Polytechnic University of the Philippines

Maragondon Branch
Maragondon, Cavite

DESIGN AND OPTIMIZATION OF COOLING SYSTEM FOR COLD STORAGE

FACILITY FOR 5000 LITER/DAY ICE CREAM PRESERVATION

A Thesis Presented to the Faculty of College of Engineering

Polytechnic University of the Philippines
Maragondon Branch
Maragondon, Cavite

In Partial Fulfillment of the Requirements in

SUBJECT NI AWO

by:

BSME – III

Engr. John Robert Gonzales, RMEE

Adviser

July 16, 2023

 CERTIFICATION

This thesis/dissertation DESIGN AND OPTIMIZATION OF COOLING SYSTEM FOR

COLD STORAGE FACILITY FOR 5000 LITER/DAY ICE CREAM PRESERVATION
prepared and submitted by Rein Andrea C. Alano, Azli A. Castillo, Nicole L. Corpuz,
Joseph F. De Castro, Ivan Aristotle M, Digal, Noeliza V. Encarnacion, John Robert S.
Gonzales, Royeth D. Israita, Jhim Brian E. Luay, Michael Joshua S. Monares, Russel G.
Reyes, Avegail C. Soriano, Louise Kim Jerly A. Umpay in partial fulfillment of the
requirement on MEEN 3204 – Machine Design 1 has been examined and is
recommended for Oral Examination.

Evaluation Committee

ENGR. JOHN ROBERT GONZALES, RMEE

Adviser

______________________________________________________________________
APPROVAL

Approved by the Panel on Oral Examination on July 16, 2023 with the grade of ______.

ENGR. JOSHUA SISMAET, RMEE

Chairman

ENGR. ARJAY ABONG, RMEE ENGR. LOUNELA SUNICO, RMEE

Member Member

Accepted in partial fulfilment of the requirements for the degree Bachelor of Science in
Mechanical Engineering.

ENGR. ROSALIA PINLAC

Head, Academic Programs

Date of passing the Comprehensive Examinations: _______________

ii
 ACKNOWLEDGEMENTS

The researchers would like to express their deepest gratitude and appreciation to

the people behind the success of their research paper.

First and foremost, to our Almighty God, for without His graces and blessings,

this study would not have been possible.

To their adviser, Engr. John Robert S. Gonzales, RMEE for guiding them

throughout the study and research, for his patience, motivation, enthusiasm, and

immense knowledge.

To their colleagues from Junior Philippine Society of Mechanical Engineers, who

provided insights and expertise that greatly assisted the research.

To their classmates and friends, whom they share their knowledge and struggles

in creating this study.

To their parents, for providing them with unfailing support and continuous

encouragement throughout their years of study and through the process of researching

in writing this thesis. This accomplishment would not have been possible without them.

And to all the people behind the completion of this study, the researchers’

unwavering gratitude and appreciation will always be given.

- The Researchers

iii
 CERTIFICATION OF ORIGINALITY

This is to certify that the research work presented in this thesis/dissertation, DESIGN

AND OPTIMIZATION OF COOLING SYSTEM FOR COLD STORAGE FACILITY FOR

5000 LITER/DAY ICE CREAM PRESERVATION for the degree Bachelor of Science in

Mechanical Engineering at the Polytechnic University of the Philippines embodies the

result of the original and scholarly work carried out by the undersigned. This dissertation

does not contain words or ideas taken from published sources or written works that have

been accepted as a basis for the award of a degree from any other higher education

institution, except where proper referencing and acknowledgement were made.

Alonzo, Ave Brian C.

Bautista, Brian Luis

Buenviaje, Khen Moises P.

Cabili, John Phillip M.

Cuevas, Lawrence Arnie C.

De Raya, Shiela May P.

Duploso, Mark Nonie M.

Garcia, Christian Bernard L.

Guzon, Leslie M.

Monares, Marcus Rafael B.

Muelle, Irish Mae A.

Paloyo, Jupiter

Ramos, Dan Raniell S.

Rosales, Jetro L.

Tanega, Marben Lorensus A.

Verano, Ralfrenz I.

Zapanta, Hershey G.

Researchers, Bachelor of Science in Mechanical Engineering

iv
 ABSTRACT

Title : Design and Optimization of Cooling System for Cold Storage

Facility For 5000 Liter/Day Ice Cream Preservation
Researchers : Alonzo, Ave Brian C., Bautista, Brian Luis, Buenviaje, Khen
Moises
P., Cabili, John Phillip M., Cuevas, Lawrence Arnie C., De Raya,
Shiela May P., Duploso, Mark Nonie M., Garcia, Christian Bernard
L., Guzon, Leslie M. Monares, Marcus Rafael B., Muelle, Irish
Mae A., Paloyo, Jupiter, Ramos, Dan Raniell S., Rosales, Jetro L.,
Tanega, Marben Lorensus A., Verano, Ralfrenz I., Zapanta,
Hershey G.
Degree : Bachelor of Science in Mechanical Engineering
Institution : Polytechnic University of the Philippines
Year : July 2023
Adviser : Engr. John Robert S. Gonzales, RMEE
Abstract :

This research focuses on the design and optimization of a cooling system for a

cold storage facility, specifically for the preservation of 5000 liters per day of ice cream.

