Thompson, Jim "Forced-air Cooler Design"

Postharvest Technology of Horticultural Crops Short Course 2015 6/11/2015

(c) Postharvest Technology Center, UC Davis

Forced Air Cooling

Forced Air Cooling

Jim Thompson P.E.
Bio. & Agricultural Engineering Dept.
UC Davis

Product Temperature during Forced Air Cooling

Forced Air Cooling
1/2 3/4 7/8 15/16 Cool
1/2 3/4 7/8 15/16 Cool
100 100

°C
90 90 Peaches at 0.5 cfm/lb.
Peaches at 0.5 cfm/lb. 30 30
Temperature (｡F)

80 80
Temperature (｡F)

Temperature (｡C)

70 20
70
20
60 60 first fruit

10 50 mass average
50 10
last fruit
40 Air 40
0 30 0
30
0.0 1.0 2.0 3.0 4.0 5.0 0.0 1.0 2.0 3.0 4.0 5.0
Hours of Cooling Hours of Cooling 4

Temperature Variation During 
Divide Airspace Between Coolers Forced Air Cooling
Uncooled centers
Large diameter ‐ melons

Airflow

Block warm air from uncooled fruit from 
affecting fruit that has begun cooling.

1
Thompson, Jim "Forced-air Cooler Design"
Postharvest Technology of Horticultural Crops Short Course 2015 6/11/2015
(c) Postharvest Technology Center, UC Davis

Temperature Variation During 
Forced Air Cooling Temperature Measurement

Airflow

Small diameter ‐ blueberries

Uncooled near air exit

Reversing Airflow Direction Vertical Cooler with Flow Reversal

open
closed closed
open

Effect of
Product 5 Pressure Drop vs. Airflow
Diameter
7/8 Cooling Time (hr)

4 10
Cantaloupe, dia.=6.0
Airflow (cfm/lb)

3 Strawberries, >10% vent
Tomato, 10% vent
1
Canatloupe, 6%
2 Pears, 5% vent
Peaches, dia.=3.25" Plums 4% vent
Pears, 2% vent
1
Cherries, dia.=1.0" 0.1
0.010 0.100 1.000 10.000
0 Pressure drop across pallet (in wc)
0 1 2 3 4
Air Flow Rate (cfm/lb or m3/s‐MT) • Vent area should be greater than 5% for airflow > 1 CFM/lb
11 (m3/s‐MT)

2
Thompson, Jim "Forced-air Cooler Design"
Postharvest Technology of Horticultural Crops Short Course 2015 6/11/2015
(c) Postharvest Technology Center, UC Davis

Pressure Drop vs. Airflow Airflow

4 100
Pressure Drop (in.)

3
Pear 75

(mm)
2 Grape 50

1 25

0 0
0 1 2 3
Air Flow (cfm/lb, m3/s‐MT)
Maximum airspeed
1500 fpm (7.5m/s)
• Interior packaging has a big effect omn pressure drop.
13 14

Refrigeration Capacity Calculations Evaporator Capacity
• Evaporator
– Capacity for product cooled by each unit Refrigeration Refrigeration capacity  Capacity 7/8ths 
capacity limit (tons/1000 lb of  (% of  cooling time 
• Compressor/condenser product (kW/MT)) maximum) (min)
– Capacity for sum of all evaporators Unlimited 2.43 (19) 100 150
Average for  1.80 (14) 74 155
first 1/2 cooling 
period
Average for 7/8  1.45 (11) 60 165
cooling

Based on cooling 24 pallets of broccoli with 32°F (0°C) air and 68°F (20°C) initial 
temperature. Refrigeration load for product only.

Energy Coefficient Forced‐Air Cooler Efficiency
Season
Energy Coefficient = Cooling Work / Electricity Use  Cooler Average EC
• Product cooled per billing period (lbs) Strawberry A 0.68 Oldest facility
• Temperature drop in cooling (°F) Strawberry E 0.40
• Electricity use (kWh) Strawberry C 0.33
Strawberry D 0.33
Strawberry B 0.23
High EC = more cooling for less electricity        Grape C 0.49
Grape B 0.49
Grape A 0.34

3
Thompson, Jim "Forced-air Cooler Design"
Postharvest Technology of Horticultural Crops Short Course 2015 6/11/2015
(c) Postharvest Technology Center, UC Davis

Electricity Use in Reduce Electricity Use in 

Forced Air Cooling Cold Storage and Forced‐Air Coolers
• Maximize use of refrigerated volume.
Electricity Use
(%)
Product 36
Fans 30
Lights 16
Walls 14
Lifts 4
19

FA coolers are inefficient at 
low product throughput rates Maximize Use of Refrigerated Volume
1.5 • Use racks or stack pallets ‐ Consolidate
• Divide storage and refrigerate only space 
Energy Coefficient

1.0 Strawberry cooler A needed ‐ Shut down

0.5

Strawberry cooler B
0.0
0 500 1000 1500 2000
Capacity (lb/month-ft2)

Reduce Electricity Use in  Lighting Options
Cold Storage and Forced‐Air Coolers
• Maximize use of refrigerated volume. HID         High  Bay Fluorescent

• Install efficient lighting.

4
Thompson, Jim "Forced-air Cooler Design"
Postharvest Technology of Horticultural Crops Short Course 2015 6/11/2015
(c) Postharvest Technology Center, UC Davis

Replace 400 W HID lamps with  Cold Storages are Hard to Light
High Bay Fluorescent
Location Unit cost Use Payback
($) (hr/da) (days)
Outside 293 6 1360

Cold Storage 293 16 280

Cold Storage w/ 373 4 210

motion sensor

Task Lighting Reduce Electricity Use in 
Cold Storage and Forced‐Air Coolers
• Maximize use of refrigerated volume.
• Install efficient lighting.
• Improve refrigeration system efficiency.

Refrigeration System Efficiency Refrigeration System Efficiency
• Increase suction pressure. 25 to 40% Reduction in electricity use
– Floating suction pressure control
• Decrease discharge pressure.
– Install more condenser capacity
• Speed control for screw compressors.
• Proper compressor sequencing.
• Optimum control of system.

5
Thompson, Jim "Forced-air Cooler Design"
Postharvest Technology of Horticultural Crops Short Course 2015 6/11/2015
(c) Postharvest Technology Center, UC Davis

Reduce Electricity Use in 
Cold Storage and Forced‐Air Coolers Minimize Heat Gain
• Maximize use of refrigerated volume.
• Install rapid acting doors.
• Install efficient lighting.
• Use high reflectivity exterior surfaces.
• Improve refrigeration system efficiency.
• Add wall or roof insulation.
• Minimize exterior heat gain.
• Insulate exterior refrigeration piping.

Reduce Electricity Use in  Fan  Electricity Use
Cold Storage and Forced‐Air Coolers
• Maximize use of refrigerated volume. • Reduce fan speed near the end of cooling?
• Install efficient lighting. • In storage, reduce airflow when evaporators 
• Improve refrigeration system efficiency. operate a partial capacity.
• Minimize exterior heat gain. – Fan cycling
– Slow motor speed.
• Minimize fan electricity use.

Forced‐Air Cooler Cost Approximate
(Tunnel cooler in an existing cold room, no high side)  Forced Air Cooler Cost (2012 data)
repair 20 –
capital New designs Standard tunnel
14% < energy use $/pallet 15 –
electricity
(10 hr/day
Vertical, double channel
22% << lower labor cost
100 day/yr)
lift truck ≥ capital cost 10 – Flow through
rental

labor 5–
61%