Unit 2 Storage methods.pptx

Various traditional storage methods, Improved storage methods, Modern storage structures & Controlled storage atmosphere.

1. Power Point Presentation SUBJECT CODE & NAME 20AG105PE STORAGE AND PACKING TECHNOLOGY Unit – 2 Storage Methods Prepared by, Dr. P. Dineshkumar M.E., Ph.D., Assistant Professor, Department of Agricultural Engineering, Kongunadu College of Engineering and Technology. Dr. P. Dineshkumar / AP / AGE / KNCET 1

2. STORAGE METHOD Storage methods encompass a range of techniques designed to slow down spoilage, inhibit microbial growth, and maintain the nutritional value of various food items. When it comes to storing food, different approaches are employed based on factors such as the Type of food Desired shelf life and Available resources. Dr. P. Dineshkumar / AP / AGE / KNCET 2

3. COMMON FOOD STORAGE METHODS Refrigeration. Freezing. Dehydration. Vacuum Packaging. Root Cellaring. Fermentation. Canning.

4. REFRIGERATION Refrigeration is one of the most widely used methods for short-term food storage . It involves keeping perishable foods at low temperatures, typically between 1-5 degrees Celsius , to slow down bacterial growth and maintain freshness.

5. FREEZING Freezing is a popular long-term storage method that involves lowering the temperature of food below the freezing point to inhibit bacterial growth and preserve quality. By freezing food, you can extend its shelf life for several months or even longer . Proper packaging, such as airtight containers or freezer bags, helps prevent freezer burn and maintain flavor and texture

6. DEHYDRATION Dehydration involves removing the moisture content from food to inhibit the growth of bacteria. It can be achieved through various methods such as air drying, sun drying, or using specialized dehydrators. Dehydrated foods, such as dried fruits have a significantly extended shelf life and are lightweight and convenient for storage and transportation.

7. VACUUM PACKAGING Vacuum packaging involves removing air from the packaging around food products to prevent oxidation, microbial growth, and freezer burn. It helps to maintain the quality and freshness of perishable foods. Vacuum-sealed packaging is commonly used for meats, cheeses, and other products susceptible to spoilage.

8. ROOT CELLARING

9. Root cellaring is an old-fashioned method of storing fruits, vegetables, and root crops in a cool, dark, and humid environment. Root cellars provide a consistent temperature and humidity level , which helps slow down spoilage and extend the shelf life of product. Remember to follow proper food safety guidelines and recommendations when storing food to minimize the risk of foodborne illnesses. Additionally, it's important to rotate food supplies regularly to ensure the use of older items before they expire and to maintain a fresh stock of stored food.

10. FERMENTATION Fermentation is a metabolic process in which microorganisms, such as bacteria or yeast, convert carbohydrates into simpler substances, typically in the absence of oxygen . This process involves the breakdown of sugars into alcohol, acids, or gases, producing energy and generating various flavours , textures, and preservation properties in foods. 10 Carbohydrates Microorganisms in the absence of oxygen Acid Alcohol Dr. P. Dineshkumar / AP / AGE / KNCET

11. CANNING Canning involves heat-processing food in jars or cans to kill bacteria and create a sealed, airtight container that prevents spoilage. The food is usually cooked, placed in sterilized containers, sealed, and then heated to eliminate microorganisms.

12. IMPROVED STORAGE METHODS OF GRAINS Traditional storage structures can be built upon to create a new type of storage structure known as the upgraded type of storage structures. Traditional storage structures typically have a lower storage capacity than the other forms of storage structures. The capacities of the many upgraded types of storage buildings typically range anywhere from 1.5 to 150 tons.

13. IMPROVED STORAGE METHODS Pusa Bin. Brick & Cement Bin. Silo Storage. Hermetic Storage. Modified Atmosphere Storage. Insect – Resistant Storage Structures. Integrated Pest Management (IPM) Techniques. Temperature and Humidity Control. Quality Monitoring and Testing.

14. PUSA BIN The " Pusa bin" is indeed a storage structure used in India, particularly for the storage of grains, pulses, and other agricultural produce. It is named after the Indian Agricultural Research Institute (IARI) in Pusa , New Delhi, where the design was developed. They are rectangular in shape and have a capacity of 1 to 3 tonnes .