The study analyzes existing cooling system designs and identifies their limitations. A

novel cooling system is developed, incorporating innovative techniques to improve

energy efficiency and temperature control. Experimental evaluations assess the

system's performance in terms of cooling capacity and energy consumption. The impact

on ice cream quality is also examined. The findings contribute to the knowledge of

efficient cooling system design for ice cream preservation and provide recommendations

for improvement in the food industry.

v
vi
 TABLE OF CONTENTS

Page

TITLE PAGE ….
………………………………………………………………………
…………..
i

CERTIFICATION.............................................................................................................. ii

ACKNOWLEDGEMENTS...............................................................................................iii

CERTIFICATION OF ORIGINALITY...............................................................................iv

ABSTRACT...................................................................................................................... v

TABLE OF CONTENTS..................................................................................................vi

LIST OF TABLES............................................................................................................ix

LIST OF FIGURES........................................................................................................... x

Chapter 1......................................................................................................................... 1

THE PROBLEM AND ITS SETTING................................................................................1

1.1 Introduction/Background of the Study.............................................................1

1.2 Conceptual Framework......................................................................................3
1.3 Statement of the Problem........................................................................................3
1.4 Hypothesis................................................................................................................3
1.5 Scope and Limitations of the Study.......................................................................3
1.6 Significance of the Study........................................................................................3
1.7 Definition of Terms..................................................................................................5

Chapter 2......................................................................................................................... 6

vii
REVIEW OF LITERATURE AND STUDIES.....................................................................6

2.1 Conceptual Literature..............................................................................................6

2.2 Research Literature..................................................................................................7

2.3 Relevance of the Study............................................................................................8

Chapter 3......................................................................................................................... 9

METHODOLOGY............................................................................................................. 9

3.1 Research Design.......................................................................................9

3.1.1 Research Objectives.............................................................................9

3.1.2 Research Methodology.......................................................................10

3.2 Project Development..............................................................................................14

3.2.1 Cooling System Components and its Functions..............................................15

3.2.2 Design Considerations.......................................................................................17

3.3 Operation/Testing Procedure................................................................................22

3.4 Evaluation Procedure.............................................................................................23

3.5 Evaluation Criteria..................................................................................................26

3.6 Instrument and Techniques Used.........................................................................28

Chapter 4....................................................................................................................... 31

viii
RESULTS AND DISCUSSION.......................................................................................31

4.1 Project Technical Description...............................................................................31

4.2 Project Structure and Organization......................................................................32
4.3 Project Limitation and Capabilities.......................................................................33
4.4 Project Evaluation..................................................................................................34

Chapter 5....................................................................................................................... 35

SUMMARY OF FINDINGS, CONCLUSIONS, AND RECOMMENDATIONS.................35

5.1 Summary of Findings.............................................................................................35

5.2 Conclusions............................................................................................................ 37
5.3 Recommendations.................................................................................................38

References....................................................................................................................39

APPENDIX..................................................................................................................... 40

Appendix 1: (Name of the Table, Figure, Document).................................................41

ix
 LIST OF TABLES

Number Title Page

1 Conceptual Framework 3

x
 LIST OF FIGURES

Number Title Page

1 3D Diagram 1

2 Schematic Diagram 6

xi
xii
 Chapter 1

THE PROBLEM AND ITS SETTING

1.1 Introduction/Background of the Study

Ice cream is a perishable product that has been a favorite dessert for centuries. But

its storage requires specific environmental conditions, primarily controlled temperature,

and humidity, to maintain quality and avoid spoilage. Inadequate storage conditions can

contribute to microbial growth, enzymatic reactions, and chemical changes, resulting in

product degradation, loss of quality, and potential health risks.

Cold storage facilities offer an environment that can be adapted to satisfy the specific

needs of various products. These facilities are equipped with refrigeration systems to

maintain low temperatures and prevent the growth of microorganisms, ensuring the

stored goods' safety and freshness. Insulation, refrigeration systems, temperature

control mechanisms, and ventilation systems all play a role in the efficient design of a

cold storage facility. The ventilation system ensures uniform chilling and air distribution

throughout the facility. Several studies have highlighted the importance of air in

preserving ice cream. According to Smith (2018), temperature fluctuations affect the

quality of ice cream during storage. Poor ventilation systems that cause temperature

fluctuations may result in ice crystal formation, texture deterioration, and product quality

loss. Temperature control is essential for preventing modifications in the structure and

quality of ice cream. Consequently, increasing ventilation techniques for temperature

regulation is an essential aspect of ice cream storage.

 2

Humidity management is an important aspect of ice cream preservation. Inadequate

humidity levels may result in issues such as ice recrystallization and freezer burn.

Johnson (2019) investigated different humidity control systems for ice cream storage

facilities. The study emphasized the importance of determining the optimal humidity

range and devising ventilation devices to effectively control moisture levels in the

storage environment. It is essential to properly control humidity levels to preserve the

texture of ice cream and prevent the formation of ice crystals. In addition to temperature

and humidity regulation, air circulation is essential for the storage of ice cream.

Inadequate air circulation can result in uneven temperature distribution throughout the

storage facility, resulting in hot or chilly areas. Brown (2020) examined the effect of air

circulation on the quality and freezing/melting patterns of ice cream. The study

highlighted the significance of ventilation system design in delivering uniform airflow and

temperature distribution throughout the storage area. Improving air circulation can aid in

reducing irregular freezing and thawing patterns, thereby enhancing the overall quality of

ice cream.

The design and optimization of the storage environment, specifically the ventilation

system, significantly impacts the preservation of ice cream. The Ventilation Design for

5000 liters/day Cold Storage Facility to Optimize Ice Cream Preservation can help

manage temperature, humidity, and air circulation within ice cream storage facilities,

which affects ice cream's quality and expiration life. By utilizing appropriate ventilation,

ice cream manufacturers and managers of storage facilities can maintain the quality and

extend the expiration life of ice cream during storage to maximize consumer satisfaction

and reduce product waste.

 3

1.2 Conceptual Framework

1.3 Statement of the Problem

This study was conducted to assess the Ventilation System Design for 5000

liters/day Cold Storage Facility to Optimize Ice Cream Preservation.

Specifically, the study attempted to answer the following questions:

1. What cooling load is required to maintain the desired temperature of -18C to -

30C for preserving ice cream?

