Historic, archived document Do not assume content reflects current scientific knowledge, policies, or practices. qt MV “APPLE PACKING and STORAGE HOUSES, U.S. depr i ASRCULTURe NATION») i 1p I IBRARy an O 1964 T SERIAL pe ne 602)/ rch Report No. 2)//: Resea g Service, ting icultural Marke a gr URE, © A OF NGS , Ur L-MEN EPART 25 2) : oo oO Divi search Facilities Re n ane rtatio i jane 2 aa SUMMARY Adoption of improved methods and equipment in apple packing and storage houses often requires that new facilities be constructed, or that old plants be remodeled. This report presents guides for the layout and design of apple packing and storage houses. These guides are developed around the use of newer and more efficient methods and equipment. The layouts provide for a direct flow of the fruit from the storage room, through packing opera- tions, and back to the storage room or to the ship- ping area, as well as optimum storage conditions. Layouts are developed for three packing rooms and three storage rooms. All are based on the use of lift trucks for handling boxes of fruit. The first packing room layout is based on a pack- ing line for exact sizing (dividing apples in 12 to 16 sizes) and packing fruit in standard wooden boxes. The second is based on a packing line for group sizing (dividing apples into 5 or 6 sizes) and packing fruit in trays in fiberboard boxes. The third pack- ing room incorporates both types of packing line. The storage-room layouts are for capacities of 25,000, 50,000, and 100,000 standard wooden boxes. Boxes of fruit are handled on 40- by 48-inch pallets in the two larger rooms, and in 36- by 40-inch unit loads, without pallets, in the smaller room. The layouts could be converted for handling and storage of apples in pallet boxes. Designs are developed for three packing and stor- age houses. The first is based on layouts of the exact sizing line and the 50,000-box storage; the second, on the group sizing line and the 100,000-box storage; and the third, on the double packing line and a layout for a 200,000-box storage. The plants are designed to minimize construction costs. Esti- mated costs are $156,000, $220,000, and $395,000 for the three plants, based on building costs for the Yakima, Wash. area. PREFACE This report applies previous research on improved methods, equipment, and facilities to apple packing and storage house layout and design. This study is part of a broad program of continuing research to in- crease the efficiency of physical handling of farm commodities during marketing, to hold down costs. The research on which this report is based was conducted by the Fruit Industries Research Foundation, Inc. (now known as Food Industries Research and Engineering), under a research contract with the United States Department of Agriculture. Frank Alberti, professional engineer, associated with The Fund Insurance Companies, Seattle, Wash., cooperated in the preparation of the section on “Modern Design, Materials, and Building Techniques Can Reduce Fire Losses.” Use of brand names in this report does not con- stitute endorsement of the product named or imply discrimination against other products. Complete plans and specifications for the designs presented in this report are available for review or purchase. Copies may be reviewed during office hours at the following locations: Transportation and Facilities Research Divi- sion Field Office Post Office Annex Building, P.O. Box 99 Wenatchee, Wash. Attn: Glenn O. Patchen, Mechanical Engineer Maine State Department of Agriculture State House Building Augusta, Maine Attn: George H. Chick, Deputy Com- missioner Appalachian Apple Service, Inc. Martinsburg, W. Va. Attn: Carroll R. Miller, Secretary-Manager Agricultural Experiment Station Michigan State University East Lansing, Mich. Attn: Dr. Arthur E. Mitchell, Professor of Horticulture Transportation and Facilities Research Division Agricultural Marketing Service U.S. Department of Agriculture Federal Center Building Hyattsville, Md. 20781 Missouri State Horticultural Society Whitten Hall, University of Missouri Columbia, Mo. Attn: Dr. W. R. Martin, Jr., Secretary ~ Sets of the plans and specifications, which include eight blueprints, may be purchased from: Cooper-Trent Blueprint and Microfilm Corpo- ration 2701 Wilson Boulevard Arlington, Va. Attn: Walter Boyden Prices, which include postage to any point in the continental United States are: 50,000-box—$4.50 per set; 100,000-box—$4.50 per set; 200,000- box — $7.00 per set. Related reports previously issued that are of general interest to the apple industry are: Cooling Apples in Pallet Boxes. U.S. Dept. Agr. Mktg. Res. Rpt. No. 532. August 1962. An Automatic Pallet-Box Filler for Apples. U.S. Dept. Agr. Mktg. Res. Rpt. No. 550. November 1962. Air Door for Cold Storage Houses. U.S. Dept. Agr. AMS-458. December 1961. Packing Apples in the Northeast. U.S. Dept. Agr. Mktg. Res. Rpt. No. 543. October 1962. Heat Leakage Through Floors, Walls, and Ceilings of Apple Storages. U.S. Dept. Agr. Mktg. Res. Rpt. No. 315. October 1959. Cooling Apples. and Pears in Storage Rooms. U.S. Dept. Agr. Mktg. Res. Rpt. No. 474. September 1961. Apple Handling and Packing in the Appa- lachian Area. U.S. Dept. Agr. Mktg. Res. Rpt. No. 476. June 1961. An Experimental Packing Line for McIntosh Apples. An Interim Report. In cooperation with N.Y. State Dept. Agr., and Markets, Divi- sion of Markets, and Maine Agr. Expt. Sta., Dept. of Agr. Econ. U.S. Dept. Agr. AMS-— 330. August 1959. The Effect of Apple Handling Methods on Stor- age Space Utilization. U.S. Dept. Agr. Mktg. Res. Rpt. No. 130. July 1956. Storage and Cooling Capacity in Apple Stor- ages in the Wenatchee-Okanogan, Washington District. U.S. Dept. Agr. AMS-196. July 1957. Controlled-Atmosphere Storage of Starking Delicious Apples in the Pacific Northwest. U.S. Dept. Agr. AMS-178. March 1957. Washington, D.C. January 1964 CONTENTS SUmimanycenene ensure. cece ecard Operation of apple packing and stor- apeshouseserncnee eterna rae Importance of proper layout and designtscccmcceee cea eee Scope and purpose of study... Factors affecting plant layout... nec aching roomilayoutS vances cineterseen i ae A packing room layout for group SIZING irs Metra sneatent ave a ee RR EE Two-line packing room layout—exact ANGUELOUpISIzingeeenee eerie neta Storage room layouts...... Storage pattern............... Aincirculationveasss Storage-room dimensions. ae Wightings recor epee tere eras Receiving and shipping areas.............. Future expansion................ A 25,000-box storage 50,000- and 100,000-box storage rooms... Packing and storage house designs............ General discussion of construction... Features of designs for three plants...... Construction cost estimates................ Modern design, materials, and building techniques can reduce fire losses............ Fire-resistant materials properly in- stalled cost NO MOre...........seseeeer sees Water requirements on site. SprinklerisystemsSwrrscssrenieuneomvcedea Lower premiums cut operating costs...... Bibliographyawaranineenenee tener hike vanmeenta IAPPENdi xc evem tec sssns ose rerun acct Palate NiTbeSH ese ee ene oar ats Srccnne tin Packing and storage house designs...... Estimated electrical load for the plants... Insulation requirements..............00000+8 Economic analyses of wall and ceiling NRK ERO) picocmusncooodudeaau cucncopecc. card Typical refrigeration load calculation... Determining performance of refrigera- tion systems when receiving Bartlett pears Heating Construction cost estimates for three packing and storage houses............ Fire insurance for apple packing and Sfordge NOUSESesnzsse.sresssrapssssnce-eaane ” Apple Packing and Storage Houses @ LAYOUT AND DESIGN ~ 20 ta fy “Re Yakima, Wash. . iy oan F./Herrick, Jr. marketing research analyst, and G. F./SAINSBURY, agricultural engineer, Transportation and Facilities earch Division, Agricultural Marketing Service, and EARL W CARLSEN and D Loyp|HunTER} Fruit Industries Research Foundation,” BACKGROUND OF STUDY Extensive research by the U.S. Department of Agriculture in the Pacific Northwest apple produc- ing areas has resulted in improved methods and equipment for handling, packing, and storing apples. These improvements reduce both labor require- ments and fruit loss from bruises, stem punctures, decay, and mechanical injuries. Although these improvements have been adopted in many apple packing and storage houses throughout the coun- try, operators of older plants find they must exten- sively remodel their plants, or build new ones, if they wish to use the new methods and equipment. In addition to plants that are built as replace- ments, construction of new apple packing and stor- age houses throughout the United States is increas- ing. Economic trends in the industry indicate that more new plants will be built in the next few years. Much of this new construction is not being de- signed for the improved equipment and methods. Because of the need for guides and standards in planning and constructing apple packing and storage houses, this report describes efficient layouts and designs that would minimize the cost of construction. Operation of Apple Packing and Storage Houses The general method of operation of apple packing and storage houses in the Pacific Northwest was used as a basis for development of the layouts and designs in this report. ‘Resigned from the Agricultural Marketing Service. 2Now known as Food Industries Research and Engineering. 688-765 O-63—2 In that area, all of the newer plants receive fruit either by forklift or clamp-lift trucks. As fruit is received from the orchard, it is most frequently moved directly into refrigerated storage rooms for cooling before it is packed. It is good practice to remove the field heat from fruit as soon as possible after it is picked, or much of its storage life may be lost. Depending on a firm’s marketing practices or pro- duction schedule, fruit may be packed and shipped as orders are received, or all the fruit may be packed at the same time and returned to storage for later shipment. Fruit that is packed for immediate ship- ment is loaded on refrigerated rail cars or highway trucks. In packing, fruit is dumped from field boxes at the head of the’ packing line, washed, sorted into grades, sized, and packed. The boxes of packed fruit are labeled and sorted by lot, grade, and size. The two or three grades depend upon the degree of coloring and the amount of bruises, stem punctures, blem- ishes, and other visible defects. Two methods are used in sizing fruit. In the first, “exact” sizing, fruit may be separated into 16 or more sizes. Exact sizes are by count of the apples required to fill the standard wooden box (12 by 20 by 11% inches); those most frequently used are: 48, 56, 64, 72, 80, 88, 100, 113, 125, 138, 150, 163, 175, 198, 216, and 232. The purpose of exact sizing is to assure uniformity in the pack and, though it is not often recognized, to avoid or mini- mize bruising. Recently, packers have used “group” sizing; in this method, the fruit is separated into 5 or 6 sizes. With the advent of consumer packaging, all of the smaller salable sizes (163 and below; also called the “5-tier”) are usually bagged as one size. A few of the smaller sizes are still packed individually, mostly for export. In group sizing, with the smaller sizes bagged, the remaining fruit is packed out as sizes 150, 125, 100, 80, and 64. Two types of sizing equipment are used; the first type sizes the fruit according to approximate weight, and the second, according to approximate dimension. The weight sizer may be used for either exact or group sizing. The newer dimension sizer, with higher capacity than the weight-type, is used for group sizing. Apples that are sized exactly usually are indi- vidually wrapped in oiled paper and packed in standard wooden boxes (standard wrap-and-pack). A firm using this method of sizing and packing generally packs all the fruit at once and returns it to storage. This type of pack holds well in storage. Apples that are group-sized are usually placed on cardboard trays in layers in fiberboard boxes; semi- automatic machines may be used to fill the trays. Apples packed this way usually are shipped as soon as they are packed. Importance of Proper Layout and Design In recent years, costly mistakes have been made in the design and construction of commercial apple packing and storage houses. For example, the storage room in one new plant was constructed with the main aisle 1 foot too narrow for forklift truck operation. Because of this mistake, space for one row of pallets was lost. In another instance, a storage room had about 10 percent less storage capacity than a room of equal size, but different dimensions. Many packing rooms lack adequate space for storing supplies near the packing line. This causes extra handling. Other common mistakes, that cost plant operators money or reduce fruit quality, are improper spacing of fruit in storage for good air circulation, and lack of an adequate air circulation pattern. An operator who plans to build or add to his pres- ent facilities often follows what has been done in the past in his area, without considering new methods of packing, handling, and construction which are more economical and efficient. In many cases, owners do not give the necessary thought to building size and height required for the methods of receiv- ing, handling, and storing to be used. It is not un- usual to find an owner wishing his building were just 2 feet longer or 1 foot higher. Careful planning of the layout and design of a plant may be the wisest investment a plant manager can make. In any event, the approach to any de- sign and layout problem should not be influenced by the exterior shell of the building. The handling methods, operating procedures, refrigeration sys- tems, and other features should be definitely de- cided upon before the completion of the plans and drawings for the building are undertaken. The equipment selected, its arrangement or layout, and the flow of work through a plant determine the rela- tive efficiency at which the plant operates. Proper layout and work flow keep the number of workers required to a minimum, make it easier to supervise the workers, and facilitate the movement of fruit into, through, and out of the packing and storage house. Layout and work flow are the two most impor- tant factors affecting design. Efficient design can reduce construction costs and eliminate the neces- sity for subsequent expensive alterations, by making provision in advance for expansion. 