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Common faults and solution of cold room refrigeration system in operating

During using cold room, there will  be some common faults for the refrigeration system, let us check and solve them.

  1. Refrigerant leakage:

Fault Analysis: After the refrigerant leaking in the system, the cooling capacity is insufficient, the suction and exhaust pressures are low, and the expansion valve can hear the intermittent airflow sound much larger than usual. The evaporator does not hang frost or hang a small amount of floating frost. If adjusting the expansion valve hole, the suction pressure does not change much. After shutdown, the equilibrium pressure in the system is generally lower than the saturation pressure corresponding to the same ambient temperature.

Solution: After the refrigerant leaking, don’t rush to fill the system with refrigerant. Instead, should find the leak point immediately, and fill the refrigerant after repair.

  1. Filling too much refrigerant after maintenance:

Fault Analysis: The amount of refrigerant charged in the refrigeration system after maintenance exceeds the normal volume of the system. The refrigerant will take up a certain volume of the condenser, reduce the heat dissipation area, reduce the cooling efficiency, and generally have high suction and discharge pressures. The evaporators don’t frost and the temperature cooling  is slow.

Solution: According to the operating procedure, it is necessary to stop the machine for a few minutes and then release excess refrigerant at the high pressure shut-off valve. At this time, the residual air in the system can also be released together.

  1. Air in the refrigeration system:

Fault Analysis: If there is air in the refrigeration system will reduce the cooling efficiency. The prominent phenomenon is that the suction and exhaust pressures increase (but the exhaust pressure has not exceeded the rated value), and the temperature at the compressor outlet to the condenser inlet is significantly increased. Due to the air in the system, the exhaust pressure and exhaust temperature increase.

Solution: It is possible to release air from the high pressure shut-off valve several times after a few minutes after the shutdown, and it is also possible to properly fill some refrigerant according to the actual situation.

4. The efficiency of compressor is low:

Fault Analysis: The low efficiency of the refrigeration compressor means that the actual exhaust gas volume decreases and the cooling capacity responds less when the operating conditions are constant. This phenomenon occurs mostly on compressors that have been used for a long time, and the wear is large, the clearance of each component is large, and the sealing performance of the gas valve is lowered to cause the actual exhaust gas to decrease.

Solution:

(1) Check if the cylinder head paper pad is broken down and cause leakage. If it is, replace it.

(2) Check if the high and low pressure exhaust valves are not closed tightly, If it is, replace it.

(3) Check the clearance between the piston and the cylinder. If it is too large, replace it.

 

  1. The frost on the surface of the evaporator is too thick:

Fault analysis: Long-term use of the cold room evaporator should be timed defrosting, such as no defrosting, the frost layer on the evaporator line is thicker and thicker, when the whole pipeline is wrapped into a transparent ice layer, it will seriously affect heat transfer. Causes the cold room inside temperature can’t reach to required value.

Solution:

Stop the defrosting, open the cold room door to let the air circulate, and use the fan to accelerate the air circulation and reduce the defrosting time.

  1. Refrigerantoil in the evaporator line:

Fault Analysis: During the cooling cycle, some of the refrigerant oil remains in the evaporator line. After a long period of use, when there is more residual oil in the evaporator, the heat transfer effect will be seriously affected, and the cooling efficiency will decrease.

Solution: Remove the refrigerant oil from the evaporator. Remove the evaporator, cleaned and then dried. If it is not easy to remove, it can be pumped from the evaporator inlet and then blown with a blowtorch.

  1. The refrigerant leakage in the temperature sensor of the expansion valve:

Fault analysis: After the refrigerant leaking in the temperature sensor of the expansion valve, the two forces below the diaphragm push the diaphragm up, the valve hole is closed, the refrigerant in the system can not pass, and the expansion valve doesn’t frost, the low pressure is vacuum, and no sound is heard in the evaporator.

Solution: Shut down the shut-off valve and remove the expansion valve to check if the filter is clogged  and replaced when damaged.

  1. The compressor suddenly stopped during operation

For air-cooled condenser:

Fault Analysis

1 The fan is not turned on.

2 The fan motor is damaged.

3 The fan is reversed.

4 The ambient temperature is high (up to 40 °C).

5 The condenser fins are blocked by oil dust and the air does not circulate.

For water-cooled condenser:

1 The cooling water valve is not open or opened too small, the inlet pressure is too low

2 The water volume control valve is broken.

3 The scale inside the condenser is thickness.

Solution: Clean the condensers timely.