2. What is the ideal facility size for the cold storage to fill in 5000 liters of ice cream?

3. What ventilation system design is best for minimizing the heat load from room

surfaces?

4. How many sensors are necessary to monitor and regulate the temperature and

humidity levels within the cold storage facility?

1.4 Hypothesis

1.5 Scope and Limitations of the Study

The researcher aims to create an improved ventilation system design, particularly for

an ice cream preservation-focused cold storage facility with a daily capacity of 5000

liters. This includes calculating ventilation requirements based on facility size and ice

cream volume. Furthermore, this study covers ducting design and pipework of storage.

1.6 Significance of the Study

The research on Ventilation System Design for 5000 liters/day Cold Storage Facility

to Optimize Ice Cream Preservation benefits the following:

Customer. Customers can ensure that their purchased product is high-quality by

developing an optimized ventilation system for ice cream preservation. Maintaining

 4

consistent temperature, controlling humidity levels, and ensuring proper air circulation

can prevent issues like ice crystal formation, freezer burn, and texture degradation.

Enhanced product quality leads to increased customer satisfaction and loyalty.

Cold Storage Facility. An optimized ventilation system can improve operational

efficiency within the cold storage facility. Ensuring consistent temperature and humidity

control can reduce the workload on cooling units, leading to energy savings and

increased equipment lifespan. Improved operational efficiency translates into cost

savings for the facility and better resource utilization.

Environment. Having an optimized ventilation system not only improves ice cream

preservation but also has environmental benefits. By reducing energy consumption and

greenhouse gas emissions associated with inefficient ventilation, the research promotes

sustainability within the cold storage industry. This aligns with global efforts to reduce

carbon footprints and mitigate climate change.

Manufacturers. An efficient ventilation system can significantly extend the shelf life of

ice cream products. It can help to minimize product spoilage, flavor deterioration, and

the growth of harmful microorganisms. This extended shelf life can reduce financial

losses for ice cream manufacturers and distributors while promoting sustainability by

reducing food waste.

Engineers. The research can guide engineers in designing and operating cold

storage facilities for ice cream preservation by identifying the most effective ventilation

techniques and providing guidelines for optimal system design. This research promotes

innovation and continuous improvement within the ice cream industry.

 5

Future Researchers. This will serve as a future reference for future researchers that

will also be dealing with Cold Storage Facilities. For design, this research can be their

base and will guide them to improve it more in the future.

1.7 Definition of Terms

The following terms are used in this study:

Cold Storage Facility. Cold storage facility involves the storing of perishable or
other sensitive goods like food at a specific temperature range to maintain their integrity,
shelf-life, and quality (Conger Industries Inc., 2022).

Cooling Load. The cooling load is the quantity of heat energy that must be
added to an area in order to keep the temperature within a reasonable range (New
South Whales, 2023).

Heat Transfer. Any time there is a temperature difference between two items,
heat transfer happens. It also happens in the direction of decreasing temperature, that
means from a hot object to a cold object (Access Science, 2023).

Humidity. Water vapor content in the air is referred to as humidity. Humidity

levels will be high if there is a lot of water vapor present. It feels wetter outside when the
humidity is higher (National Geographic, 2023).

Preservation. It can be defined as the process of treating and handling food in

such a way as to stop or greatly slow down spoilage and prevent foodborne illness while
maintaining nutritional value, texture and flavor (ScienceDirect, 2023).

Ventilation System. A comprehensive system of ventilation is essential to

effective HVAC. Ventilation is a separate mechanism from heating or air conditioning but
works in conjunction with both, maintaining the airflow necessary to effectively heat or
cool a building (Data Center, 2021).
 6

Chapter 2

REVIEW OF LITERATURE AND STUDIES

This chapter introduces the conceptual literature, research literature, and

relevance of the study. It presents a concise overview of the theoretical frameworks and

existing research related to the project, highlighting their significance and informing the

reader about the study's context and its practical implications.

2.1 Conceptual Literature

Explanation of key concepts and definitions

Theoretical foundations and models relevant to cooling systems and cold storage
facilities
Overview of ice cream preservation techniques and requirements
Principles of cooling system design and optimization
Integration of relevant concepts and theories to support the research
 7

2.2 Research Literature

Review of published research papers, journals, and conference proceedings

Identification of studies related to cooling systems for cold storage facilities
Analysis of literature on ice cream preservation methods and technologies
Evaluation of research on energy efficiency in cooling systems
Examination of studies on cooling system optimization techniques
Summary and synthesis of key findings from the research literature
Identification of gaps and opportunities for further investigation
 8

2.3 Relevance of the Study

Discussion on the importance of cold storage facilities for ice cream preservation
Significance of efficient cooling systems in the food industry
Addressing the challenges and limitations in current cooling system designs
Relevance of energy efficiency in cooling systems for sustainability and cost reduction
Contribution of the research to the field of cooling system design and optimization
Potential impact of the study on ice cream preservation practices
Practical applications and benefits of implementing the proposed cooling system
Justification for the research and its contribution to existing knowledge
 9

Chapter 3

METHODOLOGY

This chapter presents the research design and project development, providing a

comprehensive overview of the testing and evaluation procedure, evaluation criteria, as

well as the instruments and techniques employed for this study. It will serve as a

foundation for understanding the systematic approach adopted in the research,

highlighting the essential elements necessary for accurate data collection and rigorous

analysis.

3.1 Research Design

3.1.1 Schematic Diagram of the cooling system

3.1.2 Schematic Diagram of the freezer room

3.1.3 Block Diagram

3.1.4 Flow chart Diagrams

3.2 Research Objectives

1. To analyze the existing cooling system designs and technologies used in cold

storage facilities for ice cream preservation.