3 Scope and Purpose of the Study The layouts and designs presented in this report are intended to serve as guides for the planning and construction of apple packing and storage houses of various sizes throughout the country. Layouts are developed for: Three packing rooms, using different methods of sizing and packing apples, or having a different packing capacity; and three storage houses, with capacities of 25,000, 50,000, and 100,000 standard wooden boxes. The first packing room layout is for a single packing line for exact sizing, the second is for a single line for group sizing, and the third is for a double line —one for exact sizing and the other for group sizing. The equipment in each packing line was selected to pro- vide the most efficient and economical overall operation. Designs, construction details, and cost estimates are developed for three complete apple packing and storage houses. These houses are designed around the following layouts: @ The exact sizing line and the 50,000-box storage. ®@ The group sizing line and the 100,000-box storage. @ The double line and an additional layout for a 200,000-box storage. All plants are single-story buildings, designed for lift truck operations. It is assumed that the standard wooden box is used for handling and storing fruit, and that both fiberboard and standard wooden boxes are used as shipping containers. Boxes are handled on 40- by 48-inch pallets, except in the 25,000-box storage, where a 36- by 40-inch unit load without pallets is used. Complete plans and specifications for these plants are not included with this report, but are available for review or purchase, as stated in the Preface. The building codes, economic requirements, industry conditions, and wind and snow loads in the area of Yakima, Washington, were used as a basis in developing the designs. Most of the construc- tion designs can be used as basic guides in all apple-producing areas, but the data should be care- fully applied to meet local conditions. Operators considering constructing new plants, modifying or rebuilding their existing facilities, or changing their handling and packing equipment, can weigh the data in this report and select the ele- ments that apply best to their operations. New developments in apple packing and storage are taking place, and others may occur, that should be considered before remodeling or construction plans are made. Pallet boxes, for example, are being rapidly adopted for handling and storage. There is no standard pallet box in general use, however, and the standard wooden box is still used in many plants. The layouts and designs presented here may be converted to the use of pallet boxes. See the Bibliography, page 27, for reports dealing with handling and storage of apples in pallet boxes. Operators should obtain qualified engineering advice when planning remodeling or new construc- tion. Such advice may be available through State Agricultural Experiment Stations, State Depart- ments of Agriculture, or private engineering firms, that are experienced with the problems that arise in handling, storing, and packing fruit. FACTORS AFFECTING PLANT LAYOUT Marketing and storage practices have a most important influence on plant layout. If an operator decides to pack apples out as they are received from the orchard, relatively less storage space and more packing line capacity—meaning more or different types of equipment—would be needed. Or, a smaller packing line capacity and larger stor- age facilities would be required if the plant followed the policy of moving all fruit into storage for holding and later packing at a slower pace, as market re- quirements dictate. Or, again, they may prefer to pack their apples out in selected types of packs which efficiently utilize certain types of equipment. Thus, the choice of equipment and layout are often prescribed by the decisions of management about storing and packing the fruit. 4 There are dynamic changes occurring in market- ing which affect plant layout. For instance, the development of self-service merchandising has brought about a need for new types of packages that can deliver fruit with fewer bruises to the con- sumer. The tray-pack shipping container and consumer packages of many types, which fill this need, are,in increased demand. The packing room layout must be versatile, so that management can easily switch from one type of package to another. Additional area for supplies is required, space requirements for segregating may be altered, and other features of the plant layout are influenced by the newer merchandising trends. Group sizing is a relatively new development in the marketing of apples. It is preferred by super- markets or large-volume retail stores, who find it simpler to handle fewer sizes of apples. These stores report that they are better able to meet the demands of the consumer with fewer sizes. Group sizing permits use of less complicated sizing equip- ment, and makes it more practical to use return-flow belts for packing, instead of rotating tubs. In a similar way, plant layout is affected by the site on which the building is to be placed, including topography of the land and the amount of space available. The building may have to be located near rail sidings or roads that limit one or more of its dimensions. Also, even if old buildings are abandoned and new ones built, there nearly always is some equipment from the old plant that can be effectively used in the new one. All these conditions and requirements will influ- ence the plant layout. PACKING ROOM LAYOUTS Layouts are developed for three separate pack- — ing rooms. The first is for a single packing line doing exact sizing, the second is for a single line doing group sizing, and the third is for a double line, one doing exact sizing and the other, group sizing. All layouts include space for general offices, a shop, lunch and rest rooms, and storage of supplies. The equipment and method of operation of each line is selected to provide the most efficient overall operation at the lowest cost, based on the type of pack desired. All lines provide for some flexibility in the type of pack used. Basic features, principles, and assumptions are: 1. All layouts are designed for handling both loose and packed boxes of fruit by forklift trucks and pallets (fig. 1). 2. All layouts provide for possible future expan- sion of the packing line and room. 3. Most of the loose fruit is received and moved directly to refrigerated storage rooms and later to the packing line. 4. The stacking patterns, aisles, equipment, work stations, and doors are arranged to provide the most direct flow of fruit from refrigerated storage rooms through the packing room and back to storage with a minimum of out-of-line and return hauls. 5. Space is provided between work areas, where necessary, for supplies, such as at the dumping station and at the segregating area. This permits continuous work, with little influence on the rate at which different workers are able to perform their respective jobs. 6. Work areas are separated so that there is little possibility of one worker interfering with another. Workers from one area will seldom find it necessary to go through other work areas. 7. The packing lines are arranged to provide a straight-line flow, to: Facilitate production; avoid changing direction of travel of the fruit on the con- veyors: and minimize the distance fruit drops as it moves from one piece of equipment to another. BN-14773-X Ficure 1.—Placing a 48-box pallet load of loose fruit in storage. qi 8. Space for rest rooms is based on the total number of employees, to satisfy building code requirements. 9. The commonly accepted amount of office space is provided for the ofice and management person- nel, and the foreman or other supervisory personnel. A Packing Room Layout for Exact Sizing This layout is for a single packing line for exact sizing and manual packing of apples from rotating tubs (fig. 2). The layout is primarily for firms that sell hand- wrapped fruit packed in standard wooden boxes. Such firms usually pack in advance of sales and hold the packed fruit in cold storage, instead of catering to the day-to-day demands of the market. Tray packs may also be packed from the rotating tubs, however, and the layout provides for both packing methods. Consumer-size apples are ac- cumulated on a return-flow belt, and automatically filled into bags or boxes. The packing line can be used with either a large or a small storage. Average capacity of the line, operated by 39 workers, is 420 boxes of loose apples per hour. Maximum capacity is 600 boxes per hour. The line is designed for sorting apples into two grades, but it may easily be switched to three. Equipment Required The items listed are well-known in the apple industry. Certain terms, which may be unfamiliar to the general reader, are described in a following section, “Description of Operations.” The princi- pal items of equipment in the layout of the packing line to do exact sizing are: Stack-breaker with 10 feet of floor chain conveyor for moving stacks of boxes into it. An automatic drum-type dumper. A 25-foot gravity conveyor and gravity curved section, for moving empty boxes from the dumping station to the empty-box area. A 3-foot section of 48-inch-wide belt conveyor, serving as a dumping apron. A 2-foot leaf eliminator. This is a short section of roller conveyor that leaves can fall through. A 3-foot chain, or wire screen, eliminator to re- move “juicer” apples. They fall to a power belt conveyor, which extends, at a right angle, 3 feet to an automatic box-filler. A 5-foot length of gravity conveyor and an auto- matic box-filler for filling juicer apples into boxes. A washer with wash, fresh water rinse, and drying sections. A 10-foot float-roll sorting table. A 55-foot belt conveyor for moving cull fruit from the sorting table. A cull lowering device for filling cull apples into large pallet boxes or tote bins. Conveyors of various lengths above the sorting table for conveying apples to each section of the weight sizer. A 3-foot chain, or wire screen, eliminator for taking out bagging size apples of the major grade with a belt conveyor, extends 3 feet to a return- flow belt accumulating station for bagging fruit. - — WitsEe iG) OHO Ty TRY A BaGe: Sol, z PACKED BOX ACCUMULATOR EB the Ss a = 4a ts (ES IN TU ésB CHAIN SEC ir eit ie) ELIM, CHAIN LEAF ELIM, ENON NCVEN ONO OOOO OOS ANA QAI a2aAXiQiagaeay He = = ELIM. CHAIN STEP STEP OVER [ rae a ipTee PUCARENE RS oe NS — S\N NO | PAN AROUND WASHER MECHANICAL CONVEYOR NONE AE EEL at i OF. : NUDUMFER —=— = = = —— Ling] FLOAT ROLL : =e] > ———— i = ——= WA S H ER E 4 =a = ; SORTING TABLE — = - = |p) ages ea er) eS =—— ———— ———— —— ——— | DI PDF PVF PVF JVI TTT TT DIF FTV TT TT VIF IF TT TTT TDF IN = SUAT ROA = CULL BELT q step LJ 1 di. ox ROLLER CONVEYOR - ' soote FRUIT O — Beant EMPTY BOX b = ‘ —— FILLER (POWER CURVE STEP OVER —-[— {} ROLLER CONVEYOR ——~ | BE ——— ROLLER CONVEYOR <7 =| , SCALE STAMP AREA LABEL TALLY SMALL FRUIT ELIM LIDDER AREA 7 aeaeaate ss es ONAN AN ae AN ee ar CONVEYOR PACKED \{ BOX ea ity Tad Ga Ge AKC S< Pax Va ae WA a aN ve Sf NON / \ Va 4% SS . / NG \ o WY \/ ROLLER CONVEYOR BOX MAKE-UP ¢ A | Ss L E ay wy AREA ¢ a 1 SSE E 2) FA 2 & & < fe) F i © a z w tS uw g ; a uw nee —— Gy t. -W sek COMPRESSION UNIT \ 's c = ——=—— ————— ———— = = = ———- SS a IR SSS MACHINE ROOM 7 c ° L D) s T ° R A G € SCALE OF FEET a —————] ONi2i 18 I) ing line is relatively reduced; then, all of these workers might be working below capacity. Segregating is done by one worker, but it might be necessary for the segregator to work above normal effort, at times, in order to handle the full volume coming off the packing line. Under these circum- stances it would be desirable to have this worker periodically change assignments as described above. One general worker is needed to furnish supplies to the packing line, and handle other general duties. When the work is sufficiently organized, this worker then might not operate at full capacity. A Packing Room Layout for Group Sizing This layout is for group sizing and low-cost mechanical packing of apples from return-flow belt tables (fig. 8). The layout is designed primarily for operators who pack on order and move the fruit directly onto FicurE 8. — Layout of a single-line packing room for group sizing. carriers, rather than back into storage. It is as- sumed that most fruit is packed in trays in fiber- board boxes by semiautomatic