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Cold room compressor units for seafood freezer exported to Africa

Cold room Bitzer compressor units and stainless trolley for seafood freezer room exported to Africa

Bitzer compressor condensing units for seafood freezer room and cold storage

High quality 304 stainless trolley and zinc tray

Loading containers in our factory.

Your cold room experts, from design to installation&maintenance service, we provide one stop cold room solutions for your fresh life.

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Whole cold room exported to Ghana

Our cold room refrigeration units and panels with accessories exported to Ghana today. It’s shipping season coming.

175mm polyurethane sandwich panels for freezer and Bitzer compressor refrigeration unis for the cold room.

Bitzer air cooled refrigeration units
Loading containers in our factory
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cold room panels exported to Mozambique

We exported 2*40GP cold room panels and freezer room panels to Mozamnique for a seafood factory.

200mm polyurethane sandwich panels for blast freezer, 150mm polyurathane sandwich panels for cold storage.

It’s convenient installation and good quality and performance.

cold room panels
Loading containers in our factory
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Do you know these cold room storage knowledges?

1, What is cold room?

Cold room is a building warehouse using refrigeration machine to reach a certain temperature and has insulation to hold the temperature.

2, Cold room classification:

  • According to the structure

◇ Civil engineering cold room building

◇ Steel structure cold room

◇ Mixed structure

  • According to the cold room usage

◇ Production type cold room used in food, meat, fish factory

◇ Distribution type cold room used for logistics

◇ Retail cold room used for supermarket

◇ Household cold room

  • According to the cold room scale

◇ Large cold storage over 10,000 tons

◇ Medium-sized cold storage 1000-10,000 tons

◇ Small cold storage less than 1000 tons

  • According to the cold room temperature

◇ High temperature cold room design temperature (-2~8°C)

◇ Medium temperature cold room design temperature (-10~-23°C)

◇ Low temperature cold room design temperature (-23~-30°C)

◇ Ultra-low temperature cold room design temperature (-30~-80°C)

  • According to the cold room goods

◇ Seafood and meat cold room

◇ Dairy and ice cream cold room

◇ Fruit and vegetables cold room

◇ Pharmaceutical and chemicals cold room

◇ Flower cold storage

3, Cold room Floor frost heave and protective measures

It is the frost heaving drum of the soil layer under the cold storage floor. The frost heaving phenomenon in the cold room is related to the thickness of the floor insulation layer, the movement of the freezing point isotherm, the migration of water in the soil, the soil quality and the water content. Although the cold room floor is covered with a certain thickness of insulation, it is not completely isolated from heat transfer. Floor frost heaving is also the biggest problem facing the cold room storage ground structure.

Ways to prevent floor frost heave

Overhead floor (direct and reliable, high cost)

Ventilation floor (with certain limitations)

Heating floor (cost saving, high construction requirements)

When the geological conditions of the multi-layer cold storage are poor, it is recommended to use the overhead floor. When better, the other methods can be considered. When the geological conditions of the single-layer cold storage are poor, it is recommended to use heating or ventilation floor. When the temperature is poor, the overhead floor can be considered.

4, Cold room refrigerant choice

◇Ammonia: the oldest in history, the best choice in the field of industrial refrigeration worldwide. Due to the characteristics of the ammonia system, it is generally used for centralized refrigeration, with a special machine room for large-scale refrigeration systems (more than 10,000 tons of cold storage). There is a trend toward miniaturization and modulation, with an emphasis on improving safety and reducing the amount of charging.

◇ Freon: It is widely used in cold storage to disperse refrigeration. It is suitable for small and medium-sized cold storage and large-scale cold storage with limited ammonia. For environmental protection, large-scale cold storage The Freon system should be avoided as much as possible.

◇ CO2: The cold storage application is mainly based on cascade system and loading system. The low-temperature field is more suitable for cascade. The high-temperature field is suitable for loading. The cascade system is more expensive than the traditional ammonia and Freon system.