2. To identify the key challenges and limitations in current cooling system designs

for ice cream preservation.

3. To design a novel cooling system that ensures efficient and reliable preservation

of 5000 liters/day of ice cream.

4. To optimize the cooling system design to enhance energy efficiency and reduce

operational costs.

5. To evaluate the performance of the designed cooling system in terms of cooling

capacity, energy consumption, and temperature control.

 10

6. To assess the impact of the cooling system on the quality and shelf-life of the

preserved ice cream.

7. To provide recommendations for further improvements and best practices in

cooling system design for ice cream preservation.

8. To contribute to the knowledge and understanding of efficient cooling system

designs for cold storage facilities in the food industry.

3.2.1 Research Methodology

Calculation Based Method:

a.) Heat Load Analysis:

 Calculate the heat load from external sources, such as ambient temperature,

solar radiation, and heat transfer through walls or insulation.

 Consider the thermal properties of the cold storage facility and the ice cream

containers.

b.) Cooling Capacity Calculation:

 Calculate the amount of heat energy that needs to be removed from the cold

storage facility to preserve 5000 liters/day of ice cream.

 Consider factors such as the specific heat capacity of ice cream, temperature

differentials, and required cooling time.

c.) Power Consumption Estimation:

 Estimate the power consumption of the cooling system components, including

the compressor, fans, and pumps.

 Consider the electrical efficiency of the components and the load profile of the

system.

d.) Coefficient of Performance (COP) Calculation:

 11

 Calculate the COP of the cooling system using the formula: COP = Cooling

Capacity / Power Consumption.

 Use measured or simulated values for cooling capacity and power consumption.

e.) Energy Efficiency Ratio (EER) Calculation:

 Calculate the EER of the cooling system, which represents the cooling capacity

per unit of electrical power input.

 EER = Cooling Capacity (BTU/hr) / Power Consumption (W).

f.) Pressure Drop Calculation:

 Calculate the pressure drop across various components of the cooling system,

such as pipes, valves, and heat exchangers.

 Use pressure drop formulas or consider fluid flow simulations to determine the

resistance and efficiency of the system.

Simulation Based Method:

 Utilize CFD simulatioh software AutoDesk CFD to simulate the flow and heat

transfer behavior within the cooling system and cold room.

 Apply appropriate boundary conditions, including inlet and outlet specifications,

ambient temperature, and ice cream storage conditions.

 Conduct transient or steady-state simulations to analyze the temperature

distribution, velocity profiles, and heat transfer performance.

 Validate the CFD model by comparing simulation results with experimental data

or established benchmarks.

Sensor-Based Measurements:

 Install temperature, pressure, and flow rate sensors at key locations within the

pipeline and cold room.

 12

 Ensure proper calibration and synchronization of the sensors for accurate

measurements.

 Collect real-time data during system operation to monitor and analyze the

system's performance.

 Measure temperature differentials, pressure drops, and flow rates to assess the

efficiency and effectiveness of the cooling system.

 Use appropriate data acquisition systems to record and store the sensor data for

further analysis.

Data Collection and Analysis Plan

 Analyze the collected CFD simulation results and sensor measurements to

evaluate the cooling system's performance.

 Compare the simulation and experimental data to validate the CFD model and

identify any discrepancies.

 Identify areas of improvement and optimization based on the data analysis.

 Utilize optimization techniques, such as parametric studies or design of

experiments (DoE), to fine-tune the cooling system design for enhanced

performance.

 Iteratively modify the cooling system design parameters and re-run simulations to

optimize cooling capacity, energy efficiency, and temperature control.

Result Validation and Interpretation

 Validate the optimized cooling system design by comparing the final simulation

results with the experimental data and benchmarks.

 Interpret the findings and draw conclusions regarding the cooling system's

performance, efficiency, and ice cream preservation capabilities.

 13

 Discuss the limitations and uncertainties associated with the methodology and

propose recommendations for future research.

Ethical Considerations

a) Informed Consent: Ensure that all participants, including personnel involved in

the research and individuals whose data may be collected, provide informed

consent. Clearly explain the purpose, risks, benefits, and procedures of the

research to participants in a language they understand.

b) Privacy and Data Protection: Protect the privacy and confidentiality of individuals

whose data is collected during the research. Comply with relevant data protection

regulations and obtain necessary permissions for data storage, sharing, and

analysis. Anonymize and secure personal data to prevent unauthorized access

or disclosure.

c) Community Engagement: Engage with the local community and stakeholders to

establish a collaborative relationship. Communicate the research objectives,

potential benefits, and any potential risks or impacts. Seek community feedback

and address concerns to ensure the project aligns with the community's needs

and values.

d) Environmental Impact: Consider the potential environmental impact of the cooling

system and associated activities. Implement measures to minimize energy

consumption, waste generation, and pollution. Comply with relevant

environmental regulations and adopt sustainable practices wherever possible.

e) Health and Safety: Prioritize the health and safety of researchers, participants,

and personnel involved in the project. Implement appropriate safety measures,

provide necessary training, and adhere to relevant occupational health and

safety guidelines to prevent accidents or harm.

 14

f) Ethical Research Conduct: Adhere to the principles of research integrity,

honesty, and transparency throughout the project. Follow ethical guidelines and

standards set by the relevant research institutions, organizations, or professional

bodies.

g) Cultural Sensitivity: Respect local customs, traditions, and cultural practices

during the research project. Seek permission and collaborate with local

communities or indigenous groups when conducting research on their land or

involving their knowledge.

h) Intellectual Property: Respect intellectual property rights by properly

acknowledging and citing sources, obtaining necessary permissions for using

copyrighted material, and adhering to patent laws if applicable.

i) Ethical Review: Seek ethical clearance and approval from the appropriate

research ethics committee or institutional review board before commencing the

project. Adhere to the committee's guidelines and regulations.