packing machines. Consumer-size apples are automatically filled into bags or boxes. This line may also be used to turn out the stand- ard wrap-and-pack manually, or other types of pack- ages as the market demands. Automatic box fillers could be used to fill loose fruit into cartons or boxes for sale or return to storage. Bagging machines could also be used along the packing table. Average capacity of the line, using the semiauto- matic packing machines and a total of 27 workers, is over 420 boxes of loose fruit dumped per hour. Maximum capacity is 600 boxes per hour. This line is designed for sorting apples into two grades only, and would require additional equip- ment for packing three grades. Equipment Required In this layout the weight sizer is used for group sizing, with the units placed side by side. The dimension sizer may also be used for group sizing, but the weight sizer was selected for this layout to show how presently owned equipment can be used in a newer type of packing operation. Many opera- tors now have weight sizers. The dimension sizer is shown in the layout for the double packing line. Other principal items of equipment are the same as those in the exact sizing line as far as the elimi- nator at the end of the sorting table. There is one difference in this part of the line: Culls are con- veyed a shorter distance. From the eliminator for bagging-size apples on, the packing line differs greatly from that previously described. The items of equipment are: Stack-breaker, with a 10-foot floor-chain con- veyor for moving stacks of boxes into the stack- breaker. An automatic drum-type dumper. A 25-foot gravity conveyor and gravity curved section, for moving empty boxes from the dumping station to the empty box area. A 3-foot section of 48-inch wide belt conveyor on which dumped fruit is released; it serves as a, dumping apron. A 2-foot leaf eliminator like that in the exact sizing line. A 3-foot chain or wire-screen eliminator for elimi- nating juicer apples with a power belt conveyor extending 3 feet to an automatic box-filler. An automatic box-filler for filling juicer apples into boxes and a 5-foot gravity conveyor. A washer with wash, fresh rinse, and drying sections. A 12-foot float-roll sorting table. FIGURE 9.—Model of a packing line for group sizing. A 24-foot belt conveyor for moving cull apples from the sorting table. A cull lowering device for filling cull apples into large pallet boxes or tote bins. Narrow belt conveyors of various lengths above the sorting table and beyond the eliminator, for conveying apples to each section of the sizer. A 3-foot chain, or wire-screen, eliminator for removing bagging size apples of the major grade, and a power belt conveyor that extends 3 feet to a return-flow belt packing table. Four double-sections of weight sizers. Five 10-foot cross belts running under three double sections of sizing equipment. Two return-flow-belt packing tables, with two 20- inch wide belts. One table is 40 feet long; the other, 96 feet. Ten semiautomatic packing machines with tray racks and conveyor connections to the main packing tables. One automatic box-filler, with the necessary lengths of gravity conveyor, for holding supplies of boxes. Two bagging machines, with a 10-foot belt con- veyor for moving bagged apples from the bagging machine to the packing stand or sta- tion, and a 6-foot gravity conveyor to convey the boxes to the main conveyor. 10 A 220-foot power chain conveyor with drives, motors, and right-angle transfers for conveying packed boxes to the case sealer and the lidding areas. A 97-foot gravity roller conveyor and a 16-foot power belt conveyor for accumulating boxes before lidding. One scale for weighing boxes of fruit. One power lidder. One case sealer with a compression unit. A 200-foot overhead conveyor for conveying empty boxes to the packing stations. Two optional items of equipment might also be included. Fourteen gang adjustors for tying together the spring adjustments on_ sizing scales; all positions can be adjusted simul- taneously from one position. Two or more mechanical box transfers for lowering the packages of larger apples of the two different grades that will be packed by hand onto the main conveyor. Description of Layout The packing room layout for a group-sizing pack- ing line is shown in figure 8. This line can operate at high capacity, without workers in one area inter- fering with those in another. The layout features are essentially the same as those in the exact sizing line. The packing line proper is essentially in a straight line. BN-14802-X In the group sizing layout, the segregating area is moved to one side of the room, and an aisle for industrial lift trucks runs between the packing line and the segregating area. This makes handling supplies convenient, and minimizes the transporta- tion distance from the segregating area to the out- side door. It is desirable in a mechanical packing operation to provide space for storing fiberboard box supplies behind the workers. The layout arrange- ment provides this space. The packing line is designed for packing two grades. The major grade is packed on return-flow conveyor tables at either side of the sizing machine. About 40 feet of one of the return-flow belt conveyor tables would be used to pack the minor grade. In this packing line arrangement, as with the previous one, only a small amount of office space is needed. In fact, less office space may be required because a smaller crew is used when mechanical packing is done. Description of Operations The essential operations of this packing line may be visualized by referring to figure 9. Many opera- tions are the same as those of the exact-sizing pack- ing line: Supplying the line with loose fruit; dump- ing; empty box handling; leaf eliminating; eliminat- ing juicer apples; washing; and sorting. Operations which are not the same are discussed below. HANDLING CULL APPLES.—The method of han- dling cull apples with the group sizing line is the same as for the exact sizing line, except that culls are conveyed a shorter distance to the pallet box. The return-flow bagging table in the exact sizing line is no longer needed, and there is room for the cull bin nearer the sorting table. HANDLING BAGGING APPLES. — Bagging apples are conveyed from the eliminator at the end of the sort- ing table onto the end of the return-flow belt packing table. A box-filler, or bagging units, handles the fruit. It is similar to that described for the exact sizing line, with one variation—after the bagged apples are placed in the master container, they roll by gravity conveyor onto the main packed-box con- veyor under the sorting tables. The boxes of bagged apples move through the case sealer to the segregating area, where they can be conveniently handled with all other packed containers. Sizinc.— While sizing in this packing room lay- out is done by exact-weight machines, the sections of weight sizers are arranged side by side, and are used for group sizing (fig. 10), except for a sizer for the minor grade. Only a part of the weighing, posi- BN-14803-X Ficure 10.—Sections of weight-type sizers arranged side by side for mechanical group-size packing. tions on each section of the sizer is used. Belts, at right angles to the sizer, convey the apples of each size group to return-flow-belt packing tables on both sides of the sizer. Alternate belts move the fruit to the right and the left of the sizer. If the volume of fruit of a particular size going to one position should become too great, the amount of space devoted to that size group on the return-flow- belt packing table can be increased by changing the position of the shunt. The layout is designed so that a peak size and a nonpeak size will usually adjoin each other on the packing table. Since this research was completed, improved machinery has been developed. Converters of older facilities may need the equipment described; constructors of new plants should determine the equipment best suited to their operation. PACKING.—This operation is semiautomatic (mechanical). Figure 11 shows one packing ma- chine with a rack on either side for a supply of trays. These machines are so located that if there is a shift in the peak of size groups, an appropriate shift can be made in the machines by moving a shunt on the return-flow-belt table. In using the semiautomatic packing machine, the operator removes a fiberboard box from the over- head monorail conveyor, or, more often, makes it up from a stack of collapsed cartons behind her. She folds the carton and places it into position in the machine, puts a tray in the rack provided for it, fills the tray and straightens the fruit, then releases the tray into the box. The box contains 4 or 5 trays. She ejects the box by pressing a foot- operated pedal (fig. 12). The filled box then rolls onto the main conveyor, underneath the return- flow belt conveyor packing table, and moves on to the lidding and case sealing areas. A manual wrap-and-pack operation can be carried on at this packing table by using packing stands with the operators packing directly from the return-flow belt table (fig. 13). The boxes could be placed on the main conveyor under the return-flow belts by roller box transfer (fig. 14), which gently lowers boxes from packing-stand height to the low conveyor. BN-14804-X FicurE 11.—A semiautomatic (mechanical) tray packing station. 688-765 O-63—3 CONVEYING PACKED BoxEs.—In this layout, all packed boxes are conveyed under the return-flow belt packing tables by a chain conveyor (fig. 15), which takes the boxes or cartons directly to the lid- ding and case sealing area. STAMPING, LIDDING, AND TALLYING. — This work varies with the type of carton or container. If full telescope boxes are used, a worker folds the tops up and places them on filled boxes, ready for the case sealer. If regular slotted cartons (RSC) are used, the lidding operation is eliminated because the top is part of the filled box. If telescope fiberboard containers are used, stamping and tallying could very well be combined with lidding by prestamping stacks of tops for various sizes, then folding and placing the proper top of each container of apples. Precounting the tops would record what was packed. If packers are paid by the hour, it would not be necessary to record each packer’s work, and the rest of the task of tallying could be eliminated. Another alternative for stamping and tallying would be to place automatic stamping devices and counters on the mechanical box fillers, so that the containers would automatically be stamped and counted (fig. 16). Stamping could be combined with packing, by putting an automatic roller stamper at each packing station. Still another method of stamping, used with mechanical packing of RSC cartons, is to prestamp the stacks of flats. Tallying also could be done by one other method: Counting the number of pallet loads of each size and grade of fruit that is packed and’stacked at the segregating area during the tally period. LABELING.— When mechanical packing is done, it is the general practice to use preprinted con- tainers. The printing includes the brand name, so labeling is not necessary. SEGREGATING. — Segregating packed fruit at the group size packing line is essentially the same as at the exact size packing line except that fewer separations are needed with the smaller number of size categories. However, if both wood boxes and BN-14806-X FicurE 12.—The filled box is ejected by depressing the pedal, which permits the packed box to roll onto the conveyor. ll BN-14807-X ° Ficure 13.—Worker packing fruit in the standard box (wrap and pack) from a return-flow belt conveyor. fiberboard containers are packed at the same time, there may be a lot of necessary separations, unless the two types of containers are used for different grades. Number of Workers Required The main feature of the group sizing packing line is the use of mechanical packing equipment. This reduces the number of workers required in the plant, and simplifies some operating problems. It is estimated that 27 workers, including the super- visor, are needed in the packing room to perform packing and associated operations (table 6, appen- dix). Of these workers, only eight are packers. Even though the packing crew is small, it is able to handle fruit at a rate of more than 420 loose boxes an hour. The maximum capacity of the line is estimated to be 600 loose boxes per hour, like the exact sizing line, because both lines use the same 12 amount of sizing equipment. Fast and well trained workers using semiautomatic packing equipment have been known to pack at twice the average of 40 boxes per hour. The number of other workers in the plant is the same as for the exact sizing line. Bagging also re- quires three workers, unless the volume of bagging fruit is low enought to permit these workers to place bags in the master containers. Then, the bagging crew could be reduced by one worker. One worker is needed to stamp containers. If the fiberboard flats are prestamped, part of the time of this worker could be used to assist in other opera- tions. Fiberboard containers are closed auto- matically by a case sealer. No worker is required, other than for occasional maintenance. If full telescope boxes are used, the time of one worker will be needed to place the outer telescope lid over the box. This worker could also stamp. One worker is needed for tallying the boxes; this can be combined with other operations, by tallying boxes after they have been placed on the pallets, or by attaching counters to the mechanical packing machines. Because fiberboard containers usually are printed with the label on the ends, no labeler is required. The work of segregating and providing supplies -for the packing line is essentially the same as for the exact sizing line, and requires two workers. Two-Line Packing Room Layout — Exact and Group Sizing This layout is developed around two packing lines—one for exact sizing and manual packing, and the other for group sizing and mechanical packing. The two-line layout provides both flexibility in type of pack and packing capacity for a large volume of fruit. The layout is designed primarily for opera- tors of large plants who store loose fruit and pack out a large total volume during the marketing sea- son, and for operators of medium-size plants who do not store loose fruit, but pack as rapidly as fruit is received. The exact sizing line is specifically designed to turn out the standard wrap-and-pack, but may also be used for manual packing of tray packs. The group sizing line is specifically designed for semi- automatic packing of the tray pack, but it can readily be adapted to manual packing of the standard wrap- and-pack or other types of pack, if this is what the market demands. Both lines use bagging machines for consumer-size apples. SPECIAL BOX BN-14808-X. FicurE 14.