5, Cold room defrosting ways

Hot-gas defrosting

Water defrosting

Electricity defrosting

6, Cold storage room mold removal ways

Molds generally grow in dark, damp areas and can withstand lower temperatures. Usually in the high temperature cold room, the situation is the most serious. The mold grows in the cold storage, and the spores fly everywhere, which pollutes the goods and products stored in the warehouse.

◇ Mechanical mold removal (manual cleaning and removal of moldy parts)

◇ Physical mold removal (using temperature, humidity, ultraviolet light, high frequency electricity and copper mesh filters)

◇ Chemical mold removal (carbon dioxide, bleaching powder, sodium fluoride, etc.)

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How to control and reduce the operating costs of cold storage?

As owner, we not only have to consider the construction and material costs of cold storage, also should consider the follow up operating costs of cold storage. It directly affects our cold storage effectiveness.

The keys to managing energy efficiency are reducing operational costs, during managing a cold storage warehouse, we should strictly control the energy costs from five parts “ice, frost, water, doors and lights”. Meanwhile using remote monitoring can have a significant impact on reducing energy, maintenance and overall operating costs. Here we only discuss it from how to correctly operate the refrigeration unit and evaporators and how to do the cold storage management.

1, Reasonably adjust the operating parameters of the refrigeration system to improve equipment efficiency.

According to actual cold storage temperature and goods conditions, adjusting system pressure and temperature parameters which can ensure the safety of machinery and storage products, fully utilize equipment efficiency, and save Water, electricity, oil, etc.

2,  Prevent evaporating temperature being too low, in common the temperature difference between evaporating temperature and cold storage temperature is 3-5℃.

When the temperature difference between the evaporating temperature and the cold storage temperature increases, the evaporating temperature will be too low, which will result in a decrease in the refrigeration coefficient and an increase in energy consumption. It is estimated that under the same conditions, when the evaporation temperature is lowered by 1℃, it will consume 1~2% more electricity. In addition, as the temperature difference increases, the dehumidification amount of the air cooler is increased, and the humidity of the cold storage warehouse is reduced, thereby causing an increase in dry food consumption and a decrease in food quality.

3, The refrigeration system is a sealed circulation system, keep the refrigerant circulating in the system is clean and free of impurities.

4, Timely remove the frosts on the evaporator and scales on the condenser.

The second importance is energy saving in the cold storage management.

The cold storage is a special building used for freezing and refrigerating foods and maintaining a certain low temperature. The floor, walls and roof are covered with a certain thickness of moisture-proof layer and insulation layer to reduce the introduction of external heat, and at the same time, in order to reduce the radiant heat of the sun, the surface of the exterior wall of the cold storage is generally painted white or light.

Since the cold storage building has the above characteristics, in addition to ensuring the building quality with strict heat insulation, sealing, sturdiness and frost resistance in design and construction, it should also be based on the characteristics of the cold storage in daily use management. Scientific management is implemented to ensure safe production, so as to achieve the purpose of prolonging the service life, reducing production costs, saving maintenance costs, and improving the economic benefits of enterprises.

1, Cold storage door should be closed tightly; Minimize the frequency door opening and door opening time.

2, Reasonable stacking to improve cold storage warehouse utilization

The utilization rate of the cold storage warehouse directly affects the economic benefits of the cold storage, the utilization rate is low, the cooling capacity of the unit weight is increased, and the dry consumption is increased, and the cost is increased. Therefore, strong packaging, shelves, etc. should be adopted, and the code height should be increased to improve the utilization of the warehouse. When the goods are not full, if the storage characteristics of the goods are the same or similar, and they do not affect each other, they can be mixed for a short time.

3, Cold storage warehouse lighting control

The lighting of the cold storage warehouse not only consumes electric energy, but also increases the heat in the warehouse. Therefore, the lighting of the warehouse should be controlled in groups according to the front, middle and back. After entering the warehouse, the staff should minimize the number and time of turning on the lights, and turn the lights off when go out.

Coordination between preservation and refrigeration technology is an important guarantee to reduce operating costs and improve enterprise efficiency. Adopting modern refrigeration technology and cold storage management will reduce the whole cold storage cost.

Atlascool-your cold room expert, more than 18 years refrigeration experience, from design to installation and maintenance service, we provide one stop cold storage service for your fresh life. Best practice for building cold storage and controlling energy saving.

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Cold storage room for fruits and vegetables in Tashkent, Uzbekistan

We finished a turn key cold storage room for fruits and vegetables to our customers in Tashkent, Uzbekistan.