3.3 Project Development

3.3.1 Construction Procedure

1. Excavate the foundation area in accordance with the design specifications.

Prepare the essential utilities connections, such as electricity and water supply. Clear

the building site and make sure it is level and clear of any obstructions.

2. Build the foundation in accordance with the structural design guidelines.

Concrete may be poured or precast foundation components may be used in this. Give

the foundation enough time to cure so that it can reach the necessary strength.
 15

3. Use appropriate materials, such as concrete, steel, or prefabricated panels, to

construct the cold storage facility's walls and roof. Install doors and any ventilation

systems that are required.

4. Attach insulation materials to the walls, ceiling, and floor of the storage room,

such as polyurethane foam, EPS, or XPS panels. Ensure adequate sealing and

insulation to reduce heat transfer and maintain low temperatures.

5. Choose an appropriate location for the evaporator unit inside the storage space.

Mount the evaporator on the ceiling or wall, being sure to place it where it will have the

best airflow.

6. Make sure the evaporator is positioned for ideal air circulation before mounting it

to the wall or ceiling.

7. Install fans or air circulation devices to ensure that cold air is distributed evenly

throughout the storage space. Install the condenser unit(s) outdoors, such as on the

building's roof or outside the structure.

8. Install fans or ventilation systems to disperse the heat produced by the

condenser before connecting the condenser to the refrigerated piping system.

9. Install temperature sensors, pressure gauges, and other monitoring equipment to

enable correct management and monitoring of the refrigeration system. Connect the

evaporator, condenser, and other refrigeration components to the electrical power

source.

3.3.2 Construction Steps and Procedure

Building a cold storage facility with an evaporator and condenser entails a number of

phases and operations. Here's a high-level overview of the procedure:

 16

1. Site selection and layout:

Choose a good location for the cold storage facility, taking into account variables such

as accessibility, proximity to transit, and utility availability.

Design the facility's layout, including storage, loading and unloading bays, administrative

space, and insulation requirements.

2. Installation of insulation and panels:

Install insulating materials on the storage area's walls, ceilings, and flooring.

To prevent heat transmission and maintain low temperatures, ensure good sealing and

insulation.

3. Design of a Refrigeration System:

Determine the cooling requirements depending on the desired temperature range and

storage capacity (5000 liters of ice cream per day in this case).

Based on the cooling load calculations, size the evaporator and condenser units and

choose appropriate equipment.

Create the refrigeration piping system while keeping the distance between the

evaporator and condenser and the refrigerant type in mind.

4. Installation of an Evaporator:

Install the evaporator unit(s) on the storage area's ceiling or wall, ensuring correct

orientation for efficient air circulation.

Connect the evaporator to the refrigeration piping system, making that the pipes are

properly insulated.
 17

Install fans or air circulation equipment to ensure that cold air is distributed evenly

throughout the storage area

5. Installation of a Condenser:

Place the condenser unit(s) outside, preferably on the roof or outside the cold storage

facility.

Connect the condenser to the refrigeration piping system, making sure that the pipes are

properly insulated.

Install fans for ventilation systems to dissipate the condenser's heat.

6. Installation of Electrical and Control Systems:

Connect the electrical power source to the evaporator, condenser, and other

refrigeration components.

Install temperature sensors, pressure gauges, and other monitoring devices to ensure

effective refrigeration system control and monitoring.

Install a control panel or digital temperature controllers to regulate the cooling process

and maintain temperature stability.

7. Commissioning and testing:

Thoroughly evaluate the complete refrigeration system, including checking for refrigerant

leaks, appropriate component performance, and temperature control accuracy.

Adjust the system as needed to obtain the desired temperature range and to ensure it

meets the ice cream storage requirements.

Obtain the certifications and permits required to comply with local regulations.

8. Maintenance and Monitoring:

 18

Create a maintenance schedule for inspecting and cleaning the evaporator, condenser,

and other components.

Monitor the functioning of the refrigeration system, including temperature management,

energy consumption, and any indicators of malfunction.

Address any concerns as soon as possible to ensure the cold storage facility's

continuing efficient operation.

Figure 1. Cooling System Components

3.2.1 Cooling System Components and its Functions

1. Compressor:

 Function: The compressor is responsible for compressing the refrigerant

vapor, raising its pressure and temperature.

 Purpose: It circulates the refrigerant throughout the system and maintains

the necessary pressure levels for efficient heat transfer.

2. Condenser:
 19

 Function: The condenser facilitates the transfer of heat from the

refrigerant to the surrounding environment, causing the refrigerant to

condense into a liquid state.

 Purpose: It dissipates the heat absorbed by the refrigerant during the

cooling process, enabling the refrigerant to release heat and cool down.

3. Evaporator:

 Function: The evaporator allows the refrigerant to absorb heat from the

cold storage facility, causing it to evaporate and turn into a vapor state.

 Purpose: It extracts heat from the ice cream and the surrounding

environment, creating the necessary cooling effect for preservation.

4. Expansion Valve:

 Function: The expansion valve regulates the flow and pressure of the

refrigerant entering the evaporator.

 Purpose: It controls the refrigerant flow rate and lowers the pressure,

enabling the refrigerant to expand and absorb heat efficiently in the

evaporator.

5. Refrigerant:

 Function: The refrigerant is a fluid with specific thermodynamic properties

that undergoes phase changes (from vapor to liquid and vice versa) to

transfer heat.

 Purpose: It facilitates the heat transfer process by changing states and

carrying heat energy between the various system components.

6. Control System:
 20

 Function: The control system regulates and monitors the operation of the

cooling system, ensuring optimal temperature control and efficient system

performance.