—A roller transfer used to lower and move boxes from packing stand to conveyor under packing table. Total capacity of the lines, when the exact sizing line is turning out the standard wrap-and-pack and the group sizing line, the tray pack, is 920 boxes of loose fruit per hour. Total labor requirements for this capacity are 68 or 69 workers. Maximum capacity of the lines is 1,300 boxes per hour. The dimension sizer, which is of greater capacity than commonly used weight sizers, is used in the group sizing line in this layout for the major grade of fruit, which accounts for the increased capacity of the combined lines. Both packing lines are designed for sorting apples into two grades. The exact sizing line may easily be converted to sort three grades by installing a belt- conveyor for the third grade over the sorting table, to deliver this fruit to one or more sections of the sizer. Equipment Required The equipment used for the exact sizing line in this layout is the same as that described earlier, except that the overhead monorail conveyor is about 50 feet shorter. Its overall length is approximately 285 feet. The main difference in equipment between the group sizing line in this layout and the single line layout is in the use of the dimension sizer. The equipment up to the discharge end of the sorting table is the same. The dumper and dumper-feed chains, however, are at right angles to the packing line in this layout. The eliminator for bagging apples is not required at the end of the sorting table, because the dimen- sion sizer also serves as the eliminator. Items of equipment that are the same as for the single line layout are: Ten semiautomatic apple packing machines, with connecting conveyors and transfers; One automatic box filler for bagging size apples; Two bagging machines, with approximately 10 feet of chain and belt conveyor to carry the bagged apples to a packing stand; and One case sealer with compression unit and scale for weighing packed containers. BN-14809-X Ficure 15.—Packed cartons of apples being elevated to working level by chain conveyor from under the return-flow belt packing table. From here the cartons move to the case sealing area. Additional items of equipment are: Two return-flow-belt packing tables, consisting of two 20-inch-wide belts, one table 80 feet long and another 60 feet long. One 187-foot chain conveyor, running under- neath the return-flow-belt packing tables, and connecting with other conveyors to move fruit to the segregating area. Part of the same con- veyor system also consists of 8 feet of belt con- veyor, for raising boxes from the low conveyor to the regular conveyor level, and 60 feet of roller conveyor for accumulating apples at the segregating area. A 52-foot distributing belt, used to distribute apples from the sizer to the return-flow-belt packing table for bagging apples. One 14-foot dimension sizer, 4 feet wide, with take-away belts for five group sizes (fig. 17). One section of weight sizer for sizing the second grade of fruit, with approximately 50 feet of double-wing feed belt to convey the apples from the sorting table to the sizer. Description of Layout Figures 18 and 19 show the details of the layout. A main aisle for industrial lift trucks is between the two packing lines. This aisle serves both segregat- ing areas, to conserve space. The mechanical packing line is the shorter of the two and is arranged with the dumping area at a right angle to the pack- ing line, to shorten it further. This permits the lift trucks to have access to the ends of both lines without crossing any work areas. In this layout, the work space and the doors are so arranged that the main supply area is best located near the ends of both lines; here it does not interfere with work areas or aisles. Additional space is pro- vided around the mechanical packing line for sup- plies; this space is necessary because the fiber- board containers used with this line are rather bulky. Supplies are conveniently at hand and yet do not interfere with production. Office and rest room facilities are somewhat larger than those in the previous layouts, to accommodate a larger crew and greater volume of business. FOOT LEVER Vy AUTOMATIC STAMPER re AND COUNTER TRIPPING FOOT LEVER STAMPS, COUNTS, \ AND ALLOWS | CARTONS TO ROLL DOWN CONVEYOR. FicuRE 16.—An automatic stamper and counter used with a mechanical packing machine. Description of Operations With this two-line packing room layout, the opera- tions are identical with those for the exact sizing line and group sizing line; each of the two lines is a com- plete packing unit in itself (fig. 18). There is, how- ever, a possible variation in operations for bagging- size fruit. Perhaps the best operation would be to bag fruit from both lines at the bagging table of one line. Bagging sizes from the other line would be accumu- lated in loose boxes and transported by lift truck to this table. Combining the operations might make it possible to reduce the bagging crew by one or two workers. Whether this method is used depends on the rate with which the bagging sizes accumulate from a particular lot of apples, and whether or not the bagging sizes can be pooled into one lot. Number of Workers Required The average output of the two lines would be 920 boxes, with 420 boxes packed in the exact sizing line and 500 on the group sizine line. The maximum output would be 1,300 boxes —600 with the exact, and 700 with the group sizing line. Approximately 68 workers are required to achieve these outputs (Appendix, table 6). These workers would be assigned as follows: 37 to the exact line, 28 to the group sizing line, and 3 would divide their time be- tween the two lines. Moving pallet loads of loose fruit, culls, empty boxes, and bagged fruit would require two workers, using lift trucks. Hand-trucking stacks of boxes from the pallets to the start of the lines would require two workers. Stacking empty boxes and placing boxes on the overhead monorail conveyor would also require two workers. There is a difference in the number of sorters required, compared with the two single lines discussed previously. Each of these lines re- quired eight sorters. The group sizing line in this layout is operated with a dimension sizer which can handle a greater volume. To supply fruit for this greater volume, it is necessary to have two additional sorters, making a total of 18 sorters for the two lines. 13 BN-14810-X Ficure 17.—A high-volume 12-foot dimension sizer with 4 take-away belts. Because of the increased volume moving over the group sizing line, one additional packer is needed. This means 9 workers on mechanical packing and 18 on wrap-packing. With some methods of operation, the number of workers bagging fruit would be the same as on the two lines separately—six workers. During slow periods, the workers could place the bags directly in the master containers, rather than using an additional worker. Then four workers are needed. Accumulating the loose fruit in boxes on the one line, and bagging it on the other line can also reduce the number of bagging workers from six to four. 14 Stamping containers, lidding and closing packed containers, tallying, labeling, and segregating are the same as for the two separate lines. Eight workers are required, unless some of the variations in tallying and stamping boxes discussed under the single line for group sizing are used. Combining the two lines in one room allows one supervisor and one man supplying the packing lines to serve both lines. An additional worker is required for maintenance to relieve the super- visor of some of this work. (In the single-line layouts, the supervisor might do some mainte- nance work, and may be helped by the worker handling supplies.) BN-14811-X Ficure 18.— Model of equipment for a two-line packing room — one line for exact sizing and the other for group sizing. STORAGE ROOM LAYOUTS Layouts are developed for three cold-storage rooms of the following standard-box capacity: 25,000, 50,000, and 100,000. All storages are of one-story design to facilitate lift truck handling of fruit. The layouts are planned to provide proper air circulation for the stored fruit and to minimize space requirements and construc- tion costs. The storages are designed for completely auto- matic refrigeration systems. Outside areas for receiving and shipping fruit are paved. Parts of these areas are covered to provide both protection from the weather for handling operations and stor- age for empty boxes or other supplies. The two larger storages are designed around 48- by 40-inch pallet loads of 48 unpacked boxes of apples, and the small storage, around 36- by 40- inch loads of 36 unpacked boxes of apples without pallets. Storage Pattern In the two larger storages, pallet loads are stacked three-high; each pallet load is six boxes high. The unit loads in the smaller storage are six boxes high, and are stacked two loads high. Each storage has only one main aisle. Cross aisles take up valuable storage space and are un- necessary when lift trucks are used. The pallets or unit loads are stored in single rows, facing the center aisle, with a 6-inch space between each row. An 8-inch space is left along the side walls and a 9-inch space at the back wall. These spaces are provided to permit proper air circula- tion, facilitate handling operations, and prevent damage to the walls and insulation. Air Circulation Refrigeration units are installed over the center aisle (fig. 20). Air circulates from the center of the rooms outward to the walls, down through and be- tween the rows of fruit, and back up through the center of the room. Storage-Room Dimensions The dimensions of the rooms are designed to keep the rows of stored fruit as short as possible for con- venience of checking fruit quality and removing specified lots, and to use roof trusses of a standard length to keep costs low. Short pallet rows are PACKED BOX ACCUMULATOR CHAIN ; ae | JM. CHAI ul 1M. STEP OVER mn AN sTee gee e STACKBREAKER t WE) TSG enn 7, TeoYp PRE! SI1ZERS = 40% Eon. Tues Ss Ec TtoONS fELOOR CHAIN yicnanican CONVEYOR NY OGAVAEYOAAYAEYAEI imaaa\aaalaaalantaaaaaaaaa'a'= aaa\a\a\aaaaa\! zz) PAH AROUND MASHER — a | é j|_ FLOAT ROLL nT) Oe [ WAS HER = J oe a ING TABLE (i in SHOP = III IIIT III OI OOS WITT DI OOS WID IDI TDS Ww JIT =| = PLATFORM | L-—oVvERHEAD MONORAIL nat CULL BELT "PALLET HEIGHT” } =| ROLLER CONVEYOR- C Rox Loose FRUIT - EMPTY BOX FILLER JL iT —POWER CURVE stepover Fo “RETURN FLOW —1 Ses BELT EMPTY 80x PA T SCALE STAMP AREA Toor, LABEL TALLY PAGKNG | Basan 80x FILLER Nees Ri “AREA AREA ames) | fees Gemes| eee | Commi | Gana | Geaear | wees deme | Games| lama 0 | Tal SMALL FRUIT ELM, PACKED Box PEvAW eee le paras KED = LOUNGE fs | | a a | ee | FRUIT) U BELT CONVEYOR 4 = SWic ELEVATING BELT Na-o- a FD. WOMEN (Cx keen someees ESE.) (Siewes aan eens) alae SUPPLY 2 Q| STORAGE | (sea Fee el rc peel eed rel paella ome Sy |5 P oA kK —€ D Box P fA IL 1 ee Th as = K < RT-ANGLE ! \. AREA wee 4 Le es ee [E 4 H er AISLE SUPPLY STORAGE AREA SMALL FRUIT ELIM. Fe PACKING STAND | Puarronu FIRE LUNCH SCALE ree ELEVATING BELT, PALLET HEIGHT RAIL ROOM PACKED aur. ag FILLER CONVEY LL PACKED BOX "eULL AS At —LOosE ACCUMULATOR MECHANICAL PACKERS vai ‘leMery|! empty eox FRUIT CHAIN H CULL|| PALLETS BAGGING i Ul) om it = UNITS Prt LIODING AREA ELEVATING CULL BELT FILLER ¢| Il BEL TRANSFER COMER ES 20 NEUNUE errs = —FLOOR CHAIN CONVEYOR ROLLER CONVEYOR-EMPTY BOX ACMRELKER OFFICE PAN AROUND WASHER: m 4 SMALLEST Oro i] 2 \gre WASHER Hl + DUMP BELT y l= FI = 5 e SECOND GRADE FRUIT 2 is lo WEIGHT TYPE SIZER | -MECHANICAL OUMPER FA E 2 5 y; ua = STEP ELIM. CHAIN B by 5 2 7 LEAF ELIM~ 2 < 3. = 5 3 RT, ANGLE z sup'T. MANAGER z TRANSFER é by \ ME GW osAP A) eh APL PAc K ERS \Cpackeo Box = CHAIN CONVEYOR we J ——— MACHINE ROOM SCALE OF FEET ore § io © o vt o s T 0 “RA e Ficure 19. — Layout of a high-volume two-line packing room for exact and group sizing. 15: BN-14812-X FIGURE 20.