At one of the exhibitions, we were approached by a farm owner who was planning to build a new fruit storage facility. He already had an idea: to store up to 1,000 tons of apples in four chambers so that batches could be separated by variety, storage period, and customer.
We talked at the stand, then continued the dialogue at the facility. The client showed us the premises, told us how they organize harvesting and shipping, and pointed out the bottlenecks in the existing infrastructure. After that, it became clear what kind of complex he needed and where the solution could be optimized without compromising quality.
Initial conditions and tasks
The main request was simple: to build a fruit storage facility that would work consistently throughout the season, not just on paper. But behind this request lay several specific tasks.
First, it was necessary to organize the storage of apples in four separate chambers in order to be able to work with different modes. Some products would be sold quickly, while others would be stored for a long time.
Second, it was important to reduce losses: shrinkage, spoilage, loss of marketable appearance—all of which cost money. The customer needed a predictable result, not “whatever happens this season.”
Thirdly, we immediately discussed that without supply ventilation, a normal fruit storage facility would not be able to work not only with temperature but also with air in the chambers.
And one more fundamental requirement: a modern control system that can be connected remotely to see what is happening in the storage facility, even when you are hundreds of kilometers away.
Implemented solution
After inspecting the facility and agreeing on the tasks, we offered the client a phased solution and took on the entire scope of work.
1. Calculation and selection of equipment
First, we sat down to do the calculations: chamber volumes, heat flows, loading modes, and the amount of incoming products all affect the configuration of the system.
Based on this data, we selected refrigeration equipment that covers the required modes with a margin, but without “overshooting” in terms of power. We thought about where it would be best to place the units and how to organize the wiring so that it would be technically correct and maintenance would not turn into a quest.
2. Manufacture, supply, and installation of refrigeration systems
After agreeing on the solutions, we moved on to the practical side of things.
We manufactured and supplied refrigeration system kits for each chamber, installed the equipment on site, connected the pipelines, and carried out commissioning.
We paid special attention to ensuring that the system maintained the mode not only “under ideal conditions,” but also under real load, when the chambers are filled differently, there are frequent door operations, staff movement, etc.
3. Supply and installation of supply ventilation systems
Next, ventilation. For this type of storage facility, it is important not only to cool, but also to work with air correctly. We supplied and installed supply systems that allow fresh air to be supplied in the required volume and at the right time.
This helps to maintain a stable microclimate in the chambers, reduce the risk of product spoilage, and make storage more predictable.
4. Remote access control and monitoring system
At the final stage, we implemented a control and monitoring system.
Through it, the owner and responsible specialists can see real temperatures, equipment status, and emergency signals. Remote access is possible — there is no need to go to the facility every time to check if everything is okay.
The system also stores parameter history, which over time provides useful analytics: how the cameras behave, when the loads are highest, and where there is potential for further optimization.
Result for the customer
As a result, a simple building was replaced with a fruit storage facility capable of holding 1,000 tons of apples in four chambers, which actually works rather than just looking good on paper.
The client received:
- the ability to flexibly manage batches and storage periods;
- a stable microclimate, which directly reduces write-offs and “warehouse losses”;
- an intuitive management tool, both on-site and remotely;
- a basis for further development: the system can be expanded and refined as needed.
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