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Home » Zambia’s first mobile racking state-of-the-art cold store

Zambia’s first mobile racking state-of-the-art cold store

By Eamonn Ryan with technical input from Jan Eagar (JAE Cooling Solutions) and Shawn Gray (Acrow)

The Lusaka Commercial Cold Store project is a significant greenfield initiative undertaken with the goal of improving the cold chain infrastructure in Africa.

Completed facility highlighting refrigeration plantroom and ground-based pods for maintaining -25°C inside the building
Completed facility highlighting refrigeration plantroom and ground-based pods for maintaining -25°C inside the building. Supplied by JAE Cooling Solutions

Commencing in 2021 and completed in 2022, this state-of-the-art facility was designed to enhance the region’s ability to store and transport temperature-sensitive goods, such as meat products, across the continent. Located in Lusaka, Zambia, the cold storage facility spans 4 000m2 with an internal ceiling height of 12m, making it one of the largest of its kind in the area.

In terms of project specifications, the client had clear objectives for the cold storage facility. The Lusaka Commercial Cold Store (LCCS) was designed to accommodate 5 400 pallet positions in Phase One, ensuring sufficient capacity for the initial operational requirements. Based on return on investment projections, the land was acquired and the facility designed with future expansion in mind, with provisions storage operations such as this. This facility operates across a temperature range of -25°C for the deep-freeze area and for the two other cold rooms which can operate at any temperature from ambient to -25°C, as well as maintain the receiving areas at +10°C degrees utilising DX from the high-pressure liquid ammonia supply – allowing for versatile storage solutions. The use of GEA compressors and Evapco condensers, as well as coolers from HC Heating Centre in combination with a dehumidifier supplied and installed by CFW, all contribute to the effectiveness of the refrigeration plant. Acrow supplied the mobile racking systems with rails from Kredit Industrie – all of which ensures that the cold storage environment remains optimal and flexible, adapting to the various types of goods stored. Importantly to note that Completed facility highlighting refrigeration plantroom and ground-based pods for maintaining -25°C inside the building. made to add additional compressors and refrigeration units as needed without disrupting ongoing operations. This flexibility was essential for the long-term viability and scalability of the project.

Shawn Gray, senior sales executive at Acrow, says it is the first mobile racking installation in Zambia, to the best of his knowledge. The project was therefore a pioneering effort to create a modern cold storage solution from the ground up. Unlike retrofits or replacements, this greenfield development was built on a fresh plot of land specifically chosen. The LCCS project sought to address the logistical challenges faced by African countries, where efficient cold storage facilities have historically been limited. The goal was to create a facility that could support the growing demand for refrigerated storage of perishable goods, ultimately enhancing trade and food security.

Jan Eagar, owner of JAE Cooling Solutions, overviews the project: One of the key technical features of the LCCS is its refrigeration system. The facility uses an economised single-stage ammonia system with a combination of pumped and DX evaporation coils with full redundancy. This application of ammonia as refrigerant simplifies the installation, which uses one compressor to maintain various temperature regimes and is consequently highly efficient and effective for small to medium scale cold storage operations such as this. This facility operates across a temperature range of -25°C for the deep-freeze area and for the two other cold rooms which can operate at any temperature from ambient to -25°C, as well as maintain the receiving areas at +10°C degrees utilising DX from the high-pressure liquid ammonia supply – allowing for versatile storage solutions.

The use of GEA compressors and Evapco condensers, as well as coolers from HC Heating Centre in combination with a dehumidifier supplied and installed by CFW, all contribute to the effectiveness of the refrigeration plant. Acrow supplied the mobile racking systems with rails from Kredit Industrie – all of which ensures that the cold storage environment remains optimal and flexible, adapting to the various types of goods stored. Importantly to note that without a properly installed insulated box to ensure the cold stays inside the building, IDS, a Cape Town based insulated panel manufacturer and installer, was responsible to ensure vapour barriers were perfectly installed. In addition to the refrigeration equipment, the facility was equipped with reliable power generators from Namib Diesel to address any potential interruptions to the local power supply given unreliable power supply in Zambia, and ensuring the facility could continue to operate smoothly.

Gray says that the success of the project is demonstrated by the fact that the facility has experienced zero significant downtime over the past two years, a testament to the reliability and robustness of the systems installed.

Stefanutti Stocks was the overall contractor, with Cape Town-based JAE Cooling Solutions contracted for the design of refrigeration system, racking and panelling installations. GEA Africa, IDS and Acrow were contracted by Stefanutti Stocks and responsible for the installation of refrigeration, insulated panelling and the racking respectively. Eagar attributes the success of the LCCS project to the well-coordinated efforts of the professional team involved. “From the outset, the project team used a sophisticated design platform, including 3D modelling or building information modelling (BIM) tools, to pre-plan and resolve potential issues before construction began. This forward-thinking approach allowed for smoother execution during the construction phase.” Eagar attributed the success to Stefanutti Stocks’ insistence to ensure that a fully coordinated model of the building and services be in place before the commencement of construction.