The fruits and vegetables cold storage main equipments and materials:

1. Refrigeration system:

  1.1 Compressor: Bitzer, Copeland etc for choice,

  1.2 Condenser units: water cooled, air cooler or water and air cooled for choice.

  1.3 Evaporator: air cooler and grid evaporator for choice.

2. Electric system: Siemens and Schneider electric components or the other brand for choice.

3. Insulation panel, cold store panels:

  3.1 Material: polyurethane (PU), metal sheet.

  3.2 Density of PU: 38~40 kg/m3, 40~42kg/m3, 42~45kg/m3 for choice,

  3.3 Metal sheet: painted steel sheet, stainless steel sheet, aluminium steel sheet or mixed together for choice.

  3.4 Thickness of panel: 75mm, 100mm, 110mm, 150mm and 200mm for choice.

4. Cold store door:

  4.1 Sliding door and swing door for choice,

  4.1.1 Sliding door: manual opened, automatic opened for choice.

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Happy Mid Autumn Festivals to all customers

Atals cold room refrigeration company  sincerely wishes all my customers happy mid autumn festivals!

As a professional cold room manufacture for more than 18 years,
What can we manufacture?
Cold room, prefabricated cold room, Cold storage, industry cold storage, commercial cold storage;Freezer room, blast freezer room, walk in freezer room; Chiller room, small chiller room, chiller room;

We specialize in a full line of cold room refrigeration system solution including cold room panels&doors,Bitzer condensing unit, evaporators and condensers, blast freezer, ice making machines and refrigeration parts etc.

 

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Important Points of Banana Ripening Room

We supply banana ripening room and chambers.This type of cold room needs special temperature and ripening system, it required highly precise controlling for time.

Banana Ripening  Room design for bananas are important:

  1. Ripening rooms are very important for proper and efficient banana ripening; not just any room will suffice. A commercial ripening room must have the following:

  2. The room must be as air tight as possible to prevent ethylene loss.  This also prevents ethylene from entering unwanted areas (like other banana rooms or cold storage rooms holding ethylene-sensitive items).

  3. The room must be properly insulated to be able to control the temperature within a degree or so.

  4. The room must have adequate refrigeration capacity to accurately control pulp temperature.

  5. The room may need heating equipment in order to maintain proper room temperature in cold weather.

  6. The room must have adequate air circulation. Because uniform pulp temperatures throughout the load are essential for even ripening, the refrigerated air in the room must circulate at all times and uniformly throughout the load. For pressurized, forced air ripening rooms, this is typically inherent in the design.  However, for non-pressurized rooms, the boxes of bananas should be “air stacked”. That is, the boxes should be offset to allow the air to circulate among all the boxes since a non-pressurized room design will not pass air through boxes but around them.

Important reminders when banana ripening:

Monitor pulp temperatures closely:

  • Avoid “chilling” or “cooking” the fruit. Bananas are very sensitive to temperatures. Chilling will occur if the fruit is subject to temperatures below  (13°C) for several hours. It causes the peel to have a smoky, dull gray appearance. This may not show up for 18 to 24 hours after chilling occurs.

  • Cooked bananas result from excessively high temperatures; avoid temperatures above (18°C). The peel will have a brown to orange appearance. The fruit may be soft and have a short shelf life.

Maintain proper humidity levels:

  • For best ripening results, humidity should be 85 to 95%. If the humidity is too low, install a humidifier; wetting the floor of the room with water may increase the humidity but may cause sanitation issues.

When ready to ripen:

  • Determine how in how many days the room of bananas will be needed; raise pulp temperatures to at least (14°C).

  • Follow proven ripening schedules (like the one above) to adjust daily pulp temperatures.  No chart however can account for the unique differences in every load of bananas that will be ripened.  Frequent inspection of pulp softening and color change followed by temperature adjustments are vital to proper color achievement.

  • Apply 100 – 150 ppm ethylene for a minimum of 24 hours during the initial phase of the ripening cycle.  Fruit that is less mature may take an additional 24 hours of ethylene application.

