
of cost of conventional heating and cooling cost.
Water circulated can be reused and replaced
occasionally hence the cost is negligible.

CONVENTIONAL THERMAL INSULATION
 The most of the REFIGERATION and AIR
CONDITIONING SYSTEMS in India are
operated through on off not on proportional
control. For example Cold stores during
holding period run 8-10 hours in 24 hours
with a intermittent gap of 3-4 hours
stoppage.
 During shut down of refrigeration and
ventilation system, the temp. and humidity
goes hay wire and results into huge
variation of temp. and relative humidity in
entire building /chamber.

DRAWBACK OF CONVENTIONAL
TECHNOLOGY
 Wasteful energy operations due to poor handling
of key parameters.
 Unable to control the fluctuations in energy
requirement due to changing seasonal and day to
day weather conditions.
 Use of weak thermal barriers.
 Lack of automation for minimizing human errors/
neglect.
 Unbalanced and non synchronized running of
plant operations.
 Excessive maintenance and cumbersome servicing.
 Use of unskilled professionals for handling
operations.
The conventional practice of
insulation from inside
On ceiling (very poor practice)
Insulation from inside thermal
bridged due to penetration
of columns and beams prefab
puf panel
Outside view of conventional
cold storage at Gujarat
Inside view of conventional cold
storage

TEMP. AND HUMIDTY CONTROL
 Any technology of storing them must ensure less
variations in temp. and humidity due to shut down
of refrigeration system.
 During shut down of refrigeration system
depending upon the conditions of insulation, the
temp and humidity goes hay wire due to ingress
and generation of heat due to breathing/
respiration of produce kept. The radiant cooling, if
well designed and control, may require only initial
cooling and/ or intermittent cooling in case if the
radiant cooling is not sufficient and fast enough to
bring down the temp. of the wall at preset
conditions.

WHY APC INSULATION TECHNOLOGY?
The conventional insulation refrigeration
system are highly inadequate to provide the
constant and uniform temp. and humidity as
technology used by them do not permit
whereas incorporating radiant barrier and
cooling and constructing the building envelope
with drywall with appropriate system design
will not only reduce the operating cost
significantly (only 25-30% of conventional
cost) but also provide the ideal conditions of
uniform and constant temp. and humidity
APC Polycoat Bhiwadi factory,
EIFS insulation on exterior walls
Residential flat Drywall
construction roof, floor and
ceiling
Gupta Nursing Home,
wall & roof insulation with XPS
Metal/ asbestos roof insulation

MULTI CHAMBER
ENERGY EFFICIENT WAREHOUSE
PRIMARY OBJECTIVE OF REFRIGERATED
WAREHOUSE:-
 To maintain chamber atmosphere as per need of
product in order to prolong the life of perishable
produce & maintain natural nutrition quality for
proper consumption.
 By strategically locating the radiant barrier and
cooling system, we can design highly energy
efficient refrigerated warehouse (cold storage)
which may only use 20-30% power when
compared with conventionally run cold store in
India.
 To provide the house at highly optimum and
reasonable cost.

ICE SLURRY TECHNOLOGY

CONVENTIONAL TECHNOLOGY
DRAWBACKS
 Inefficient system.
 Seasonal fluctuations in energy
requirement.
 Use of weak thermal barriers.
 Unbalanced and non synchronized
plant operations.
 Excessive maintenance and
cumbersome servicing.
 Use of unskilled professionals for
handling operations.
 Harmful refrigerant to human &
environment

ICE SLURRY AS GREEN
SECONDARY REFRIGERANT
 Ozone depletion and global warming
are big problems. Ice Slurry can act as
green secondary refrigerant.
 No leakage issues with ice slurry.
 Wide range of industrial applications
varying from comfort cooling and
commercial refrigeration to industrial
production processes medicine and in
the milk production
APC Polycot Pvt Ltd
Confidential