15. Pusa bin is like traditional storage structure made of mud. To make storage structure moisture proof as plastic film is used in all insides of the bin. To construct Pusa bin first a platform of mud bricks is made. On this platform a sheet of 700 gauge plastic is overlaps the platform on all sides by at least 6 cm. Walls are made of Kachha bricks and these are sealed with mud plaster. When the walls are raised to proper height a wooden frame is placed on it. The upper roof is made of burnt bricks. For unloading of grains on inclined wooden or steel pipe is fixed in such a way that grains may come out the mouth of pipe is closed by cover. The inside of all the four walls and roof are covered by plastic sheet. On the top an open surface of about 50 cm * 50 cm is left for loading of grains leaving this open space the roof is sealed by mud.

16. The key features of the Pusa bin include Aeration System : The bin is designed with perforations or small vents to allow airflow , which helps control temperature and moisture levels within the storage structure. Air Plenum: The bin has an air plenum, which is a space at the bottom of the structure that allows for the distribution of air evenly throughout the stored grain. Rat Guards: Pusa bins often have rat guards installed at the entrances or openings to prevent infestations . These guards act as barriers to keep rats and other pests from entering the storage structure.

17. Capacity: Pusa bins come in various sizes and capacities, allowing for storage of different quantities of grains or agricultural produce. The size of the bin can be chosen based on the specific storage requirements of the user. Eg : 2 tonne pusa bin: Base – 140 x 100 cm. Height – 160 cm. Length – 8.5 m. Kachha bricks – 1150 Nos. Burnt bricks – 100 Nos. Pipe for outlet

18. IMPORTANCE OF PUSA BIN The Pusa bin is known for its effectiveness in maintaining grain quality and reducing post-harvest losses It provides a controlled storage environment that helps extend the shelf life of grains and ensures their availability during periods of high demand or price fluctuations. The design of the Pusa bin has been widely adopted and recommended by agricultural authorities and organizations in India for improving grain storage practices.

19. BRICK & CEMENT BIN

20. These storage structures are very strong and therefore, the effect of season on them is negligible. The bin is made on a platform raised at 60 cm above the ground . A ladder is provided on one side of the bin for loading of the grains. A hole of about 60 cm diameter is provided on the roof for the purpose of loading the material (Grains) . The walls of bin are about 23 cm thick with cement plastered on both the sides

21. Roof is made of Reinforced concrete (R.C.C). The base of bin is made inclined and an outlet is provided for unloading of grains. The capacity of such bin is usually between 1.5 to 60 tonnes . Cleaning of bin and complete unloading, a provision of iron rings steps is provided inside the bin for person can enter and exit the bin.

22. The key features and benefits of a brick and cement bin include. Durability: The use of bricks or cement blocks ensures that the structure is durable and resistant to weather conditions, providing long-lasting storage capabilities. Protection: The solid construction of the bin offers protection against moisture, pests and other external factors that could damage or contaminate the stored materials. Size and Capacity: Brick and cement bins can be built in various sizes and capacities to accommodate different storage needs. They can be customized to store large or small quantities of materials.

23. Temperature Regulation: Depending on the specific requirements of the stored materials, brick and cement bins can be designed with insulation or ventilation systems to regulate temperature and moisture levels within the structure. Accessibility: Access points such as doors are typically included in the design to allow for easy loading, unloading, and inspection of the stored materials. Cost-effectiveness: Compared to other storage options brick and cement bins can be a more cost-effective solution , especially for larger-scale storage requirements.

24. SILO STORAGE Silos are large, airtight structures designed to store bulk grains. They provide protection against moisture, pests, and fungi while maintaining optimal conditions for grain storage. Modern silos are often equipped with ventilation systems, temperature and humidity monitoring, and insect control measures. Silo storage may helps for transporting the grains to required place.

25. HERMETIC STORAGE Hermetic storage involves s toring grains in airtight containers or bags, creating an oxygen-deprived environment that suffocates pests and inhibits their reproduction. Common hermetic storage options include airtight bags, plastic liners or metal containers with airtight seals .

