Technical Proposal & Operational Manual for Frozen Durian Cold Storage
Technical Proposal & Operational Manual for Frozen Durian Cold Storage
一、 Project Background
Malaysia, a global leader in durian production, faces challenges with the fruit’s short shelf life (2-3 days at room temperature). This project utilizes -45°C ultra-fast freezing technology to minimize ice crystal formation (<50μm), preserve over 99% of flavor compounds, and extend shelf life to 18 months, enabling premium durian exports to China, the Middle East, and Europe.
二、 Technical Design
1. Refrigeration System: CO₂/NH₃ Cascade Unit
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Specifications
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Freezing Chamber: -45°C (core temperature ≤-18°C within 30 minutes)
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Storage Chamber: -25°C (±1°C fluctuation)
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Humidity Control: RH≤85% (freezing), RH 90-95% (storage)
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Innovations
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Tropical Climate Efficiency
CO₂ (high-stage) + NH₃ (low-stage) cascade system achieves COP 2.8 in humid climates, 30% more efficient than traditional HFCs. -
Frost-Free Operation
External evaporators + ducted airflow with auto-pulse defrosting eliminate frost accumulation. -
Ultra-Low Carbon Footprint
CO₂ (GWP=1) + NH₃ (GWP=0) reduce emissions by 98% vs. HFCs.
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2. Construction & Materials
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Insulation
150mm PU sandwich panels (thermal conductivity ≤0.022 W/(m·K)), compliant with ASTM C1289 for humid environments. -
Corrosion Resistance
Stainless steel 304 cladding (1.2mm) + epoxy flooring resist acidic durian pulp.
3. Smart Control System
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IoT Monitoring
Real-time monitoring with SMS/APP alerts for anomalies. -
Blockchain Traceability
Immutable records of freezing parameters and logistics for QR code verification. -
AI Energy Management
AI-driven load balancing cuts peak energy use by 15%.
三、Operational Procedures
1. Pre-Processing
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orting & Washing
Manual selection of Grade A Musang King/Golden Phoenix durians, dehusked, washed with 50°C high-pressure water. -
Pre-Cooling
Pre-cool pulp to ≤10°C in 4°C chamber to retard enzymatic activity.
2. Flash Freezing
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Freezing Process
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Single-layer pulp on trays (5cm spacing), transported by AGV robots.
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Freeze at -45°C with 8m/s airflow to reach core ≤-18°C in 30 minutes.
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Spray 1% antifreeze protein solution to prevent freeze-thaw damage.
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3. Storage & Packaging
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Storage Protocol
Store at -25°C (≤5 pallet layers) with 800ppm CO₂ for microbial control. -
Vacuum Packaging
High-barrier aluminum packaging (OTR<0.5) with nitrogen flushing (O₂<1%).
4. Logistics
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Cold Chain Integration
Pre-cooled trucks (-25°C), ≤15-minute loading, GPS + temperature tracking.
四、Key Value Propositions
1. Economic Benefits
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Export Premium
Frozen Musang King retails at 200-300 CNY/kg in China, boosting profits by 50%. -
Scalable Capacity
20-ton daily throughput, annual revenue >150 million MYR.
2. Quality Assurance
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Nutrient Retention
≥95% retention of vitamin C and thiamine, fresh-like texture.
3. Sustainability
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Renewable Energy
Solar PV integration (1,700 kWh/m²/year) for 30% energy self-sufficiency. -
Farmer Empowerment
20% higher procurement prices for 5,000+ smallholder farmers.
五、Technological Highlights
| technical dimension | traditional solution | Advantages of this plan |
|---|---|---|
| Refrigeration efficiency | Single-stage compression has low energy efficiency（COP≤1.5） | Cascade system COP 2.8, energy saving 30% |
| temperature uniformity | Temperature difference in the warehouse≥3℃ | Air duct design temperature difference ≤1℃ |
| Environmental protection | HFCs refrigerants（GWP≥1,000） | CO₂/NH₃（GWP≈1） |
| automation | Manual monitoring, high error rate | AI+blockchain full-chain traceability |
六、Scalability
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Modular design scales from 10 to 100 tons/day for farm-to-freeze models.
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Adaptable for mangosteen, rambutan, and other tropical fruits.