Embed Size (px)
Citation preview
1
FreshPort Asia Cold Chain & Perishable Innovation
Case Study
The Use of Thermal Covers to reduce refrigerated transport cost&
improved environmental impact
Pack Ship Sell Pick
The “Simple” Fresh Produce Supply Chain
3
Lower logistics cost per kg:
Increased Shelf Life on arrival
Reduction in Damage Claims / Shrink
Reduction in Transportation costs
Load Optimization & Consolidation
Value that Retailers support:
Pre-conditioning / Pre-cooling of produce prior to Shipping
Thermal Protection & Monitoring (Every Step)
Compliance with General Food Laws
Improved Transport Handling & Thermal protection (2-8°C, 8-15°C)
Environmental Benefits:
Lower Carbon Footprint (elimination of gel pack & Foam packaging landfill)
Lower energy consumed at each stage of handling
Reduction in single use packaging / A pallet sized solution that can be returned folded and flat
Product Freshness & Food safety
Driving Change: Cost vs Quality in a Responsible Manner
4
Shipper
Packing Staging
Current Method 35°C
60 Mins
35°C
120 Mins
15°C
60 Mins
10°C
60 Mins
35°C
60 Mins
24°C
20 Mins
28°C
10 Mins
Just in Time
Staging
Dry Ice added to hot container
Hand
unloading
Product
hot on tarmac
No
protection airborne
Perishable
Packing (Data logging)
Warm build-
up product temp 17C
Pallets kept
on truck
Hand loading
Broken cold-
chain
Product
hot on arrival
What started the project – broken cold / huge wastage
Thai Fresh Produce exporters had become logistically uncompetitive
Loading Temperature 24ºC
25% wastage
Unknown Post-
Harvest care
5
Immediate Improvement 2°C
10 Mins
2°C
20 Mins
2°C
90 Mins
2°C
60 Mins
2°C
90 Mins
2°C
10 Mins
2°C
10 Mins
Shipper
Packing Pre-cooling
Pallet return to packhouse
Pre-
Cooling
2°C (or as reqd)
Rapid Dock
Receiving
using trolley
jack or tail
gate
unloading
Thermal
Protection at Ramp <17°C
ULD
Protection airborne
Perishable
Packing
Using liner plate
on base
Of pallet – lift side
ETV Cold
Storage 10-12°C
All through
pallet usage
Rapid Dock
Loading
using forklift
or tailgate
PMC
Build & Weight Pallet cover
Development of Thermal Covers to cover the breaks
Good Post-Harvest
Intervention, Pre-cooling
& Shelf ready packaging
Loading Temperature 1ºC
ZERO claims or wastage
Fish & Seafood (to reduce wet ice usage, reduce
truck weight and substitute use of polystyrene)
Fresh cut produce (improved temperature control /
gaseous contamination with both refrigerated &
ambient vehicles)
Dairy & Frozen (improve handling quality for certain
products for shorter deliveries <18C <24hrs with
Eutectic for longer periods)
Chilled Meat (improved cold chain control and
reduced food safety risk)
Dry Goods sensitive to temperature (Chocolate &
Confectionary, Wines, Some cosmetics)
Temporary Cold storage in store on receiving –
reduced dependency on fixed cold rooms.
Thermal Covers – The airfreight solution was good enough
to provide cold chain integrity for road transportation The target usage for thermal covers includes both the transportation and storage of temperature
sensitive products such as:
Improve cold chain integrity
Low cost alternate to refrigerated transport / dedicated cold chain boxes
Allows multi temperature deliveries with one truck
Pre-cooled product for short to medium duration deliveries (< 24-36 hours)
Target temperatures are between -18C, 2C and 15C, depending on product requirements.
Covers are being used successfully for wet ice transportation of fresh fish & frozen with Eutectics
Successfully tested for metro delivery of ice-cream i& chilled dairy n ambient trucks
Protects products from extremes of temperature during loading transportation / unloading.
Final Beta trials for
Dairy and ice cream ambient transportation in Thailand
Thermal covers can eliminate the need for polystyrene packaging.
Thermal Covers – offering a low cost cold chain solution
Thermal cover placed
on top
before taking out of
cold room
Product palletized
inside cold room
Optional cooling
bricks precooled
Saves energy cost, as
an alternate to
refrigerated transport,
turning off
refrigeration during
transport
Cover removed at
store and returned to
truck
Optional cooling
bricks removed at
same time
Thermal cover
removed and ice tray
returned to driver to
go back to Distribution
Centre for next
journey.