 Purpose: It maintains the desired temperature within the cold storage

facility, adjusts the operation of components, and safeguards against

potential system faults.

7. Sensors:

 Function: Sensors are used to measure and monitor various parameters

within the cooling system and cold storage facility, such as temperature,

pressure, and humidity.

 Purpose: They provide real-time data for system performance analysis,

control system feedback, and adjustments to maintain optimal conditions

for ice cream preservation.

8. Pipes and Valves:

 Function: Pipes and valves form the network for refrigerant flow,

connecting different system components and facilitating fluid circulation.

 Purpose: They transport the refrigerant between the compressor,

condenser, evaporator, and expansion valve, ensuring proper distribution

and control of the refrigerant flow.

These main system components work together to facilitate the transfer of heat

and maintain the required temperature conditions for the efficient preservation of ice

cream in the cold storage facility.

3.3 Operation/Testing Procedure

1. Initial System Check:

a. Ensure all system components are properly installed, connected, and powered.
 21

b. Verify that sensors and data acquisition systems are functioning correctly.

c. Perform a visual inspection of the system for any leaks, damages, or abnormalities.

2. System Startup:

a. Turn on the power supply to the cooling system.

b. Activate the control system and set the desired temperature for ice cream

preservation.

c. Monitor the startup sequence to ensure proper functioning of the compressor,

condenser, evaporator, and expansion valve.

d. Verify that the refrigerant flow and pressure are within the specified range.

3. Performance Testing:

a. Measure and record the initial temperature of the cold storage facility and ice cream.

b. Monitor the system parameters, such as cooling capacity, power consumption, and

temperature control, using sensors and data acquisition systems.

c. Conduct testing over a specified period to assess the system's performance under

normal operating conditions.

d. Collect data at regular intervals to analyze trends and variations in temperature,

pressure, and other relevant parameters.

4. Load Testing:

a. Introduce the desired load of ice cream into the cold storage facility, ensuring it is

distributed evenly.

b. Monitor and record temperature changes within the storage facility as the cooling

system operates.

c. Measure and record the cooling capacity and power consumption while the system

maintains the desired temperature for ice cream preservation.

d. Assess the system's ability to maintain consistent temperature levels and evaluate

the impact of the load on system performance.

 22

5. Efficiency and Optimization Testing:

a. Implement optimization strategies, such as adjusting control system settings or

modifying design parameters, to enhance energy efficiency and cooling capacity.

b. Monitor and compare the performance of the optimized system with the initial

configuration, analyzing parameters such as COP and energy consumption.

c. Conduct tests under different operating conditions to evaluate the system's

adaptability and efficiency across varying loads and ambient temperatures.

6. Data Analysis and Evaluation:

a. Analyze the collected data, including temperature, pressure, and power

consumption measurements, using statistical methods and relevant software.

b. Compare the system's performance against the defined objectives and

specifications.

c. Evaluate the system's efficiency, cooling capacity, temperature control, and energy

consumption based on the testing results.

d. Interpret the findings to identify areas of improvement and provide

recommendations for enhancing the cooling system design and operation.

3.4 Evaluation Procedure

1. Performance Metrics:

a. Identify the performance metrics for evaluating the cooling system, such as cooling

capacity, energy consumption, temperature stability, and ice cream quality.

b. Define the measurement units and criteria for each performance metric.

2. Data Collection:

a. Install sensors at key locations within the cooling system and cold storage facility to

measure temperature, pressure, flow rate, and other relevant parameters.

b. Set up data acquisition systems to collect real-time data during system operation.
 23

c. Ensure proper calibration and synchronization of the sensors for accurate

measurements.

d. Collect data at regular intervals to capture a comprehensive picture of the system's

performance.

3. Data Analysis:

a. Analyze the collected data using appropriate statistical methods and data analysis

techniques.

b. Calculate performance indicators such as the coefficient of performance (COP),

energy efficiency ratio (EER), temperature differentials, and pressure drops.

c. Assess the cooling system's performance based on the defined performance

metrics.

d. Compare the experimental data with the simulation results, if applicable, to validate

the accuracy and reliability of the data.

4. Ice Cream Quality Evaluation:

a. Conduct sensory evaluations or laboratory tests to assess the quality and shelf-life

of the preserved ice cream.

b. Evaluate factors such as texture, flavor, consistency, and microbiological safety.

c. Compare the quality of the preserved ice cream using the designed cooling system

with industry standards or benchmarks.

5. Performance Evaluation:

a. Evaluate the cooling system's performance in terms of cooling capacity, energy

consumption, and temperature stability.

b. Analyze the effectiveness of the system in maintaining the desired temperature

range for ice cream preservation.

c. Assess the impact of different operating conditions, load variations, and optimization

strategies on the system's performance.

 24

d. Compare the system's performance against the defined objectives and

specifications.

6. System Efficiency and Optimization:

a. Analyze the energy efficiency and optimization potential of the cooling system.

b. Evaluate the system's COP, EER, and power consumption to assess its energy

efficiency.

c. Investigate the impact of optimization strategies on the system's performance,

energy efficiency, and cooling capacity.

d. Compare the optimized system's performance with the initial design and existing

cooling system designs.

7. Result Interpretation and Conclusion:

a. Interpret the findings from the evaluation process, considering the performance

metrics, ice cream quality, and system efficiency.

b. Draw conclusions on the overall performance of the cooling system and its suitability

for ice cream preservation.

c. Discuss the strengths and limitations of the system design, operation, and

optimization approaches.

d. Provide recommendations for further improvements, best practices, and potential

future research directions.

 25

3.5 Evaluation Criteria

1. Technical Criteria:

- Cooling Capacity: The ability of the system to remove the required amount of heat

energy from the cold storage facility to preserve 5000 liters/day of ice cream.