—Refrigeration units in the truss area of the storage room. Lights mounted on the trusses down the center aisle are directed to shine parallel to the rows of pallets. preferable for storing fruit from a number of growers or for many small lots of apples of different variety and grade. In the two larger storages, the clear height under the trusses is 21 feet, to allow ample space for circu- lation and to position and remove the top load. Normally, pallets holding packed fruit will be stacked 5 boxes high, so that a clear height of 20 feet under the trusses would be adequate. These stor- ages are designed to accommodate 6-box-high pallet loads, to provide ample space during peak produc- tion years. The extra space is worth a great deal compared to the small cost of extra construction. The main aisle is a minimum of 12 feet wide. Doorways at each end of the aisle are a minimum of 8 feet wide and 10 feet high, to accommodate industrial lift trucks.$ Lighting Lighting of the storage rooms provides suffi- cient illumination for handling operations without increasing refrigeration requirements. ’Doorways of cold-storage rooms are usually equipped with batten or bumper doors, as described on page 20. Air doors, which are becoming increasingly popular, might be substituted for the batten doors. 16 The lights are installed over the center of the main aisle and are directed outward to the back walls so that they illuminate the length of the stor- age row (fig. 20). This type of installation is less expensive than placing lights all over the room. The switches are arranged so that lights need be turned on only in the section of the storage being used. Lighting is also provided for the outside receiv- ing and shipping areas. These areas may be used at night, and some lights may also be left on all night for security. Receiving and Shipping Areas Truck loading areas or aprons are of ample size, to enable several highway trucks to unload at one time, with space between them to permit forklift trucks to operate on either side. A minimum of 15 feet is allowed between trucks. Unloading areas are paved and properly sloped for adequate drainage. Paved areas should be smooth and permit fast forklift truck operation. During the winter, unpaved unloading areas would soon be a mass of mire, and interfere with unloading operations. If possible, it is recommended that the fruit unloading area be put on the east side of the build- ing, away from the prevailing wind. This will provide some shelter against strong winds. The covered areas have been designed 19 feet, 3 inches high, to permit stacking pallet loads 3 high. A minimum of posts and columns is used to allow freedom of fruit handling with a minimum of inter- ference. Another feature, common to all of these storage- room layouts, is that they are planned for quick receiving and shipping. The receiving period is usually the busiest time of the year, so the layouts are made as efficient as possible by locating the covered receiving areas near the cold-storage rooms. Future Expansion One of the more important considerations in designing a storage, and one that is frequently over- looked, is providing for future expansion. It is difficult to generalize plans for expansion because so much depends upon the proximity of roads and railroads, and topography of the particular site. In the layouts discussed here, provisions for expansion have been made on the assumption that the topog- raphy is rather uniform. The direction of expansion is determined almost entirely on the basis of the efficiency of fruit handling in relation to the location of the packing line and the rail siding. 1 | o Zi] { ! AS — Crecva_) = | = = ——— — WUD OOOO LJ] dat | +| |-to* [ ol bee" Ir | é 4 COLD STORAGE ROOM r | fa] 40"X 36" STACKS = | 36 BOXES PER STACK- | jy) I 2 STACKS HIGH F < = ay 25,920 BOXES TOTAL L w Fs Pall « 2 L_J LJ] “ = Fl eq = ] «FRUIT RECEIVING g | Jol { e Lid Le = E l i ° Fd =r n . | \e is = re = = a | Yon, Y ¥ ¥ x ; kanes AISLE SPACE -o ‘STRUCK SHIPPING TRUCK AREA x = x x x x wl! — 6'xa' REF t ‘Loop LicHts——" 6'X6' REF, © g DOOR \ DOOR z \e STEEL COLUMN Fa ir CONCRETE RECEIVING o 2) APRON s || SAME LEVEL AS STORAGE ROOM FLOOR a 5 jg FRUIT RECEIVING = & a| ° Ks a A| q 0 FLOOD LIGHTS ° a ° re FUTURE COLD STORAGE EXPANSION AREA S | iS | | fl | l = 7 — - | | _ a | I 6I'-0" iad 20'-0 4 | | SCALE OF FEET [= 85 2 a ——— 0 5 10 I 20 1 7— REFRIGERATION FINISHEO CEILING LINE | BLOWER UNITS = = = é = we AIR _FLOW a STACKED FRUIT FIN. FLOOR LINE 4-2" = of a o 3 0 ro) ! — 9i'-6" FicuRE 21.—Layout of a 25,000-box-capacity refrigerated storage room. A 25,000-Box Storage General Characteristics The cold-storage room designed for the 25,000-box plant is shown in figure 21. It actually holds 25,920 loose boxes of fruit. This type of storage is suit- able for the small ranch or farm operated by a grower with his family, and several full-time employ- ees. Extra help is hired during the packing season. Although this type of storage seldom would be expanded, provision is made in the layout for an expansion to double its capacity. The usual practice, in storages of this type in the Pacific Northwest, is that all the fruit is moved directly into storage; packing is done after the harvest season. It is assumed that all fruit is loaded onto highway trucks for shipment to market. These plants are usually not located near or on railroad sidings. Occasionally packed fruit is hauled to a railroad siding where it is loaded, but more frequently load- ing is directly onto a highway truck. All shipping is usually completed, and the storage emptied, before spring orchard activities start. A completely automatic refrigeration system is recommended. The calculated refrigeration load is 16.5 tons. This is based on a daily average fruit and outside temperature of 65° F., a roof temperature of 75° F., a daily average inside temperature of 32° F., a loading period of 12 to 13 days, and an average receiving rate of 2,000 field boxes per day. Description of Operation Handling operations of a 25,000-box storage are based on the use of a 36-box-capacity clamp truck. This is a lift truck that can be conveniently used for receiving fruit from orchard trailers. These trailers will probably be used, because the plant is located in or near the orchard. The clamp-truck operator can build unit loads, 3 boxes high—the way they are received—to 6 boxes high, for storage. Two methods of unloading and moving to storage are possible. The lift-truck operator may build the loads 6-high on the orchard trailer, lift them off the trailer and place the loads on the apron so that the trailer can return to the orchard. After the trailer has gone, the lift-truck operator moves the unit loads into storage, placing dunnage, or stabilizing strips, usually l-inch by 4-inch material, between . the unit loads to stabilize the upper load. The alternative practice is for the dift-truck opera- tor to build the unit load 6-high on the trailer, lift the yload and move it directly into cold-storage without ~ setting it down on the apron. This method requires less lift-truck operating time, but ties up the trailers a little longer. As fruit is moved into cold storage, it is placed in rows at right angles to the aisle with a space for air circulation between each row of unit loads. When fruit is removed from cold storage and taken to the packing line, the lift-truck operator transports loads of apples from the storage room. He stacks several loads in the dumping area, where packing room workers dump the fruit onto the packing line. As frequently as is necessary, the lift-truck operator picks up a unit load of packed, segregated fruit and places it in storage or takes it to the loading area. At other times, he will remove empty boxes, or boxes of culls or juicer apples. 50,000- and 100,000-Box Storage Rooms General Characteristics The important layout features of the 50,000- and 100,000-box cold-storage rooms are so similar that they are presented together. Both are designed for operation by a large grower or a central packer. When full, the 50,000-box room accommodates 51,840 unpacked boxes stacked in 48-box unit loads on pallets, 3 pallet loads to the stack. The 100,000- box room accommodates 100,800 boxes. It is assumed that both plants pack some of their fruit as it is received, but most of it is moved into cold storage for packing later. Both pack fruit late into the season. The two rooms are laid out to receive fruit at one end of the building and to load out to railroad cars at the other, reducing congestion in the handling operations. The layouts of these two storage rooms are shown in figures 22 and 23. Description of Operation During the receiving-season, most fruit that is packed is loaded out directly; only part of it goes back to cold storage. Later in the season, after the receiving period is over, the loose fruit is moved out of storage to the packing room, packed, segregated, and returned to cold storage. Only part of the pack- ing line output is loaded out directly from the pack- ing room. Most frequently, loads of packed fruit are blocked out in the storage room or in the covered area on the outside, and from there moved onto railroad cars or highway transport trucks. The pallet loads of fruit are stored in rows at right angles to the aisle. The unit loads on the aisle in each row can be marked to indicate the lot or the grower to whom the fruit belongs. Occasionally, fruit in one of the rows might be of two different lots, or belong to two different growers. This could entail extra handling of the unit loads in moving them from cold storage or getting them ready for shipment. The cost for the extra handling is quite small, however, since it requires only a small amount of time with a forklift truck. The forklift truck operations are carried on rela- tively efficiently, combining hauling of loose fruit from storage with transporting the empty boxes, culls, juicer fruit, and packed fruit out of the pack- ing room. Seldom will the forklift truck be moving about empty. PACKING AND STORAGE HOUSE DESIGNS Once an efficient layout has been developed, a building can be designed to fit the operating pattern. Using 5 of the layouts already discussed, and a lay- out developed for a 200,000-box storage, three apple packing and storage houses were designed. The first incorporates the exact sizing line and the 50,000-box storage; the second incorporates the group sizing line and the 100,000-box storage; and the third incorporates the double packing line and a 200,000-box storage. Each of the designs includes plans for future expansion of the storage. Flow dia- grams for the three plants are shown in figures 24, 25, and 26. Detailed plans and specifications were developed for each plant and supplement this section of the report. The plans and specifications are available for inspection or purchase as listed in the Preface. General Discussion of Construction There are many possible construction materials for apple packing and storage houses. Some plants are constructed completely of wood, bricks, or blocks; others have steel frames and roofs. Some plants are built of reinforced concrete. Still other plants include a combination of these types of construction. The cost of a building varies greatly, depending upon the materials selected. For example, an office in a plant could have the outside walls faced with brick and the inside walls fully plastered, or concrete block walls painted on the inside. Other examples of how building costs could vary include: The use of copper flashing and gutters instead of galvanized iron; and radiant heating installed in the floor of the packing room, instead of portable heaters. Other factors that are not directly controllable may affect costs. For instance, it may be neces- sary to use a great deal of fill on the building site; or the soil may be such that extra large footings are required. Examples such as these and others can add 20 to 50 percent to the construction cost of a packing and storage house. Generally, plant managers can obtain several cost estimates which will permit alternative choices of quality, materials, and other items included in the facility, which in turn influence costs. These choices can be made as plans progress, if an archi- tect or engineer has been selected to work with the owner in developing the plans. Another factor that should be considered is providing for future expansion. Often, because of budget limitations, only a portion of the complete unit can be built. The future building program should be planned from the beginning, to avoid unnecessary costs when additions are made. Complete and detailed plans and specifications, which are part of the contract documents, allow for competitive bidding among contractors, and pro- vide precise and concise understanding between contractor and owner. These documents give the plant manager detailed information of what he is to receive for money spent, and also show the con- tractor what is desired by the owner. Plans and specifications help hold additions and plan changes during construction to a minimum. Whenever final construction costs far exceed initial estimates, these two factors are usually the causes. For the contractor, plans showing detail and dimensions eliminate guessing, errors, and loss of time, and minimize risks, all of which must be reflected in the contractor’s bid. Local conditions also influence cost. For example, concrete blocks or gravel fill in one area may be considerably cheaper than in a neighboring community. Because gravel is generally available in the Yakima area, reinforced concrete construc- tion is desirable there. Local ordinances sometimes permit variation in the structures. For example, within city limits of Yakima, ordinances require steel columns to be encased in concrete, and all steel members in the building completely covered. The same building could be built in an outlying area, with nearly the same structural strength, but at a substantially lower cost. ily « By) lit Ei = RAIL CAR 18 SCALE OF FEET 5 10 15 PACKING ROOM A |-—— 20'-0° ———>-_—_____________— —72'-0" —— + = 33-0" —-| FUTURE DOOR lS + = = =] f m sh. fh 7 = = 7 a: i. F4 a ae oO Tf ww ELEC e. Fy a 2 i — ig] Fa Lactow 6" Seite en ey eS IB) MACH. RM. °° = SPACING ‘ ! i ||COMP. nN 2 | oy S| a 1 ©. Fa oad po DEFR. TNK. > ' C4 Pe H fi sad 3 g u \ —12'-0' g fs) col S| eee > 2 OLD STORAGE ROOM Fl CFRUIT RECEIVING © w | 40" 48" PALLETS lo} a 7 c ! fs] 48 BOXES PER PALLET Hy us ' 3 PALLETS HIGH Fd 2 51,840 BOXES TOTAL = cu) 4 | r 2 Ni z h z Fd Fa a 6 | —___ — — ee S| z ' = | a —Y i] | FLOOD LIGHTS Hl ES 8 RAIL SHIPPING © : sy 2 au 2 7 i 2? Qg , r4 sl ° a > 3 PAVED AREA a a wa ¢ a 2 2 a OG: Zs TRUCK AREA a a a . STRUCK SHIPPING > ASPHALT PAVING | t FLOOD LIGHTS a ———— ee = L FLOOD LIGHTS SAME LEVEL AS STORAGE 8'x\0' REF \ | ia "Y e'KI0" REF DOOR DOOR ' ll « ' | < Fe ' > 6 a ae ey | . | S 4 = = 20 FiGURE 22.