26. MODIFIED ATMOSPHERE STORAGE Modified atmosphere storage techniques involve altering the composition of the storage environment by controlling temperature, humidity, and gas concentrations . This method helps reduce insect activity and fungal growth . Example: Carbon dioxide (CO 2 ) or nitrogen (N 2 )gas can be injected into grain storage facilities to displace oxygen and create an unfavorable atmosphere for pests.

27. INSECT - RESISTANT STORAGE STRUCTURES These structures are designed with specific features to deter (protect) or control insect infestations. Examples Metal storage bins with smooth surfaces that prevent insects from crawling. Grain storage bags with insect-repellent liners. Storage facilities with insect screens or traps .

28. INTEGRATED PEST MANAGEMENT (IPM) TECHNIQUES IPM combines multiple strategies to control pests in grain storage. It involves practices such as regular cleaning, proper sanitation, and monitoring for early detection of pests . Additionally, biological control methods like the introduction of natural enemies or using grain protectants can be employed.

29. TEMPERATURE AND HUMIDITY CONTROL Maintaining appropriate temperature and humidity levels is crucial for grain storage. Low temperatures (below freezing) can prevent insect activity. Controlling moisture levels can inhibit fungal growth and reduce the risk of grain spoilage. Ventilation systems and moisture control equipment can help regulate these factors in grain storage facilities.

30. QUALITY MONITORING AND TESTING Regular quality monitoring and testing of stored grains are essential to detect any signs of spoilage or deterioration. Physical inspections, moisture content measurements and periodic sampling for laboratory analysis can help identify potential issues and take corrective actions.

31. MODERN STORAGE STRUCTURES Modern storage structures encompass a range of innovative and advanced designs and technologies aimed at optimizing storage efficiency, maximizing space utilization, improving accessibility, and enhancing preservation capabilities . These structures leverage modern materials, construction techniques and automation to meet the evolving storage needs of various industries.

32. Automated warehouse. High-Density Storage Systems. Vertical Lift Modules. Shuttle Systems. Climate-Controlled Storage. Smart Storage Systems. Modular Storage Solutions. Cold Storage Automation.

33. AUTOMATED WAREHOUSES Automated warehouses employ robotics and advanced conveyor systems to streamline the storage and retrieval processes . Automated guided vehicles (AGVs) and robotic arms are utilized to transport and organize goods within the warehouse. These systems are often integrated with inventory management software, allowing for efficient tracking and inventory control .

34. HIGH-DENSITY STORAGE SYSTEMS High-density storage systems such as pallet racking, push-back racking and mobile racking which maximize vertical space utilization while providing easy access to stored items. These systems are designed to efficiently store large quantities of goods in a compact footprint

35. VERTICAL LIFT MODULES (VLM S ) VLMs are automated storage systems consisting of vertical columns with trays that can be accessed by an automated lift . These systems optimize storage density and facilitate order picking by automatically retrieving the required trays , reducing the need for manual searching and handling of items.

36. SHUTTLE SYSTEMS Shuttle systems are automated storage and retrieval systems that use robotic shuttles to transport goods within the storage structure . The shuttles can move horizontally and vertically along storage racks, enabling high-speed and accurate order fulfillment while maximizing storage capacity

37. CLIMATE-CONTROLLED STORAGE Climate-controlled storage structures provide precise temperature and humidity control to preserve sensitive items such as pharmaceuticals. These structures employ advanced HVAC (Heating, Ventilation, and Air Conditioning) systems and insulation techniques to maintain stable and optimal storage conditions.

38. SMART STORAGE SYSTEMS Smart storage systems utilize Internet of Things (IoT) technology and data analytics to optimize storage operations These systems integrate sensors, RFID tags, and cloud-based software to monitor inventory levels , track item location and generate real-time insights for improved inventory management and supply chain efficiency.

39. MODULAR STORAGE SOLUTIONS Modular storage structures are flexible and scalable, allowing for easy expansion or reconfiguration as storage needs change . These structures are typically constructed using pre-fabricated modular components, enabling rapid installation and customization according to specific requirements.

40. COLD STORAGE AUTOMATION In the field of cold storage, automated systems are increasingly employed to optimize operations and maintain the integrity of perishable goods . Automated storage and retrieval systems (AS/RS), conveyor systems, and robotic picking technologies enhance efficiency and accuracy while ensuring the cold chain is maintained.