- Temperature Stability: The system's capability to maintain a consistent and optimal

temperature range for ice cream preservation.

- Energy Efficiency: The efficiency of the system in converting electrical energy into

cooling capacity, measured by metrics such as the coefficient of performance (COP) or

energy efficiency ratio (EER).

- Control System Performance: The accuracy and effectiveness of the control system

in regulating temperature, pressure, and other system parameters.

- Adaptability and Scalability: The system's flexibility to accommodate variations in

operating conditions, load demands, and potential future expansion.

2. Economic Criteria:

- Capital Costs: The initial investment required for the design, installation, and

commissioning of the cooling system.

- Operational Costs: The ongoing costs associated with system operation, including

energy consumption, maintenance, and servicing.

- Return on Investment (ROI): The financial benefits gained from the cooling system

over time, considering factors such as energy savings and ice cream preservation

quality.

- Life Cycle Cost Analysis: The comprehensive evaluation of costs over the system's

entire lifespan, including capital costs, operational costs, and potential replacement or

upgrade expenses.

3. Environmental Criteria:
 26

- Energy Efficiency and Greenhouse Gas Emissions: The system's energy efficiency

and its contribution to reducing greenhouse gas emissions and environmental impact.

- Refrigerant Selection: The choice of refrigerant with low global warming potential

(GWP) and ozone depletion potential (ODP), considering environmental regulations and

sustainability.

- Waste Management: The system's impact on waste generation and the

implementation of proper waste management practices, including proper disposal of

refrigerants or cooling system components.

4. Ice Cream Quality and Preservation Criteria:

- Temperature Uniformity: The ability of the cooling system to maintain a uniform

temperature distribution within the cold storage facility, ensuring consistent ice cream

quality throughout.

- Microbiological Safety: The system's effectiveness in preventing microbial growth and

maintaining the desired microbiological safety of the ice cream.

- Texture and Consistency: The preservation of ice cream texture, avoiding ice

crystallization, and maintaining the desired consistency.

- Flavor and Aroma Preservation: The system's ability to preserve the original flavor

and aroma of the ice cream, minimizing any off-flavors or odors.

5. Safety and Reliability Criteria:

- System Reliability: The reliability and robustness of the cooling system in maintaining

continuous operation without frequent breakdowns or malfunctions.

- Compliance with Safety Standards: The adherence to safety regulations and

standards for electrical systems, refrigeration, and overall system operation.

- Emergency Shutdown Procedures: The availability of proper procedures and

safeguards to handle emergency situations and ensure the safety of personnel and the

facility.
 27

- System Monitoring and Alarms: The presence of monitoring systems and alarms to

detect any abnormalities, failures, or deviations from set parameters, ensuring prompt

response and preventive measures.

3.6 Instrument and Techniques Used

1. Instruments for Data Collection:

- Temperature Sensors: Use thermocouples, resistance temperature detectors (RTDs),

or thermistors to measure the temperature at various points within the cooling system

and the cold storage facility.

- Pressure Sensors: Utilize pressure transducers or pressure gauges to measure the

pressure at critical locations, such as the condenser, evaporator, and expansion valve.

- Flow Rate Meters: Use flow meters, such as ultrasonic flow meters or

electromagnetic flow meters, to measure the flow rate of the refrigerant or coolant

circulating within the system.

- Power Meters: Employ power meters or energy meters to measure the electrical

power consumption of the cooling system components, such as the compressor and

fans.

- Data Loggers: Install data loggers to record and store the sensor measurements over

time for further analysis.

2. Computational Fluid Dynamics (CFD) Simulation:

- Use CFD software, such as ANSYS Fluent, COMSOL Multiphysics, or OpenFOAM,

to simulate the flow, heat transfer, and temperature distribution within the cooling system

and cold storage facility.

- Implement appropriate boundary conditions, define material properties, and set up

the geometry of the system for accurate simulations.

 28

- Analyze the simulation results, such as temperature profiles, velocity vectors, and

heat transfer rates, to assess the system's performance and identify areas for

optimization.

3. Experimental Setup and Testing:

- Construct a scaled-down physical model or a test rig that represents the cooling

system and the cold storage facility.

- Install the necessary sensors, such as temperature sensors and pressure

transducers, at strategic locations within the experimental setup to collect real-time data.

- Conduct performance tests under different operating conditions, load variations, or

optimization scenarios to evaluate the system's efficiency, cooling capacity, and

temperature control.

- Use data acquisition systems to record and store the experimental data for further

analysis.

4. Ice Cream Quality Evaluation:

- Sensory Evaluation: Conduct sensory tests with trained panelists to assess the

texture, flavor, consistency, and overall quality of the preserved ice cream.

- Microbiological Analysis: Perform microbiological tests to evaluate the microbial

safety and quality of the ice cream samples stored in the cold storage facility.

- Texture Analysis: Utilize texture analyzers to measure the physical properties of ice

cream, such as hardness, viscosity, and meltdown characteristics.

- Chemical Analysis: Employ chemical analysis techniques, such as gas

chromatography or spectrophotometry, to assess the composition and stability of the ice

cream samples.

5. Optimization Techniques:

- Design of Experiments (DoE): Utilize DoE to systematically vary and analyze the

design parameters of the cooling system to identify the optimal configuration.

 29

- Numerical Optimization: Implement numerical optimization algorithms, such as

genetic algorithms or particle swarm optimization, to optimize the system design by

adjusting parameters and objective functions.

- Sensitivity Analysis: Perform sensitivity analyses to identify the key design

parameters or operating conditions that significantly influence the system's performance

and efficiency.

6. Manual Calcuation and Formulas:

LIST OF FORMULAS USED

 30

Chapter 4

RESULTS AND DISCUSSION

This chapter offers a brief overview of the project's technical description,

structure and organization, as well as its limitations, capabilities, and evaluation. It

provides essential insights into the project's specifications, team dynamics, constraints,

outcomes, and performance.