Distribution Centre Store
Replacing refrigerated with ambient transport typical savings 30-50% vehicle cost
Turning off refrigeration during transportation – typical savings 5-10 % in fuel cost
Using collapsible thermal covers in lieu of Olivo Box typical return savings 35USD / pallet position*
(dependent on implementing a new thermal blanket for frozen – in process)
Thermal Covers – ensure cold chain integrity
9
Refrigerated Delivery Vehicles
(minus 20ºC – 5ºC)
Problematic temperature control
Ambient Delivery Vehicles
can be run at 20- 35ºC
Cream tests successful with truck temp at 48C
No cold chain breaks during loading
Trip Cost
~30-50% lower
Fuel & Energy
~5-10% less
Replacing Refrigerated Transport
with Ambient Transport with lower cost / less fuel usage
Insulated Ambient truck temp 27c
Pallet starting temp 5-7c
Pallet arrival temp 6-7c
Chiller truck temp average 8c
Pallet starting temp 4-5c
Pallet arrival temp 5.5-6c
Cream transport using normal chilled truck - 7 hours
Cream Transport using Ambient Truck & Thermal Covers - 6 hours
Cream Transport using Normal Chilled Truck – 7 hours
11
Polystyrene waste is a huge environmental problem in Asia resulting in significant pollution
of waterways & energy waste – it cannot be recycled – but often un-hygienically reused.
South East Asia’s Retail Logistics Curse
12
Expanded polystyrene is an
irresponsible packaging material
that cannot be recycled and
which is often discarded or
thrown away
Example of expanded polystyrene foam cartons – not popular with consignees
Objective to remove polystyrene from the Fish Supply Chain
13
Elimination of single use polystyrene cartons
A solution was developed for reusable / returnable / foldable thermal
eco-friendly packaging
Eco box
Eco Box (Dairy, Fresh Cut Produce, Frozen)
Design Concept
Foldable / washable / re-useable
100cm long x 60cm wide x 30cm high
Avoids use of oversize polystyrene cartons / reduced wet ice
Reduces requirement for refrigerated transport (<36 hours)
Prevents damaging oversize products in standard size crates
Target Performance:
Target produce weight 30-50kg, including wet ice / eutectics
Light weight chilled produce Pre-cooled 2-5C /
Fish transport in minimal wet ice 0-2C, Whipping Cream 2-5C
Stackable 4 layers high / 2 boxes per pallet layer - folds flat for return
Additional insulated transportation inside thermal pallet cover
Eco-Box (Loose Load or pre-packed less than Palletized Product)
Collapsible, nestable, returnable. Supports Chilled (Frozen version in development)
Two sizes developed
Oversize Pallet Box
100/107cm x 60cm x 30cm
Delivery Box (frozen)
60cm x 40cm x 20cm
Can be used in conjunction with
Eutectic cold bricks or stand-
alone.
Uses an inner plastic liner to
contain wet ice.
Vacuum insulated panels to be
used for frozen box
Project Benefits:
Maintains cold chain integrity for multi modal and long distance transport (2- 3 days)
Lower energy cost using ambient transportation in lieu of refrigerated transport.
80% reduction of wet ice used in transportation of fish (reducing product damage)
Improved quality / shelf life and reduced waste for chilled & highly perishable products
Prevention of chilling injury during transportation for certain products
Lower environmental impact by using reusable thermal packaging in lieu of polystyrene
Lower in-store infrastructure costs (reduction in use of back room refrigeration)
Cover folds up for lower cost return transportation, must be washed on each cycle of use
Thermal Covers – Benefits
Dependencies
Thermal Covers can only perform properly if part of an overall end to end cold chain solution
Selected products must be tested & correctly pre-cooled to ensure stable temperature
Crates & cartons need to be compatible with standard pallets & allow optimal stacking
Staff require training in the use of covers and in cold chain handling of fresh produce
Reusable Thermal covers require the use of standard pallets (120cm x 100cm base)
Pallet heights need to be standardized for particular categories (i.e. fish 140cm high)
Thermal Covers – Dependencies
Thermal Covers – Test Results
Testing
A number of tests were carried out to confirm that thermal covers could perform with the different
products / handling requirements of Metro, they involved Fish and F&V. These tests met or exceeded
expectations. Test Summaries are as follows:
Fish
Maintained 2 – 5 kg wet ice in plastic crates for a period of 3 days @ 1- 2C
Improved quality of fish received in store (less damage)
Dairy & Cream
Transportation from manufacturer to distributor warehouse 5 hours 2-5C
Ice Cream
Transport from manufacturer to retail DC 5 hours <18C
F&V
Maintained temperature of pre-chilled apples at 4C for 3 days at 8 -15C
Maintained pre-chilled apples <8C exposed to 30C ambient for 3 days
Prevented chilling injury with sensitive produce for 3 days in 2-5C environment
Page 20
Trial 1: Chilled Apples in low Ambient for 3 days
Pallet 3: 20mm thermal cover
No eutectics
Pallet 1: 10mm Thermal cover
No eutectic blocks
Pallet 2:10mm Thermal cover
3 eutectic blocks <18C
Result: Maintained exactly
4.5C for 52 hours.
Result: Maintained
between 4 & 5C for 52
hours
Result: Maintained b/w 4.5C
and 2.5Cfor 52 hours
Page 21
Average temperature differential 25C over 24 hours
25 cases of chilled apples. Exposed to extreme temperature / direct sunlight
Product core temperature increased 3C / 24 hours.. Which is equivalent to normal heat given
out during oxidation (senescence) . Temperature increase: 1C temperature rise / 8 hours.