41. TEMPERATURE CHANGES IN STORAGE STRUCTURES To mitigate the effects of temperature changes in storage structures, it is essential to implement proper temperature control measures . This includes insulation to minimize external temperature influences, utilizing HVAC systems to regulate temperature and humidity , monitoring systems to track and respond to temperature variations. Regular monitoring and maintenance help ensure that storage structures provide a stable and controlled environment for the stored items, preserving their quality and extending their shelf life.

42. Product quality : Temperature fluctuations can significantly impact the quality of stored items . Perishable goods such as fruits, vegetables, and dairy products are particularly sensitive to temperature changes. Microbial Growth: Temperature variations in storage structures can affect microbial growth . Bacteria, molds and yeasts thrive in specific temperature ranges. Chemical Reactions: Temperature changes can trigger chemical reactions in stored items, affecting their composition and properties. In beverages, temperature variations can impact carbonation levels, causing changes in taste and texture.

43. Physical Changes : Extreme temperature fluctuations can cause physical changes in stored items and the storage structure itself. Temperature variations can also impact the integrity of packaging materials , such as plastic containers or glass bottles, potentially compromising the safety and quality of the stored items. Moisture Control: Temperature changes can affect humidity levels within storage structures. High temperatures can increase moisture levels, leading to condensation , which can promote mold growth and spoilage. Energy Consumption: Temperature control in storage structures requires energy for heating or cooling . Fluctuating temperatures or inadequate insulation can lead to increased energy consumption and higher operating costs for the storage facility.

44. MOISTURE CHANGES IN STORAGE STRUCTURES Product Quality and Shelf Life: Moisture fluctuations can directly impact the quality and shelf life of stored items . Excessive moisture can lead to increased microbial activity, mold growth, and the development of off-flavors, odors, and texture changes. It can accelerate spoilage and deterioration of food. Mold and Fungal Growth: Moisture fluctuations provide favorable conditions for mold and fungal growth . High humidity levels can promote the proliferation of molds, which can contaminate and spoil stored items and also produce mycotoxins , which are harmful to human health.

45. Structural Integrity: Excessive moisture in storage structures can lead to structural issues. It can cause corrosion of metal surfaces , deterioration of wood, and degradation of building materials .

46. Construction and operation of C ontrolled A tmosphere of storage facilities

47. Constructing a controlled atmosphere (CA) storage facility is a meticulous process that requires careful planning, adherence to industry standards, and consideration of various factors. These facilities play a critical role in preserving the quality and extending the shelf life of stored commodities. In this essay, we will explore the key steps involved in the construction and operation of CA storage facilities, highlighting the importance of proper design, construction techniques, and operational practices.

48. DESIGN AND LAYOUT The first step in constructing a CA storage facility is to develop a comprehensive design and layout plan Optimized layout planning ensures smooth material flow, efficient space utilization, and compliance with safety regulations The design should consider factors such as storage capacity, accessibility, energy efficiency, ventilation systems, and equipment requirements

49. CONSTRUCTION PROCESS The construction process begins with site preparation, including clearing the land, leveling, and addressing any environmental considerations It is crucial to use high-quality materials that provide adequate insulation to minimize heat transfer and maintain the desired temperature within the storage facility Special attention should be given to proper sealing and insulation to prevent air leakage and maintain a controlled atmosphere

50. Refrigeration Systems and Equipment Installation The heart of a CA storage facility is the refrigeration system It is responsible for maintaining the desired temperature and humidity levels within the storage space The equipment, including compressors, condensers, evaporators, and controllers, must be selected based on the specific requirements of the commodities being stored Regular maintenance and calibration of the equipment are essential to ensure optimal performance and energy efficiency

51. VENTILATION AND AIR CIRCULATION Proper ventilation and air circulation are critical in CA storage facilities The facility should be equipped with well-designed ventilation systems that allow for the controlled exchange of gases and the removal of excess heat and moisture This helps maintain the desired gas composition and prevents the buildup of harmful gases or condensation

52. MONITORING AND CONTROL SYSTEMS CA storage facilities require advanced monitoring and control systems to maintain the desired atmospheric conditions This includes temperature, humidity, gas composition, and pressure monitoring Alarms and alerts should be integrated to notify operators in case of any deviations from the desired parameters

53. OPERATIONAL PRACTICES AND STAFF TRAINING Once the CA storage facility is constructed and operational, implementing proper operational practices is essential for its effective utilization Staff members should receive comprehensive training on handling and operating the facility, including temperature monitoring, equipment maintenance, and emergency procedures Good inventory management practices, such as FIFO (first-in , first-out), should be followed to minimize stock discrepancies and ensure the timely rotation of stored commodities .