—Layout of a 50,000-box-capacity refrigerated storage room. Features of Designs for Three Plants All three plants are on ground level and. are designed for lift truck operations. The shapes of the buildings, the materials from which they are constructed, and the other features have been decided upon after careful consideration of costs of construction, insurance, and maintenance and operating problems. SITE SELECTION.—Sites for the three packing and storage houses should be selected with the following points in mind: @ Access to a rail siding; @ Access to a highway; ®@ Availability of such utilities as electricity, fuel, telephone lines, water, and sewer; @ Adequate area to allow for parking, loading and unloading, and future expansion; and @ A site as level as possible to minimize the cost of excavations, retaining walls, and steep driveways. FouNDATION.—A_ concrete ringwall extends around the perimeter of the building; it has footing pads for concrete pilasters, which support the roof. All foundation walls and footings are reinforced with steel, to insure proper tie and bond, and to pre- vent undue shrinkage or settling. Foundation bases are a minimum of 3 feet below the finished grade around the building, to prevent heaving or settling from frost. This type of construction is rodent- and termite- proof, and is not subject to rot or to deterioration from the weather. The floor is a 5'%-inch rein- forced-concrete slab, thick enough to withstand heavy trucking and stacking loads. Under all con- crete floors, except in the covered area, a 6-inch gravel fill is provided, to prevent moisture and dampness from entering the floor slab by capillary action. The gravel also tends to distribute the loads over. small soft spots that may occur after excavation and backfilling. Wire mesh acts as reinforcing steel in all concrete floors, to prevent cracking and failure of concrete over soft spots or voids. In an attempt to save money, asphalt has been used for floors in buildings instead of concrete, but it has not proved satisfactory. Asphalt tends to compress or “run” under heavy use. The small tires on forklift trucks that continually carry heavy +Thickness determined from Portland Cement Association publication “Concrete Floors on Ground for Industrial and Other Heavy Uses.’ 6 pp., illus. 1951, > loads over the same route intensify the problem, and the result is constant maintenance. Asphalt’s rough surface is hard to clean and maintain. Wood floors have also been used, but do not with- stand the heavy traffic of forklift trucks. The cost of wood to take the same loading as on grade con- crete is unreasonably high. WALLS OF THE PLANTS ARE OF PRECAST CON- CRETE. — Mobile cranes can raise sections of walls, which are precast at the site, into position. This eliminates double-form wall construction and greatly reduces the cost of concrete walls. Wall sections are poured at ground level, where steel and concrete placement is simplified, and the slabs may be easily troweled and finished, to eliminate voids, gravel pockets, and the like, which so often occur in walls formed in place (figs. 27 and 28). The walls are essentially nonload bearing, ex- cept that they must be adequately reinforced to withstand hoisting into place and wind loads. They must also be braced in position until the permanent concrete pilasters are poured. PACKING ROOM OFFICE AREA =f. at Coon); LN a i | : | i ‘ALLOW 6" SPACING — 40"X 48" PALLETS = = = LI LI SET 9° FROM WALLS FRUIT TO PACKING LINE DEFR. TNK COLD STORAGE ROOM 43,200 BOXES COLD STORAGE ROOM = ce a jaa 1 57,600 BOXES orRuir RECEIVING | = i | —= : nae = | f—| | ALLow 2" spacinG i to. 2 2p -- -- -- - -- -- -- --- me =f Y vd U 2 AISLE > ; > a a a a a --|-- ~~ FLOOD LIGHTS a uy 3 = Fs) 5 | e Wl Ed S oe Z| Fs 3 é FLOOD LIGHTS 2 id 2 4 eta Y AISLE o ren \ S A a A A a ‘ STRUCK SHIPPING > { ~ 8'X10' REF, DOOR TRUCK AREA ; , ASPHALT PAVING SAME LEVEL AS 1 STORAGE \ RAIL SHIPPING ©“ 8'x10' REF door There are many methods of tilting or raising the wall sections. Some contractors prefer to pour an entire wall section, usually 20 by 20 feet, and raise the entire slab. Others have developed a technique LOADING ASPHALT PAVING where lighter hoisting equipment is used. In this i INSULATE CURTAIN ||: | ! > WALL | ' > method the panels are made 5 or 6 by 20 feet and reeTiMoraooue ae CoFauiT RECE WING placed one on top of the other until the desired se shen | : covertco height is reached. ; AREA PILASTERS.—The pilasters and footings are de- signed to permit future expansion and to carry the increased loads of this expansion. In addition, they are designed to carry the entire weight of the roof and snow and wind loads. Forms for making concrete pilasters are usually made of wood. Concrete is poured into them after the wall sections are set in place. These pilasters fill the voids between the wall sections and also tie them together into a solid reinforced wall. The pilasters are reinforced to tie them down to the foot- ing. This makes a strong wall, capable of with- standing high winds and mild earthquakes. Roors.—Different types of roofs are specified for the packing and storage rooms. —— FUTURE COLO STORAGE EXPANSION AREA oO -— ~33'-0 4 _— tt t = Tt 7 a: an x +—— 20-0" ——+| A -0" — REFRIGERATION BLOWER UNITS SCALE OF FEET ~ o 66610) «61520 4 STACKING PATTERN 40°X48" PALLETS 48 BOXES PER PALLET STACKED FRUIT —— » 3 PALLETS HIGH [00,800 BOXES TOTAL 4h 2 3s re 6 ey fT — t FIN. FLOOR LINE SECTION A-A The storage-room roof consists of bowstring wood trusses, wood joists, and roof decking, with adequate bracing, bridging, and blocking. The roof area is then covered with a bonded, 20-year, built-up felt Ficure 23.—Layout of a 100,000-box-capacity refrigerated storage room. paper and tar roof. Because wood is more widely available in the northwest, wood was chosen for the roof trusses instead of steel. Insurance rates for wood are con- siderably less expensive than for steel. Roof main- tenance and repair are comparable. 19 688-765 O-63—4 The space between trusses is spanned by 2- by S= 12-inch joists. The spacing of the joists is governed 4 WASHING DUMPING DE- STACKING by the span and the loading. For a total load of 4 SORTING p pee aonanso approximately 60 pounds per square foot, the joists A Ww “Ai TO" UTI L— 4 3 are spaced 12 inches on centers. The joists are WEIGHT TYPE SIZING EMPTIES . . . J t PACKING LIN i, covered with shiplap, which is laid diagonally to give ) ey: PACKED BOX ACCUMULATOR _/ CHAIN ON MRAIL. a | j (on ees = = =e 6 baat extra support and bracing. oe = 2tK6 SSS —_— Box || \ FRuT Two different systems were evaluated for span- — ATING AREA F : i i SEGREGATIN 4 ning the distance between the trusses. One system WEIGHING STAMPING LIODING LABEL TALLY WIN IE IES “~ = Le ew —_ { —- EMPTIES TO TRUCKS . ¢ . art e A a tee TO PACKING S SRS TONE ‘ BIRD MTEL CRAGE ROT ORAGEIOr was using the 2- by 12-inch joists, which was se- | LINE ON MONORAIL ereren ans TRucks lected, and the second system made use of 10- by 12- ae i inch purlins on 8-foot centers. The purlin system Seen was 15 to 20 percent more expensive, mainly be- cause of the end bays in the room; the 2- by 12-inch joists were merely ‘‘jackknifed’”’ down to the wall. | Purlins required extra furring, sheathing, and [women LUNCH OFFICE OFFICE insulation. Cold-storage and packing-room roofs are designed for a live load of 30 p.s.f. (pounds per square foot) plus 15 p.s.f. wind load, a total live load of 45 p.s.f. for the Yakima area. Live loads should be deter- mined for local conditions. Open-web steel roof joists were selected for the packing-room roof. Steel joists were selected in- stead of wood trusses, because steel lends itself to longer spans and takes less room than wood FRUIT RECEIVING . . — = trusses. In this case, for the span required, the overall height of the packing room was lowered by using steel, which still allowed the same head room inside and resulted in lower wall construction and ——— ———- PACKING LINE TO STORAGE —~« —> PACKING LINE TO TRUCKS better heating conditions. PACKING LINE TO RAIL SHIPPING = = PACKING LINE TO STORAGE LOOSE FRUIT TO PACKING LINE Another advantage to these steel joists in the LOOSE FRUIT TO STORAGE 2 . . . . packing room is the ease with which electrical con- duit and water piping may be installed. The open joists permit placing the piping laterally or longi- tudinally without cutting and patching or twisting around wood members. Costs for wood and steel were very nearly the same, but steel saved about 2 percent. The solid tongue-and-groove roof decking speci- fied not only provides a strong roof deck, but also gives a finished appearance to the ceiling inside the room. This saves the cost of plywood or other wood joist covering. The roofing specified is bonded, 20-year- guaranteed roof.® It consists of built-up layers of tar and felt paper and has an excellent service record. While it requires some maintenance, it is FUTURE DOOR tl MACHINE ROO FRUIT TO PACKING LINE COLD STORAGE ROOM AREA = STORAGE TO TRUCKS LOADING STORAGE TO RAIL SHIPPING — SPUR TRACK CAR FRUIT RECEIVING = a qt the most economical and is as widely accepted as a ea) any type of roof application. REFRIGERATION DOORS.—Insulated refrigeration Figure 24.—Fruit flow diagram for apple packing and storage house of 50,000-box capacity. doors are provided. Doors are of sufficient height 5 Determined from ‘West Coast Lumberman’s Associated Structural Data and Design Tables for Douglas Fir.” 312 pp., illus. Rev. 1961. ®Some roofing companies do not bond bowstring truss roofs. 20 to clear the mast of the forklift truck as it passes a through the opening. — “7 T Bumper doors that swing in or out (or air doors)? eo? E J voce are usually installed inside all refrigeration doors gox wake-up Fo csocoer se See a | wowen | because the large refrigeration door is left open dur- Bae 7 = WASHING DUMPING OE - STACKING | ‘ala == eal wal [ jute | EMPTY BOX SMALL = FRUIT LOOSE FRUIT ee BIN y PALLETS PALLETS 4 LUNCH TO STORAGE OR TRUCKS ing many operations. These swinging doors are PINE ON MONORAIL _/ = self-closing and can easily be opened by bumping them with the forklift truck. This permits easy access in and out of the room and also prevents undue loss of refrigeration. Several types of | | | { PACKED BOX MECHANICAL PACKING ACCUMULATOR CHAIN aan poles TO STORAGE OR Ss EMPTIES TO TRUCK SHIPPING TRUCKS OR BOX STORAGE bumper doors are available. PaRAPET WALLS.—Parapet walls stop fire from spreading from one section of the building to an- other; they separate different portions of the build- (a nea ing. In the area studied, they are required to } WEIGHING BOX LIDDING LABEL TALLY extend a minimum of 2 feet above the roof. Sepa- a ——~ rating the cold storage room from the other parts of ee — = —— LIDDING ~ = =< ~ CARTON { OFFICE | OFFICES the building (covered areas and packing room), 5 : = = = a lowers insurance rates. A discussion of insurance | | i is in the appendix. MACHINE COVERED AREAS.—Covered area roofs are con- ROOM structed with open web steel frame joists. This | provides a maximum of headroom with a minimum of depth for the span required. In this case, much lower fire insurance rates are obtained by using steel instead of wood construction. The floors of the covered areas are concrete, for lift truck operations. OFFICE AND MACHINE Rooms. —Concrete block | | PACKING LN was chosen instead of wood or tilt-up precast con- J a =F PACKING LINE TO STORAGE =< ~< ~ Fe - 7 ] LOOSE FRUIT TO PACKING LINE |= —— —»——— —> —— — > crete construction for the office and machine room LOOSE FRUIT FOLPAGKING LINE) a walls because: ee 2 = apes = STORAGE TO n nN STORAGE TO RAIL SHIPPING ————EE— 2 = = a TRUCKS —_ FRUIT TO PACKING LINE COLO STORAGE ROOM ' > FRUIT RECEIVING | <_ — —_ + a PACKING LINE TO SHIPPING PACKING LINE AREA SPUR TRACK @ The cost of concrete-block walls is about the same as for wood; —< TRUCK @ Concrete-block walls require less mainte- Ne a FRUIT RECEIVING. nance than wood; | @ The large size of the tilt-up panels and the SCALE OF FEET need for several openings for windows and ae ah doors made concrete block construction more practical; and @ Because of the small area of these rooms, and the concrete parapet wall of the packing } | room, a wooden roof on the two rooms is | allowable without insurance penalty. i _ Se SS ee ee LUNCHROOMS AND RESTROOMS.