Please note that there are reports of bananas responding better to higher ethylene levels.  While 100 ppm is the accepted standard to initiate ripening and ethylene production in bananas, there are some companies that require their ripening personnel to use 300+ ppm, saying that today’s banana ripens quicker and more uniformly with this higher level.  If you are having difficulty with bananas ripening properly, verifying current ethylene levels and then perhaps increasing them may resolve ripening issues. There are other factors that cause poor ripening, like inadequate humidity and immature fruit; ethylene is not always the culprit.

           When bananas are ripening, they release carbon dioxide (CO2) which will build up in a ripening room. The  production begins as the fruit ripens enters the “climacteric” phase, or the period when bananas release ethylene and and have an elevated rate of respiration (along with a great deal of other physiological changes). Respiration involves the uptake of oxygen, the release of carbon dioxide, and the breakdown of starches. Carbon dioxide concentrations above 1% (10,000 ppm) will retard ripening, delay the effects of ethylene and cause quality problems. Therefore, it is recommended to vent rooms by opening the doors for 20 minutes every 12 hours, after the first 24 hours of ripening. Other venting methods are by automatic fan (either timed or sensor-based) or “flow-though” (constant) ventilation.

Banana Shipping suggestions

  • Bananas bruise easily, green or ripe. Careful handling at all stages will reduce bruising and enable you to sell the bananas for more money.

  • Bananas also chill easily, as described above.  If shipping on a mixed load at temperatures lower than (12.8°C)

        Atlas Refrigeration Technology had been specializing in delivering turn key cold room solutions to worldwide customers for 18 years. We had provided many types of effective and states of the art cold rooms and freezer rooms to over 40 countries. We have been exporetd cold rooms to Swiss, Sweden, Australia, USA, Canada, New Zealand, Pakistan, Spain, India, Malaysia, Singapore, Malaysia, Philippines, South Africa, Argentina, Indonesia, Kenya, Algeria, Ghana, Guyana, Mongolia, Chile, Peru, Dubai, Poland, Mexico, Brazil, Lebanon, Thailand, Kazakhstan, Turkmenistan, Bangladesh, Colombia, Bahrain, Papua New Guinea and so on.

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How many factors affecting cold room quality?

What is a cold room?

A cold room is a large refrigerated room or building designed for storage of goods in an environment below the outdoor temperature. Products needing refrigeration include fruit, vegetables, seafood and meat.

When we want to build a cold room, we should consider two points, one is the high building materials quality, the other one is high effective of the cold room. Then how to reach the goal? Let’s learn how many factors affecting cold room quality?

1, Whole cold room includes polyurethane insualtion panels and refrigeration systems(compressor units, evaporators, condensers, control box and valves)etc. About the panels, there are camlock PU, PUR, PIR types.Camlock PU panels is very common and easy to produce, so it’s diffcult to check the quality.PUR and PIR sandwich panel is continuous production line, they have high requirements and standard for producing process and machinery. In china, fewer factories has this ability to produce PUR and PIR panels.Then you will check the panels insulation parameters, foam density, fire resistance, and color steel thickness, becasue all these factors will affect the price of panels.

2, The refrigeration system is the core of cold room, it includes compressor units,condensers,evaporators and valves. It also has accessories such as fans, pipes and instruments. The whole refrigeration system is a sealed circuit in which the refrigerant circulates, controlling the amount of supply and the number of times entering the evaporator as needed to achieve suitable low temperature conditions. The compressor is the heart of the refrigeration system, which pushes the refrigerant around the system. The choice of cold room refrigeration system is mainly focus on compressors and evaporators. So the quality of compressors and evaporators will affect the cold room quality.Usually we will choose world famous brand compressors like Bitzer, frascold, copeland etc and evaporators like Luve, Guentner, Kuba etc.
3, Surface areas and structures of the evaporator.Surface areas of evaporators, number of fans, cross-sections of fans, air flow of fans directly affect the humidity and temperature of the cold room.
4, High effective is also important for cold room. Usually we will ask a professional designer or consultant to help us. We have long years of experience in the refrigeration industry, our engineers are all graduated from refrigeration major in university. We will analyze your product load, geographic location and facility usage. Our many years of cold room refrigeration experience will help us design a economic refrigeration system to your product. “Produce” requires a different approach from “Pharmaceuticals” or “Poultry.” We will propose the right equipment to do the job, no more and no less.
5, Properties of the product and package to be put in cold room.The changes in the entire transpination density in the cold room have a great effect on the immediate cooling of the product.