54. COMPLIANCE AND SAFETY CONSIDERATIONS CA storage facilities must adhere to local building codes, safety regulations, and industry standards Fire safety measures, emergency exits, and proper handling of hazardous materials should be incorporated into the facility design Regular inspections, maintenance, and compliance checks are necessary to ensure the facility operates in a safe and compliant manner

55. MAINTENANCE OF CONTROLLED ATMOSPHERE (CA) STORAGE FACILITIES

56. Maintenance plays a crucial role in ensuring the proper functioning and longevity of controlled atmosphere (CA) storage facilities Regular maintenance activities help preserve the desired atmospheric conditions, maximize energy efficiency, and prevent equipment failures

57. Regular Inspection : Conduct routine inspections of the facility to identify any potential issues or equipment malfunctions. Identify and address any problems promptly to prevent further damage and ensure optimal performance . Cleaning and Sanitation: Maintain a clean and hygienic environment within the CA storage facility. Thoroughly sanitize the facility to prevent the growth of molds, bacteria, and pests . Use appropriate cleaning agents and follow industry guidelines to ensure the safety of stored products .

58. Temperature and Gas Composition Monitoring : Continuously monitor and calibrate temperature and gas composition sensors to ensure accurate readings. Deviations from the target parameters should be investigated and addressed promptly. Refrigeration System Maintenance : The refrigeration system is a critical component of CA storage facilities. Conduct regular maintenance on compressors, condensers, evaporators, and other refrigeration equipment. Follow manufacturer guidelines and consult qualified technicians to perform any necessary repairs or maintenance tasks .

59. Ventilation and Air Circulation : Ensure proper functioning of ventilation systems and fans to facilitate adequate air circulation within the storage chambers. Check dampers and louvers for proper operation and adjust as needed to maintain the desired gas composition and prevent condensation . Structural Integrity and Insulation : Regularly inspect the structural components of the CA storage facility, including walls, ceilings, and floors, for signs of damage or deterioration. Repair or replace insulation materials as necessary to maintain efficient temperature control and minimize energy loss .

60. Emergency Preparedness : Develop and implement emergency protocols to address any unforeseen events or equipment failures. Maintain emergency contact information for relevant service providers and ensure the availability of backup power sources, if applicable . Documentation and Record-Keeping : Maintain thorough records of maintenance activities, inspections, repairs, and calibration of equipment. It also serves as a valuable reference for future maintenance and troubleshooting.

61. A few additional points to consider for the maintenance of controlled atmosphere (CA) storage facilities : Training and Knowledge Transfer Calibration and Testing Energy Efficiency Measures Pest Control Emergency Backup Systems Collaboration with Service Providers Continuous Improvement

62. CONTROLLED ATMOSPHERE STORAGE FOR GRAINS AND PERISHABLES

63. Controlled Atmosphere (CA) storage is a specialized technique used to create a modified atmospheric environment in storage structures This technique aims to extend the shelf life and maintain the quality of grains and perishable products We will examine practical case studies and emerging trends in CA storage, highlighting the advancements in technology and their potential implications for the industry

64. PRINCIPLES OF CONTROLLED ATMOSPHERE STORAGE Gas Composition Control is a fundamental aspect of CA storage . It involves adjusting and regulating the levels of oxygen, carbon dioxide, and nitrogen within the storage environment By modifying the gas composition, CA storage can slow down the ripening process, inhibit microbial growth, and preserve the quality of stored products .