ICE SLURRY
 Ice slurry is a phase-changing secondary fluid
consisting of both a liquid state fraction and a
solid–state fraction.
 operating temperature for ice slurry can be
chosen from 0 to at least -35ºC
 Its more efficient secondary fluid than single-
phase fluids
 Ice slurry has advantage of the stored cooling
energy (in terms of latent heat) in the ice
particles (0.1 to 1 mm size) during melting.
 Its safe & can be in direct contact cooling and
freezing of products.
 ice slurries have several times higher heat
transport capability than single-phase fluids
 Due to higher heat transport capability of Ice
slurry, higher cooling can be achieved with
less pipe dimensions
APC Polycot Pvt Ltd
Confidential

ICE SLURRY SYSTEM
Confidential Bonappetit Foods LLP

SCHEMATIC DIAGRAM
Direct-expansion scraped surface ice slurry generator

1.compressor/ condenser
supplies refrigerant to the ice
slurry generator (evaporator)
2.Ice slurry generator
(evaporator)
3.Slurry ice storage tank
4.Load control pump and
valves
5 Plate heat exchanger
SYSTEM COMPONENTS

SALIENT FEATURES
 Freezing point depression
 Better transport properties in tubes
and heat exchangers
 Reduction in tube & piping size
 Reduction in energy consumption by
20-40%
 High heat transfer coefficient
 Environmentally friendly technology
 Better peak load performance.
 Cost effective

 Ice-Slurry based energy storage
powered/integrated through Solar
Photo Voltaic (SPV) power plants for
Cooling energy.
 Very useful where there is mismatch in
source load
 Benefits of reduction in maximum
output power, average power and
energy consumption by 20-40 % as
compared to conventional systems.
COOLING THERMAL
ENERGY STORAGE (CTES)

KEY APPLICATIONS
 Comfort cooling
 Commercial refrigeration to
industrial production processes
 Milk production
 Mine cooling
 Food processing and preservation
 Fish processing
 Firefighting
 Ice pigging
 Artificial snow
 Cold Chains
APC Polycot Pvt Ltd
Confidential

ENERGY AUDIT- COLD STORAGE
APC Polycot Pvt Ltd
Confidential

Energy Losses
 The level of energy efficiency a plant or
process can achieve is inversely
proportionate to the energy loss that occurs;
the higher the loss, the lower the efficiency.
 Where and how do most of the losses occur?
 How much energy is actually lost and are
they controllable or recoverable?
 The answers to these questions remain well
concealed in a black box where once energy
is input, we do not know what really
happens to it inside and how much the
losses are. With proper energy audit we are
able to ascertain the performance of the
overall or process levels and respond more
effectively to the weaknesses in energy
management
APC Polycot Pvt Ltd
Confidential

Causes of Energy Losses
 Poor plant design.
 Inefficient equipment specification &
selection.
 Poor SOP’s & operations that run on
inefficient methods.
 non-energy efficiency-conscious
maintenance programme.
Reducing these losses will
substantially increase the plant's
efficiency, but we need data to
identify and quantify the losses and
subsequently suggest suitable
techno-economic solutions to
minimize the losses. This data can
be acquired through energy audits.
APC Polycot Pvt Ltd
Confidential

Stages of Energy Audit
APC Polycot Pvt Ltd
Confidential

Definition of Energy Audit
As per Indian Energy Conservation
Act 2001, Energy Audit is defined
as:
 “the verification, monitoring and
analysis of use of energy including
submission of technical report
containing recommendations for
improving energy efficiency with cost
benefit analysis and an action plan to
reduce energy consumption”
Types of Energy Audit
 Preliminary Energy Audit
 Targeted Energy Audit
 Detailed Energy Audit
APC Polycot Pvt Ltd
Confidential

Why We Need Energy Audit
 The three top operating expenses
are energy (both electrical and
thermal), labour and materials.
 Energy would emerge as a top
ranker for cost reduction
 Primary objective of Energy Audit
is to determine ways to reduce
energy consumption per unit of
product output or to lower
operating costs
 •Energy Audit provides a “ bench-
mark” (Reference point) for
managing energy in the
organization
APC Polycot Pvt Ltd
Confidential

Preliminary Energy Audit
 Preliminary energy audit uses
existing or easily obtained data
 Find out the energy consumption
area in the organization
 Estimates the scope for saving
 Identifies the most likely areas for
attention
 Identifies immediate(no cost or
low cost) improvements
 Sets a ‘reference point’
 Identifies areas for more detailed
study/measurement
APC Polycot Pvt Ltd
Confidential