—As is general practice in fruit packinghouses, a lunchroom for FIGURE 25.—Fruit flow diagram for apple packing and storage house of 100,000-box capacity. employees is provided. Restrooms are provided for both men and women. 7 An air door recently developed is reported in U.S. Dept. Agr. AMS-458, Air Door for Cold Storage Houses, 1961. Air doors eliminate many of the hazards and drawbacks of other doors by giving the operator of the forklift truck an unobstructed view of both sides of the doorway. 21 RAILROAD SPUR | STORAGE TO STORAGE TO PACKING LINE RAIL SHIPPING RAIL SHIPPING TO SHIPPING pat | IP WEIGHING P 4 id P : : ae - z : a 4 ‘STAMPING M } f WEIGHING KG | i | : | = aH 4 ft I | Y PACKING LINE STAMPING q p PACKING LINE TO STORAGE : LIDDING qq \ ati TO STORAGE TALLY € " LABEL qy i> TALLY K+ P| | 1 dbp } GLUEING be fq i z ae z g | | = dip =} ct CTH Weed & 71 Oo gill) = e CARTON Tl & ad Ee ay LIDDING in eal 43 at 3| A) 2 i ia] 5S wd] [p 3| 3 els ere We eae Sl | Sy] fe eT}. oll} IN—gyps | + |@ 1 Fe See! et 4 ae é z= i er [ S 2 i S dibs | Zo = ora | : Do He —-<>—W ei) Hip S412 coLo STORAGE ROOM COLD STORAGE ROOM » We a8 gio el Hes: b ay aie 3 ge Srhsy |= dlip & $ tla ol lz ollie a Ean oy = es wa as kd 2 sls yg ID w g a td a7, |e z & go (= = Y #4 dy | | gC] le\2 ips Totruck [4 hj 3? 3 m= ‘SHIPPING: 1 i ; “ft ]/\BEI 4 C4] oath | 6 PRE- ) q 4 | PACKED PRE- ! A I FRUIT PACKED > | St ' z FRUIT, 1 q a i] q | ie 2} We yy =) =F | Ee {> S)Jeaccine iy | — = te ‘SORTING| | \_JB0x FILLER BAGGING EMP fr TO | SORTING CULL BIN PACK L B | -|+— —e TO STORAGE OR | TRUCK SHIPPING fe > 4 + e g | | sa Ser) | le | =f EMPTIES g WASHING Ag > TO TRUCKS| [) = | : gMPTY OR BOX ALL | 80% ou LOOSE FRUIT Loose FRUIT H pheuds storace | Raut} TO STORAGE TO STORAGE | SMALE ? + [80x {lf i TO STORAGE fFLLeR\_ z We T IR TRUCKS EMP rot a 7 , cil curl sib} || | 3 | TO STORAGE DUMPING DE-STACKING OR TRUCK ~~ cub M SHIPPING STORAGE TO LOOSE FRUIT TO STORAGE TO LOOSE FRUIT MACHINE Foe ° TRUCK SHIPPING ’ PACKING LINE TRUCK SHIPPING y TO PACKING LOOSE FRUIT 2 LINE boas LOOSE FRUIT z PALLETS b Ll : lak ‘ pall does pate : iH : . ‘§ ' cs 1 Y ~ FRUIT TO PACKING LINES | OFFICE u 1 em | BEX du SCALE OF FEET | (1 _ orFice LUNCH MEN WOMEN 2 SHOP FRUIT ———— os) FRUIT s RECEIVING t 0 5 10 15 20 { RECEIVING SIGE: ao 3 AREA 22 FIGURE 26.—Fruit flow diagram for apple packing and storage house of 200,000-box capacity. PLUMBING.—The plumbing fixtures and sewage disposal system specified are those commonly used and are to be installed in accordance with local ordinances and acceptable standards of the trade. A septic tank and sewage disposal field is provided because city or community sewage disposal was not assumed to be available at the site. City water service was assumed to be available at. the property line, so a 2-inch pipe connection is provided to service the refrigeration units and other ° equipment and fixtures. EMPLOYEE PARKING.—Off-highway parking is planned for employees. This keeps parked cars of employees away from the fruit handling operations and permits an easy flow of truck traffic to and from the storage and packinghouse. The parking area is graveled because it will not / have to bear heavy traffic loads and forklift truck . operations. Gravel parking lots have been satis- factory where used only for passenger cars. As- phalt or concrete surfaces are better; however, management generally does not feel justified in spending the extra amount for this seasonal use. ELECTRICAL EQUIPMENT.—The main control panels in the engine rooms are designed to provide for increased power requirements to take care of additional small fractional horsepower motors for the packing line equipment, and future expansion of the refrigeration system. Subservice panels are located at several points in the packing rooms for easy access to lighting and motor control. The elec- trical system complies with all local and State codes, as well as the National Electric Code. All wiring is in conduit. In the cold-storage room, lights are installed over the center aisle. In this location there is little chance for damage or breakage by being struck with the extended masts of industrial forklift trucks. Floodlights are located to illuminate certain areas of the cold storage, which permits selective lighting of the areas as needed. This saves electricity and refrigeration. The estimated electric load for the three sizes of plants is in the appendix. A sum- mary of these loads is in table 1. INTERCOMMUNICATION SYSTEM. — Where opera- tions are as diversified and scattered as in an apple packing and storage house, an intercommunication system is needed. The system specified is one which has proved successful in new plants in the Pacific northwest. Essentially, it is a system of telephones and unit broadcasters, strategically located around the packing and handling area. Calls are announced over the broadcaster; private conversations can be carried on over telephones. BN-14817-X Ficure 27.—Form for wall section in foreground, showing reinforcing steel in place. INSULATION.—Insulation for the cold-storage rooms was selected to meet minimum refrigeration requirements. Installation methods that best fit into the structural pattern of the building are speci- fied. Insulation requirements are discussed in the appendix. TABLE 1.—Estimated electrical load for three storage and packinghouses ' Storage capacity Power demand item 50,000-boxes | 100,000-boxes | 200,000-boxes ; Amperes Amperes Amperes Refrigeration... te 123 241 458 Packing operations 65 65 127 Lighting 71 79 134 Amperage to be provided at the main circuit breaker.....| ' For additional detail, see appendix. REFRIGERATION.—The refrigerating equipment for each plant was selected to handle the loads shown in table 2. A list of equipment is in the speci- fications for each plant. Load calculations for the 100,000-box storage are in the appendix. Because palletized handling is assumed for all storages, receiving should be very rapid during the peak of the harvest season. Therefore, the calcu- lations have been made for a short loading period. A general discussion of refrigeration requirements and the types of equipment selected for the plants is given here. INTERIM STORAGE FOR Pears. — Although these plants are designed primarily as apple storages, some operators may also want to use them for Bart- lett pears during the pear season. The receiving capacity of each plant, when handling Bartlett pears, was determined by a calculation similar to that made in the section, “Determining Perform- ance of Refrigeration Systems When Receiving Bart- lett Pears,” in the appendix, p. 36. Bartlett. pears are received in mid-August, during the hottest part of the season, and impose a BN-14818-X FicureE 28.—A poured wall section being troweled. TABLE 2.—Factors considered in determining refrigeration loads for 3 refrigerated storage plants Storage capacity Factor Unit 50,000 | 100,000 | 200,000 boxes boxes boxes Average of daily out- cheeteretseas 65 65 65 side temperature and initial fruit temperature. Average daily roof 75 75 75 temperature. Average daily inside eRe seaweseessees 32 32 32 temperature. Loading period........... Number of | 14-15] 14-15 14-15 days. Average daily receiy- | Field 3,500} 7,000} 14,000 ing rate of apples. boxes. Total refrigeration Tons of 27 52 101 load. refrigera- tion. heavier load on the refrigeration >quipment than apples. In all cases, it was found that the allowable pear receiving rate was about 50 percent of the apple receiving rate. This means that, in a normal 15- day receiving period, about half of the space in the storage could be filled with Bartlett pears. It is not generally advisable to fill more than half of the storage space with pears because in normal crop years, the last of the Bartletts do not move out of storage until the end of October or the first part of November. If too much storage space is occupied by pears, it may not be available for apples when needed. Unless the storage must be planned for an unusually large tonnage of pears, the arrangement presented here, primarily designed for apples, will probably be satisfactory for pear storage. AMMONIA AS A REFRIGERANT.—Ammonia was selected for these installations for several reasons. Under fluctuating loads, such as occur in apple storages, ammonia equipment presents fewer problems than other equipment in properly feeding the evaporators, maintaining proper oil levels in the various compressor crankcases is much simpler. With the large number of evaporators planned, the full-flooded feeding of the refrigerant to the evapora- tors that is customary with ammonia is much su- perior to other feeding methods. Personnel familiar with the operation, maintenance, and repair of ammonia equipment of the size involved 23 are apparently more generally available in the area. There may be circumstances where these advan- tages will be overshadowed by other considera- tions (one will be discussed under heating), but for most storages of the sizes planned here, use of ammonia equipment seems sound practice. SELECTION OF EVAPORATORS.—A number of overhead cooling, or refrigeration, units with pro- peller fans are hung in the truss spaces above the aisles. One pair of units, back to back, draws air from the aisles, blows it to the side walls, down the walls, and back to the aisles through the fruit. There is considerable aspiration of room air into the cold air stream from the units before the air starts its passage through the fruit stacks. In this way, the total quantity of air in motion is very large and the change in temperature in passing through the fruit is quite small. Resistance through the unit is low, and there is no duct resistance. It is therefore possible to economically circulate much larger quantities of air through the room than with large cooling units distributing air through ducts. The horsepower per c.f.m. (cubic feet per minute) of air circulated with this system is about one-half that needed with the large unit and duct combination. It is possible to obtain very large evaporator surfaces, because the design of these cooling units is standardized. The units are mass- produced at relatively low cost. The proposed units have from 250 to 300 square feet of fin and tube surface per T.R. (ton of re- frigeration). The quantity of air ciculated through the units is about 1,500 c.f.m. per T.R. A similar arrangement of cooling units has been installed in a number of apple storages in recent years, and has provided very satisfactory service. In the two larger storages, the cooling units are arranged in more than one zone for flexibility of control and ease of defrosting. In the smaller storage, the units are fed, controlled, and defrosted in a single zone. Each zone is provided with liquid ammonia and suction headers connected to a suit- able suction trap, so that gravity-fed full-flooded operation of all evaporating surface is assured under all the various load conditions that may be encountered. In each zone, a single float controller maintains the desired liquid level in the trap, headers, and evaporators. A proper oil‘ trap and drain connection at the bottom of the liquid drop leg of the suction trap has been specified to guard against oil clogging the evaporators. The proposed suction traps are of ample size to guard against liquid slopover after shutdown during the low-capacity season, when this problem is critical. The specification also calls for the suction piping and valves on the outlet of the trap, arranged 24 so that any liquid condensing in the suction line during the defrost period will drain back into the suction trap. This is important in these systems. Where high-speed multicylinder compressors are used, a vertical suction trap should be used in the machine room to eliminate occasional liquid slop- over from the evaporators. The trap contains a subcooling coil through which warm liquid passes in going from the receiver to the evaporators. Heat from this source is adequate to evaporate mild intermittent slopovers that may normally be en- countered with the system. SELECTION OF CONDENSERS. —Evaporative con- densers have been selected for these storages because a good reliable supply of condensing water is not available from wells without going to a depth of more than 300 feet at many places in the area studied. There are some locations where an adequate supply of water is available from com- paratively shallow wells. However, these wells often fluctuate substantially in level from one season of the year to another, and require fairly expensive deep-well pumps to cope with the change in water level. Capacity has been specified for design conditions of 65° F. wet-bulb air to the con- denser, and 90° F. condensing temperature. Because the maximum refrigeration capacity of the system is rarely used for more than 6 weeks during a season, two-speed fan motors have been specified for the evaporative condensers on the two larger storages. During periods of full capacity, fans are operated at full speed. As soon as the load drops to about 75 percent, the fans can be operated at low speed and use only about one-third of full power. Because low-speed operation is used for the greater part of the year, the power saving will be substantial. Operation of either evaporative condensers or cooling towers in the winter months requires special consideration. A warm-water defrost system per- mits a very favorable arrangement to meet cold weather conditions. The water that is sprayed over the coils of the evaporative condenser drains from the bottom of the condenser tank to the defrost tank in the machine room. When outside temperatures are near or below freezing, the con- denser fan does not operate. Because the load at this time of year is about 25 percent of full capacity, the condenser will have sufficient capacity with the water only being circulated over the coils. Ex- perience has shown that with the temperature outside below 32° F., the condensing temperatures obtained by operating only the water circulation pump without the fan are very similar to those obtained by running the fan only and leaving the coil dry. Because the pump needs less power, its use is preferred. This system can operate without danger of freezing during the off-cycle, because the piping is arranged so that all water drains back into the defrost tank in the machine room when shutdown occurs. This system allows heating of the defrost water without any water heater in the discharge line from the compressors. SELECTION OF ComprREssors.