65. Temperature and Humidity Management play a crucial role in CA storage Effective humidity management is also essential to avoid excessive moisture or dehydration, which can impact the texture and overall quality of the stored items Packaging Considerations are vital in CA storage. The packaging should have suitable gas barrier properties to prevent gas exchange with the external environment

66. Monitoring and Control Systems are implemented in CA storage to ensure the desired atmospheric conditions are maintained Sensors and monitoring devices are used to measure and track gas composition, temperature, and humidity levels within the storage structure. Control mechanisms, such as automated control systems or manual adjustments, are employed to regulate the storage environment based on the predefined parameters

67. APPLICATIONS OF CA STORAGE FOR GRAINS CA storage offers significant benefits for grain preservation It extends the shelf life, reduces spoilage, and helps preserve the nutritional quality and sensory attributes of grains Implementing CA storage techniques tailored to specific grain varieties ensures optimal storage conditions and maximizes preservation

68. IMPACT OF CONTROLLED ATMOSPHERE STORAGE ON GRAIN QUALITY It influences grain composition, attributes, and nutritional value By maintaining the controlled atmosphere, CA storage minimizes the loss of moisture content , preserves the texture and flavor of grains, and prevents insect infestations Various quality evaluation methods, including sensory analysis and laboratory testing , are employed to assess the effects of CA storage on grain quality.

69. ECONOMIC CONSIDERATIONS AND BENEFITS OF CA STORAGE CA storage systems have economic advantages Although the initial investment may be higher compared to conventional storage methods, the extended shelf life and reduced spoilage result in decreased product losses and increased profitability CA storage also helps optimize the utilization of agricultural resources and reduce food waste, contributing to sustainable and efficient agricultural practices

70. EMERGING TRENDS AND FUTURE DIRECTIONS The field of CA storage is continuously evolving, with emerging trends and technological advancements Innovations in monitoring and control systems, integration of Internet of Things ( IoT ) technology, and data analytics are shaping the future of CA storage Controlled Atmosphere (CA) storage is a valuable technique for extending the shelf life and maintaining the quality of grains and perishables

71. CA Storage for Apples : Apples are commonly stored in controlled atmosphere conditions to maintain their quality and extend their shelf life. The gas composition is adjusted to reduce oxygen levels and increase carbon dioxide levels , which slows down the ripening process and inhibits microbial growth. CA Storage for Potatoes : Potatoes are often stored in controlled atmosphere conditions to prevent sprouting and reduce spoilage. Controlled atmosphere storage helps maintain the firmness and color of potatoes , reducing losses due to sprouting and decay.

72. CA Storage for Grains : Various grains, such as wheat, rice, and maize, can benefit from controlled atmosphere storage. By adjusting the gas composition and regulating temperature and humidity, the storage life of grains can be prolonged, preserving their nutritional quality and preventing insect infestations . CA Storage for Cut Flowers : Cut flowers, such as roses, carnations, and orchids, are commonly stored in controlled atmosphere conditions to extend their vase life. By reducing ethylene levels and maintaining optimal temperature and humidity, the quality and freshness of cut flowers can be preserved for longer periods.

73. CA Storage for Fresh Vegetables : Various fresh vegetables, including lettuce, spinach, and broccoli, can benefit from controlled atmosphere storage. By maintaining optimal gas composition and humidity levels, the shelf life of vegetables can be extended, minimizing post-harvest losses

74. CAP STORAGE

75. CAP storage structures, also known as Controlled Atmosphere Packaging , are designed to create a modified atmospheric environment around the stored products This controlled atmosphere helps to extend the shelf life and maintain the quality of perishable items, such as fruits, vegetables, and certain food products

76. Purpose and Benefits : The primary purpose of CAP storage structures is to regulate the levels of oxygen, carbon dioxide, and sometimes nitrogen within the storage environment. By controlling these gases, CAP aims to slow down the ripening process, inhibit microbial growth, and prevent quality deterioration in the stored products . Gas Composition Control : Temperature and humidity control are integral to CAP storage structures. Monitoring and regulating temperature and humidity within CAP structures are critical to optimizing storage conditions. Packaging and Sealing : It require specific packaging materials and sealing techniques to maintain the desired gas composition.

77. Monitoring and Control Systems : CAP storage structures typically incorporate monitoring and control systems to ensure the desired atmospheric conditions are maintained. Automated control systems can adjust gas composition or activate ventilation as needed, based on predefined parameters. Application and Considerations : CAP storage structures are commonly used in the storage and transportation of fresh produce, including fruits, vegetables, and cut flowers. They can also be employed in certain processed food products, such as bakery items and snack foods