Targeted Energy Audits
 Targeted energy audits are mostly
based upon the outcome of the
preliminary audit results.
 They provide data and detailed analysis
on specified target projects.
 As an example, an organization may
target its lighting system or boiler
system or compressed air system with a
view to bring about energy savings.
 Targeted audits therefore involve
detailed surveys of the target
subjects/areas with analysis of the
energy flows and costs associated with
those targets.
APC Polycot Pvt Ltd
Confidential

Detailed Energy Audit
 Detailed Energy Audit
evaluates all systems and
equipment which consume
energy and the audit
comprises a detailed study
on energy savings and costs.
 Detailed Energy Audit is
carried out in 3 phases
 The Pre-audit Phase
 The Audit Phase
 The Post-Audit Phase
APC Polycot Pvt Ltd
Confidential

The Ten Steps for Detailed Audit
APC Polycot Pvt Ltd
Confidential

10 Steps Contd…..
APC Polycot Pvt Ltd
Confidential

Questions
 What function does this system
serve?
 How does this system serve its
function?
 What is the energy consumption of
this system?
 What are the indications that this
system is working properly ?
 If this system is not working, how
can it be restored to good working
conditions/
 How can the energy cost of this
system be reduced?
APC Polycot Pvt Ltd
Confidential

Identification of Energy Conservation
Factors & Areas
 Steps for conserving
energy can be taken if we
know the correct factors
and areas to be studied
and also details of fuels
used.
These can be:
 Energy generation
 Energy distribution
 Energy usage by processes
 Fuel substitution
APC Polycot Pvt Ltd
Confidential

Technical and Economic
feasibility- Factors
Technology availability, space, skilled manpower, reliability, service, Impact of measure on safety,
quality, production or process. Maintenance requirements and spares availability
 Sample Worksheet for Economic Feasibility Name of Energy Efficiency Measure
APC Polycot Pvt Ltd
Confidential
i. Investment 2. Annual operating costs 3. Annual savings
a. Equipments
b. Civil works
c. Instrumentation
d. Auxiliaries
1. Cost of capital
2. Maintenance
3. Manpower
4. Energy
5. Depreciation
 Thermal Energy
 Electrical Energy
 Raw material
 Waste disposal
Net Savings /Year (Rs./year) = (Annual
savings-annual operating costs)
Payback period in months =
(Investment/net savings/year) x 12

Energy conservation measures
APC Polycot Pvt Ltd
Confidential
PROJECT PRIORITY GUIDELINE
Priority Economical Feasibility Technical Feasibility Risk Feasibility
A- Good Well defined & Attractive Existing technology adequate No Risk / Highly Feasable
B- May Be
Well defined & only marginally
acceptable
Existing technology may be
updated, lack of confirmation
Minor Operating Risk / May be
Feasable
C- Held
Poorly defined & marginally
unacceptable
Existing technology inadequate Doubtful
D- No Clearly not attractive Need major breakthrough Not Feasible

Understanding energy costs
APC Polycot Pvt Ltd
Confidential
An industrial energy bill summary
Conversion to common unit of energy
ENERGY BILL EXAMPLE
Type of Energy
Original Units
(KWH)
Unit Cost Rs/kWh
Monthly Bill
(Rs)
Electricity 5,00,000 10 50,00,000
Fuel Oil (kL) 200 65,000 1,30,00,000
Coal (Tonnes) 1,000 2,200 22,00,000

Benchmarking
 Benchmarking can be a useful
tool for understanding energy
consumption patterns in the
industrial sector and also to
take requisite measures for
improving energy efficiency.
 FACTORS INVOLVED:
 Scale of operation
 use of technology
 Raw material specifications and
quality
 Product specifications and quality
APC Polycot Pvt Ltd
Confidential
 Internal Benchmarking
 Historical and trend
analysis
 External Benchmarking
 Across similar industries
 Scale of operation, use of
technology, raw material
specification and quality
and product specification
and quality