Ambient temperature
Logger inside centre
of pallet
Trial 1: Chilled Apples in High Ambient (Apples) 24 hours
Ambient
Ambient
Ambient
Temperature
10mm cover &
No cooling block
10mm cover &
3 Cooling blocks
10mm cover &
3 Cooling blocks
Result: 3 pallets of apples,
with temperature maintained
<5C for 52 hours
Trial 1: Chilled Apples in Low Ambient temperatures 3 days
Whipping Cream between 2 & 5C to maintain efficacy
Average ambient temperature inside the truck. 32c
Under thermal cover
temperature readings Average temp 5c
Temperature Inside 1 gallon cream tub
Product temperature
increased 1 degree in 5 hours
2-5ºC
Trial 2: Chilled whipping Cream – Ambient Truck Transportation 6 hours
Palletized Ice-cream <minus 18C,
Average ambient temperature inside the truck. 17C
Product temperature increased 2 degrees in 6 hours
Under thermal cover
temperature readings Average temp 5c
Trial 3: Ice Cream – Ambient Truck Transportation 6 hours Metro Delivery
Normal
transportation
method of
Mackerel:
Using undersized
plastic crates
No standard
polystyrene box
was available- so
traditional method
is to use second
hand (not clean)
poly boxes or
recut standard
boxes with
contamination
from cut
polystyrene.
Trial 4: Mackerel Shipment with Wet Ice
Redline extrapolated
Control Test: Delay in Wet-Ice melt for Fish Transportation
Ambient
Temperature
2 kg Ice in in
plastic crate @ 5C 8 kg Ice @ 5C
Insulated crate
8 kg Ice in in
plastic crate @ 5C 8 kg Ice x 35 crates
in thermal cover
2 kg Ice in in
plastic crate @ 5C
Test 4: Fresh Mackerel Shipment with Wet Ice
Testing using 25kg of fresh
mackerel - average length
90cm
48 hours – delivery from
CanTho fish platform to Anh
Phu Store
Result: all wet ice intact
Maintained temperature
Test 4: Mackerel Shipment with Wet Ice
48 hours transit time: Ice intact at destination
Trial 4: Showing the same test with refrigerated transport
Ambient Truck & Platform
Temperature
Logger inside
body of fish
Temperature Logger on
top of fish
Trial 5: Protection from Chilling Injury
(Herbs, Bananas, Tropical Fruits)
Page 30
Average temperature differential 15C 18 hours
Ambient Pomelos. Exposed to potential chilling injury
Product core temperature decreased 5C / 15 hours.
1C temperature decrease / 3hours.
The thermal cover showed it can provide protection for sensitive produce from chilling injury during
transportation.
Cold room temperature
Logger inside centre of pallet
Transit time Staging & Loading Destination
Temperature inside
Stable temperatures from packhouse to end destination
Temperature
outside cover
Temperature
inside cover
Test 6: Use of Thermal Cover for Multi Modal transport 24 hrs
integrity
Blue line = Outside cover, Green line = Outside skid under cover, Black line = Attached to carton, Red line = inside carton
Ambient temperature in direct
sun was 51c for 2 hours Temperature taken inside
cover – no ice, no gel pack
Remained stable at 10C
Temperature inside carton
went up 4 degrees in 22 hours
Trial was to test effectiveness of frozen products with no additional cooling / eutectics.
Normally a 5kg eutectic brick would be used to stabilize the temperature
Test 7: Thermal Covers – Frozen Shipments without Eutectics
33
Exterior logger recording ambient temperature
Under thermal cover
Inside carton logger recording product temperature
Trial was to test effectiveness of frozen product from manufacturing site to retail DC
Result: 28 hours with temperature rise of 8C,
Product trials using frozen pastry dough – shipped from Bangkok to Narita by air.
Thermal Covers – Frozen Shipments with Eutectics
Additional successful
Trials using ambient
truck for palletized
Frozen Ice Cream from
manufacturer in
Lat Kra-bang to
distributor in BangPoo
< minus 18ºC
for 12 hours
34
New Product Offering – Low temp frozen in situ cold room
1. Frozen, deep-frozen and refrigerated commodities.
2. Inner temperature can be kept to -20C even in a midsummer.
4. Various types of cooling containers are available
Thermal Engine from Japan
35
The inner temperature can be set at 3 levels: 1 Refrigeration Mode (plus 3°C),
2 Freeze Mode (minus 20°C),
3 Strong Freeze Mode (minus 35°C).
The Freezer Unit can maintain a 60-65C temperature differential.
36
A company can only generate profitable
growth over the long term if it acts
responsibly towards society and the
environment.
That is why METRO GROUP had declared
sustainability to be an integral component
of the Company’s strategy in developing
these cold chain solutions.
This project was successful in that social
and environmental needs were considered
essential business case inputs. With
sustainability considered at an early stage
in project business decisions and
processes.
Sustainability & Environmental Responsibility
AFRIS. AsianFoodRegulationInformationService.
We have the largest database of Asian food regulations in the world and it’s FREE to use.
We publish a range of communication services, list a very large number of food events and online educational webinars and continue to grow our Digital
Library.
We look forward to hearing from you soon!