4.1 Project Technical Description

1. For project purpose 7-11 (1 COLD STORAGE) was selected, situated in

Maragondon, Cavite.

a. Total Storage Size = ex: 3m x 3m x 3m

i. Volume = 27m3

2. Insulation

a. 100 mm thick PUF sandwich panels are provided for insulating the cold

room walls and ceiling. 6-inch concrete with rigid insulation is provided for

floor insulation.
 31

Table 2. Actual Cold Storage Data

Figure 2. 3D Diagram

3. Cooling unit

a. NH3 refrigerant is used for the cooling unit. Room temperature is between

02 0C to 05 0C maintained inside the chamber. Outside daytime and night-

 32

time temperatures can vary greatly, especially during the summer

months. In temperature difference calculations, it is customary to use an

average outside summer temperature for a specific geographical location.

[2] The average outside temperature is 30 0C.

4. Electrical Work

a. Electrical work shall include main power distribution switch board, feeder

switches for cooling units, capacitors, power distribution cables, electric

lighting, and earthling of equipment

5. Stand by generator

a. Provision has to be made for stand by Generator set to meet the power

requirement during load-shedding/power cuts. The generator shall have

out starting device to start it in case of failure of electric supply.

6. Method of Storage for fruits & vegetables

a. Refrigeration (cold store) – The ideal environmental condition for storage

of fresh fruits and vegetables is the lowest temperature which does not

cause chilling injury to the product. Hence, temperature control in cold

storage is very important. In mechanical refrigeration, the refrigerated

Gas (e.g. Ammonia, Freon etc.) takes out the heat from the

chamber/store as it expands. The expanded gas is then compressed and

the heat removed from the compressed gas by means of running water or

circulation air over the tubes containing the hot gas. The gas is liquefied

and the cycle is repeated. With such system accurate temperature control

is maintained.
 33

Table 2. Design Paramaeters

Table 3. Ice Cream Properties

 34

Heat Load Calculation

Refrigerated spaces are maintained belowthe temperature of their surroundings,

and thus there is always a driving force for heat flow toward the refrigerated space from

the surroundings. As a result of this heat flow, the temperature of the refrigerated space

will rise to the surrounding temperature unless the heat gained is promptly removed from

the refrigerated space. Refrigeration system should obviously be large enough to

remove the entire heat gain in order to maintain the refrigerated space at the desired low

temperature. Therefore, the size of a refrigeration system for a specified refrigerated

space is determined on the basis of the rate of heat gain of the refrigerated space the

total rate of heat gain of a refrigerated space through all mechanisms is called the

refrigeration load, and it consists of

1) Transmission load

a. COMPUTATION

2) Infiltration load

a. COMPUTATION

3) Product load

a. COMPUTATION

4) Internal load

a. COMPUTATION
 35

Total Cooling Load

This load can be applied in the CFD model and calculate a various type of

evaporator arrangement afffeted to cold chamber performance and maintain the

temperature.

4.2 Project Structure and Organization

Team structure and roles

Responsibilities and contributions of team members
Communication and collaboration methods
Project timeline and milestones
Resource allocation (e.g., budget, equipment, software)
Project management approach (e.g., agile, waterfall)
 36

4.3 Project Limitation and Capabilities

Identified limitations and constraints of the cooling system design

Challenges encountered during the project development
Potential risks and mitigation strategies
Scope limitations and delimitations
Assumptions made in the design and optimization process
 37

4.4 Project Evaluation

Methodology for project evaluation (e.g., qualitative and quantitative assessment)

Evaluation of the cooling system's technical performance
Evaluation of the cooling system's economic feasibility (e.g., cost-benefit analysis)
Evaluation of the cooling system's impact on ice cream preservation
Comparison of project results with initial objectives and specifications
 38

Chapter 5

SUMMARY OF FINDINGS, CONCLUSIONS, AND RECOMMENDATIONS

This chapter provides a comprehensive overview of the design, focusing on the

summary, conclusion, and key findings of the research. Furthermore, it encompasses

the insightful recommendations made by the researchers, drawn from their meticulous

data collection and extensive study.

5.1 Summary of Findings

Overview of the research objectives

Recap of the research methodology
Presentation of key findings and results
During the course of this study, to simplify the model, a number of assumptions were
made;
(i) There was no heat flow through the walls of the test room.
(ii) The simplification of outside room conditions had no effect.
(iii) The air-conditioning systems studied are all in good and stable operations.
(iv) The measurements and simulation are done in a completely confined room space,
with all the doors and windows closed.
(v) The anemometer used is well calibrated and in good conditions during measurement.
Analysis of cooling system performance
Evaluation of energy efficiency and cooling capacity
Assessment of ice cream preservation quality
Comparison of findings with initial hypotheses or expectations
Identification of design successes and challenges
39
 40

5.2 Conclusions

Recap of the research problem and objectives

Restatement of the research questions
Summary of the research methodology
Recapitulation of key findings and results
Interpretation and analysis of the findings
Discussion on the effectiveness of the cooling system design
Implications of the findings for the ice cream preservation industry
Addressing the research objectives and answering the research questions
Discussion on the significance and contributions of the research
Mentioning the limitations of the study
 41

5.3 Recommendations

Suggestions for further improvement of the cooling system design

Opportunities for future research and development
Potential extensions or modifications of the cooling system
Consideration of emerging technologies or innovations
Recommendations for the ice cream preservation industry
Practical applications of the research findings
Suggestions for operational best practices
Considerations for implementation in real-world scenarios
Importance of continuous monitoring and maintenance
 42

References
 43

APPENDIX
 44

Appendix 1: (Name of the Table, Figure, Document)