Benchmarking parameters
Production or Equipment Related
 Gross production related e.g.
kWh/MT clinker or cement
produced (Cement plant) e.g.
kWh/MT, kCal/kg, paper produced
(Paper plant)
 Equipment / utility related e.g.
kWh/ton of refrigeration (on Air
conditioning plant) e.g. kWh /litre
in a diesel power generation plant.
 Measuring Energy Performance
Production Factor = Current year’s
production / Reference year’s
production
APC Polycot Pvt Ltd
Confidential
NOTE:
 Reference Year Equivalent Energy Use
 The reference year’s equivalent energy use (or
reference year equivalent) is the energy that would
have been used to produce the current year’s
production output.
 The reference year equivalent is obtained by
multiplying the reference year energy use by the
production factor (obtained above)
 Reference year equivalent = Reference year energy
use x Production factor
 Plant Energy Performance is the improvement or
deterioration from the reference year. It is a
measure of plant’s energy progress.
 Plant energy performance = (Reference year
equivalent – Current year’s energy) x
100/Reference year equivalent

Energy saving cold facilities
Operation costs in a cold
facility
 Typically energy
consumption account for a
substantial part of running
a cold facility
 This substantiates the
need for lowering energy
consumption
APC Polycot Pvt Ltd
Confidential

Objectives
Several areas can be considered when
lowering energy
 Consumption in a cold facility.
 Insulation panels
 Strip curtains
 Air curtains
 Doors
 Loading docks
 Light fixtures
 Refrigeration system
 Day-to-day basis
 APC can provide the above
products/services
APC Polycot Pvt Ltd
Confidential

Insulation panels
 Bad building insulation
(walls, floor, ceiling)
negatively affects room
temperature.
 This results in:
 High energy consumption
 Reduction of frozen food shelf
life
 Lower food quality
 Frost build-up
APC Polycot Pvt Ltd
Confidential
Frozen food shelf-life

Bad insulation
APC Polycot Pvt Ltd
Confidential

Insulation panels: Case study
 Details:
 Energy saving when
replacing 100 mm PU panels
with 200 mm PU panels
from APC
 Room size: 2000 m3
 Cold store room: -25°C
 Outside cold store room
temperature: +35°C
 Δt: 60
APC Polycot Pvt Ltd
Confidential

Insulation panels: Case study cont.
APC Polycot Pvt Ltd
Confidential
* (assuming $0.17 per kWh)
Result and notes:
• Replacing 100 mm panels with e.g. 200 mm panels will save energy costs by USD7756 per year in a 2000
m3 cold room
• Heat loss through a cold facility’s roof is higher than anywhere else. Therefore, 200mm + 100mm panels
can be installed for even higher energy savings

Strip curtains
 Excessive door
openings can result
in excess use of
energy and may
affect temperature
control within a cold
store
APC Polycot Pvt Ltd
Confidential

Strip curtains: Case study
Details:
 Cold room storing uncooked pies
 Desired pie temperature: 3-5°C
 2 doors without strip curtains
Problem:
 Pie temperature reaches 12°C
during operation hours **
 Heat infiltration through doors
responsible for 68% of heat load
on the store ***
APC Polycot Pvt Ltd
Confidential
Case study: UK pie factory, lack of strip curtains*
Solution:
• Install strip curtains on doors. APC-technologies
use high quality strip-curtains for minimum heat
loss
• Installing strip curtains saved 19% of the energy
used by the cold store (from 5.3kW / day to
4.3kW / day) ****
• Pie temperatures were kept at desired level of 5°C

Strip curtains: Case study cont.
APC Polycot Pvt Ltd
Confidential
Temp of pies in cold store with no door protection Temp of pies in cold store with strip curtains

Air curtains
Air curtain benefits:
 Reducing heat loss by up to
80%
 Energy saving: 1-10 %
 Energy savings generally pay
for the equipment and
installation costs within 1-3
years
 Maintains visibility and safety
 Improves sanitation
APC Polycot Pvt Ltd
Confidential
Using air curtains is an effective way to combat warm air infiltration and thus save energy