“The weather conditions – especially the threat of the rainy season – were taken into account early in the planning stages, ensuring that key construction milestones were completed before adverse weather could disrupt progress. The pre-manufacturing of steel elements by a dedicated, specialist contractor, JTC, was another strategy that ensured timely delivery of materials and rapid assembly streamlining the construction process,” says Eagar. As the LCCS continues to operate efficiently, plans are already in place for an expansion in Phase Two of the project, scheduled to begin in January 2025. This phase will increase the facility’s capacity to meet the growing demand for cold storage in the region. Gray notes that logistics posed a challenge in the success of the project, with the transport of goods from South Africa to Zambia taking up to seven days, primarily due to the time spent at border crossings. However, this delay could have been much worse, explains Eagar: “This obstacle was efficiently managed, thanks to Stefanutti Stocks having a local branch and who were therefore able to expedite the movement and clearance of equipment through the borders. Their knowledge of the routes and the use of managed logistics channels allowed for timely deliveries despite the potential delays.” One unique feature of the building design was the pre-manufactured cooling units, which were produced and tested at the factory before being shipped to the site. These units were ready to be installed upon arrival, eliminating the need for additional support structures or time-consuming on-site assembly. This ‘plug-and-play’ approach helped to minimise installation time and ensure that maintenance would be streamlined, with all components accessible at ground level for service without requiring extensive structural support. The refrigeration plant was designed by JAE Cooling Solutions. Regarding the refrigeration system, the project team worked closely with reputable suppliers to ensure the highest quality equipment was used. The refrigeration system was provided by GEA Africa, a leading supplier of industrial refrigeration systems. Eagar describes the refrigeration equipment as ground-based and therefore easy to maintain with no high-level access required.

The Acrow racking at Lusaka Cold Store
The Acrow racking at Lusaka Cold Store. Supplied by Acrow

Combination of mobile and static racking

Gray explains that the LCCS utilised a combination of mobile and static racking systems to maximise storage efficiency and flexibility. The facility’s design featured 5 000 pallet positions on mobile racking in the frozen area, alongside 400 pallets of static racking in the other two cold stores. The design was for only half the area to be fitted with mobile racking initially – but with rails laid in the remaining half to later also accommodate mobile racking. The decision to use a combination of mobile and static racking was part of the initial tender process and was influenced by a variety of factors, including budget and storage needs.

Kredit, a company that Acrow has developed a strong relationship with over the past decade, supplied the rails and mobile bases needed to support the system. These components were manufactured in Europe and shipped to South Africa (Zambia being landlocked), where they were consolidated with the mobile racking manufactured in South Africa by Acrow, before being transported to Zambia. The use of mobile racking allows for more efficient use of space, as the racking can be moved to create aisles for forklifts to access products.

The main responsibility for the installation fell to Acrow’s professional installation team, which handled the detailed setup of the racking system. To involve the local community and ensure the installation process ran smoothly the project team utilised local labour to assist with unloading vehicles and handling stock.

One of the key benefits of the LCCS is the high efficiency of its refrigeration and racking systems. The system has run reliably, with no significant incidents where the refrigeration system was out of operation for more than two or three hours. “Any issues that do arise are resolved remotely, eliminating the need for engineers to travel to Zambia for repairs. The remote diagnostic system, set up via internet and modem, allows Kredit or Acrow technicians to troubleshoot and guide local staff through any issues that may arise. Typically, minor issues like dirty rails or obstructions in the racking are the only problems encountered, which are easily addressed without disrupting operations,” says Gray.

While the core principles of the system remain the same, bespoke adjustments are made depending on factors such as the height of the cold rooms, the size of the rooms themselves and the weight capacity of the pallets. The mobile racking system can be adjusted to accommodate varying pallet sizes and can be moved to optimise space and workflow within the cold storage environment.

One of the key differentiators of the system is its robust manufacturing standards. The racking and refrigeration systems are produced following strict industry guidelines to ensure the reliability and capacity of the systems. This ensures that the facility is capable of storing perishable goods such as frozen foods, including meat, without compromising on storage capacity or operational efficiency. The mobile racking system, specifically, is capable of handling a large volume of stock, and its design allows for the efficient use of space, even in high ceilinged cold rooms. With its strategic location, advanced technology and well-coordinated project management, the Lusaka Commercial Cold Store is poised to play a key role in transforming the region’s cold chain infrastructure for years to come.