Doors
Problem:
 Slow speed/manual conveyor and
forklift doors allow large amounts of
infiltration due to the length of time
the doorway is open during the
operation cycle = higher energy bills.
Solution:
 Replacing an old, slow moving door
system with a modern, high-speed door
system (with the latest technology)
from APC results in significant energy
savings.
APC Polycot Pvt Ltd
Confidential

Doors: Case study
APC Polycot Pvt Ltd
Confidential
Comparison: 12 inch/second door with 60 inch/second door*
• Energy saved per year: 233,132 kWh
• $39,632 per year (assuming $0.17 per
kWh)*

Loading docks and operation
Problem:
 The time taken to load and unload products a cold store
affects:
 The amount of hot and humid air infiltrated through the doors
 Heat gained by the products in the meantime (which may lead to their
deterioration)
 Increased number of necessary defrost cycles (due to extended door
openings) = All equal to higher energy bills
Solution:
APC design system ensures minimum electricity consumption by:
 Reducing heat infiltration into cold store by installing air
curtains on the doors
 Designing ante-room (cooling down air in the ante-room
outside the frozen rooms to e.g. 5°C)
 Adding mechanical cooling in the loading dock.
APC Polycot Pvt Ltd
Confidential

Light fixtures
Problem:
 Traditional lights installed in a cold
facility have high heat energy
 Because of the heat from the lights, the
chillers need to remove the energy
created by heat from the lights to keep
a low temperature in cold storage
Solution:
 Replacing traditional lights with
HIF/LED lights/Led lights with
intelligent control will save a
substantial amount of energy usage.
APC Polycot Pvt Ltd
Confidential

Light fixtures: Case study
In a – 26C° Cold Storage 50 x 250W
sodium lamps were replaced on a one-for-
one basis with 50 x 48W LED light fittings
 80% reduction in energy consumption
 Assuming a 24/7 365- day operation,
the annual energy saving would be
175,000 kWH
 Or $29,750 in energy saving/annum
(assuming $0.17/kWh)
 Carbon emissions will also be reduced
by 94,000 tons per annum
 Additionally, the LED lights will
contribute to more room brightness
(see image)
APC Polycot Pvt Ltd
Confidential

Refrigeration system
APC Polycot Pvt Ltd
Confidential
The energy cost above call for high quality refrigeration systems to
reduce energy costs.

Refrigeration system cont.
Choosing refrigeration equipments such
as:
 Compressors
 Condensers
 Air coolers
 Chiller units
 Ice handling equipment
 Freezing equipment saves a substantial
amount of energy.
APC Polycot Pvt Ltd
Confidential
APC Polycot’s state of art ice slurry technology can reduce the refrigeration
system energy cost by 20-30%.

APC Polycot Pvt Ltd
Confidential
Reducing condenser temperature is key to saved energy bills.
Energy savings in % by reducing condenser
temperature 1°C

Appropriate condenser size:
 Increasing condenser size to match cold
room facility results in up to 10 % energy
saving *
Evaporators: another key area to reduce
energy consumption:
 Evaporators with intelligent defrost control
saves energy consumption by 9%.
 Evaporators with low fan horsepower can
save up to 25% on energy bills **
The importance of piping insulation not
to be neglected:***
 APC designed piping insulation (e.g.
properly thick insulation)
 Well insulated piping system can reduce
costs by 5%. ****
APC Polycot Pvt Ltd
Confidential

High quality refrigeration equipment
and well-operated refrigeration plant can
reduce energy consumption by 50% or
more.
For instance:
 Use a central system with a few large
industrial type compressors.
 Use of state of the art fans, motors, lamps
etc. with ultimate efficiency.
 Evaporative condensers rather than air
cooled types.
 Oversized evaporator and condenser
surfaces enables compressors to work with
high evaporating and low condensing
pressures with consequent low wear and low
energy consumption.
APC Polycot Pvt Ltd
Confidential

APC CASE STUDIES
APC Polycot Pvt Ltd
Confidential

THANKS
CONTACT US
Mahendra Singh,
Mob-9717003456, Email: mahendra@yahoo.co.in
APC POLYCOAT PVT LTD, E-57, Sector-63, Noida

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