—Multiple com- pressors have been specified for all layouts. The smaller compressors in each of the smaller proposed plants has between 25 and 33 percent of the total capacity. This means that the larger machine will have about twice the capacity of the smaller machine, so the two machines will have three capacity steps between minimum and full load—a very flexible arrangement. In the largest storage, even greater flexibility is provided by using three compressors; the smallest has a capacity of about 15 percent of full load. SELECTION OF CONTROLS.—The control system includes appropriate devices to: Protect the equip- ment against certain malfunctions; maintain the room temperatures at certain preset temperatures; select the proper increments of compressor capacity as required by the load; automatically operate the evaporative condenser fans; and automatically defrost the cooling units in the various zones. The safety controls include: High- and low- pressure safety switches to protect the system against excessive pressures or against operation on a vacuum; jacket water line thermostats to assure that compressors will not operate when jacket cool- ing water is unavailable; jacket water-line magnetic valves to admit water to jackets only when com- pressor is in operation; and oil-pressure safety switches on all pressure-lubricated compressors. Recording temperature controllers are recom- mended in each room, so that the plant operator can see any deviation from normal temperature that may occur during the periods he is not actively attending to the plant. Because these are auto- matic systems, one mechanic probably will be responsible for the refrigeration plant operation and maintenance, as well as assisting in maintenance of packing line and handling equipment. During the receiving season, these duties leave little time for observing how the refrigeration system is actually operating; a recording controller aids in this task. The controller for each room opens the magnetic liquid line and magnetic suction line valves and starts the lead compressor when the temperature rises above the control point and refrigeration is required, and closes the valves and stops the lead compressor when refrigeration is no longer required. An additional switch, upon a slight rise in room temperature, starts a second compressor. As the temperature falls, this compressor stops; the lead compressor runs until the lower control point is reached. In storages having more than one room, the controllers in either room can start both the lead and second compressor as required. A manual selector switch in the compressor room allows the plant attendant to use either machine as the lead compressor. In the large storage, that has three compressors, either the largest or the smallest compressor may be used as the lead machine. When the small machine leads, only one of the two larger machines is used as a follower. When the large machine leads, the two smaller compressors follow as one machine. Relays are specified for proper isolation of circuits and to operate the various evaporative condenser fans and pumps whenever a compressor is in operation. Cooling unit fans operate con- tinuously except during the defrost periods. DEFROSTING THE EVAPORATORS. —Defrosting for each zone is controlled by a timeclock. During the early part of the season, defrosting four times a day is normal, but after the storage has been filled, defrosting once a day is sufficient. To compensate for operating time lost during defrosting the pro- posed plant capacity has been selected to handle the design load by operating 22 hours of the day. When the clock starts defrosting a particular zone, the fans stop, and the magnetic valves on both suction and liquid lines close. The defrost pump for the particular zone circulates water from the defrost tank in the compressor room to the water distributing devices in the cooling units. The warm water passes down over the cooling surface, melts the frost on the fins and tubes, and drops into the collecting pan which forms the bottom of each unit. After a 10-minute defrosting period, the clock stops the defrost pump; there is a 2-minute period for water to drip off the coil before the timing mecha- nism places the zone in operation again. All defrost water and drain lines are sloped to drain back to the defrost tank, so that there will be no water left in the lines, either in the cold-storage room or in the exposed lines outside the building. The water piping allows city water to pass through the compressor jackets to the defrost tank, and make up for losses from the evaporative condenser. This water provides a constant overflow to dilute the build-up of salts in the water caused by evap- oration. Four defrosting zones in the large storage mini- mize the problem of distributing the defrost water among the several units, and also allow for the possibility that some storages might have four rooms, rather than two. In this case, partitions between the two zones in each room, a temperature controller for each zone, and modifications to the control wiring would be needed. All defrost and ammonia piping is above the aisles in the cold-storage room; lateral pipes are on the outside of the building, to avoid interference with stacking in the storage rooms. PIPE COVERING.—Low-pressure ammonia _pip- ing and suction traps inside the cold-storage rooms are covered with light-duty pipe covering to protect them from frosting during the operating period, and dripping water on the floor during the defrost period. Ammonia suction lines outside the storage room are to be covered with standard pipe covering to minimize heat pickup from unre- frigerated spaces, and also to cut down on the super- heat in the suction gas coming to the compressors. The defrost water and drain lines are not insul- ated. Investigation shows that the amount of heat required to warm the pipe to the defrost-water temperature at each defrost cycle is greater than the heat loss to the surrounding atmosphere during each cycle. Insulation would not minimize the heat required to warm the pipe to the defrost water temperature, but would probably increase the heat requirement by increasing the mass of cold material. This is the greatest source of heat loss in cold weather. ESTIMATED REFRIGERATION Costs. —Refrig- eration installation costs were estimated from typical bid prices of newly installed systems in the area, and their capacity, and determining the cost per ton of refrigeration. This factor was then applied to tonnages specified for these storages to determine their cost. Costs vary as size of the plant varies: refrigeration for the largest plants would cost approximately $600/T.R., and for the smaller plants, $700/T.R. The estimated installed cost of refrigerating machinery, controls, piping, and de- frost system for the various plants is shown in table 3. TABLE 3.—Estimated installed cost of refrigerating machinery, controls, piping, and defrost systems for three refrigerated storage plants for apples and pears Storage capacity Ttem 50,000 100,000 200,000 boxes boxes boxes Dollars Dollars Dollars Cost) I: Retrsaccer aceon tsrscse 667 633 600 Cost of equipment installed...] | 18,000} 33,000 60, 600 Heating Suitable heating must be provided for the office, lunchroom, restrooms, shop, and packing room. With the increased trend toward packing to order, it is normal for packing operations to continue through the coldest winter weather. Typical load calculations for the heating of the packing room during outside temperatures of —5° F. are given in the appendix. Although there are three ventilating fans in the packing room, only one 5,000-c.f.m. fan will be operated during the cold weather, to carry away fumes of the fungicide used in the apple washer. The heat-load calculations are based on heating the packing room to 60° F., because most of the occupants are performing physi- cal labor. Some additional heat will be needed in the sorting area, because sorting does not demand as much physical exertion. In the section, “Economic Analyses of Wall and Ceiling Insulation’ (appendix), an estimate is made of the total operating time for the packing room, and the estimated normal number of degree- days for the packing room heating derived from that estimate. These same figures will be used in con- sidering some of the economic aspects involved in selecting heating equipment. Typical calculations for the office heating load are in the appendix, in “Heating, Load Calcula- tions, Office.” The heating for this space is the normal 70° F. inside temperature. Table 4 gives heating loads for packing room and office for each of the three plants. TABLE 4.—Assumed winter heating loads for pack- ing rooms and offices of three plants Storage capacity Ttem 50,000 100,000 200,000 boxes boxes boxes B.t.u.Jhr. B.t.u.fhr. B.t.u./hr. 690,400 | 675, 600 990, 400 1 42,000 47, 180 65, 090 Packing room.. Office Motalitencersnssieserieacercit ys 690, 400 | 722, 780 | 1,055, 490 ' Office heating load occurs only when packing room is un- heated, so these loads are not cumulative. SELECTION OF A FUEL.—Natural gas is avail- able in the area. The average cost to a packing- house or similar consumer is $0.10 per 100,000 B.t.u. input. With 80 percent as a normal efh- ciency for gas heating equipment, the cost of heat delivered is $0.125 per 100,000 B.t.u. Average oil cost in the area is $0.165 per gallon. Witha fuel value of 140,000 B.t.u./gal. and 70-percent effi- ciency for the heating equipment, the average cost per 100,000 B.t.u. delivered is $0.168. Thus, the cost of gas is about 75 percent of the cost of oil. The first cost of the gas-fired apparatus also is less, so natural gas is cheaper. For areas not serviced by natural gas, there is a possibility of using LPG (liquified petroleum gas). The fuel cost is higher with this fuel than with oil, but the heating equip- ment is cheaper. Also, LPG is used in many plants as fuel for lift trucks, so storage facilities are then needed for the gas at the plant. Before a choice of fuel can be made, a detailed study must be made of heating equipment costs; some appor- tionment of cost of fuel-storage facilities must be charged off against handling. SELECTION OF HEATING UNITS.—To heat the packing room, multiple, overhead, propeller-fan convection heating units were selected. They are dispersed in a manner to supply heat to the points where greatest need exists and to create satisfactory circulation in the area. The largest available sizes of this unit were selected, to minimize piping and vent connections. Each self-contained unit has its own controls, burner, and air circulation. No ducts are needed with this system. To heat offices, restrooms, and shops, gas-fired wall heaters were chosen. They are reasonably priced, compared to other types of heaters, occupy a minimum of space, allow individual control of tem- peratures to suit the occupants, and require no ducts. The vents are standard shop-built com- ponents, making these items also quite economical. An analysis of the use of rejected heat from the refrigeration system for heating the office and pack- ing room is in the appendix. Construction Cost Estimates Estimates of the cost of constructing three packing and storage houses of 50,000-, 100,000-, and 200,000-box capacity are summarized’ in table 5. Details are given in the appendix, table 13. The estimates are based upon the actual construction costs, indexes of materials, and labor costs in the Yakima area as of January 1, 1961. These costs are estimates and are not guaranteed to be actual construction costs. Prices of materials, labor, and the availability of the contractor vary widely over short periods of time. The location of the building site, the nearness of labor sources, and choice of materials will also influence costs. Equivalent construction costs of the plants vary from $1.96 to $3.01 per box from the largest to the smallest plant. In-the small plant, the packing room and office construction costs are relatively the most expensive part of the plant. In the larger plants, the construction costs of the refrigerated storage rooms comprise the largest item of expense. TABLE 5.—Estimated construction costs of three packing and storage houses a aie = IT 50,000-box house | 100,000-box house 200,000-box house lem = ; 5] i Total cost! Cost per Total cost ! Cost per Total cost! Cost per loose box? loose box? loose box ¢ Dollars Dollars Dollars Dollars Dollars Dollars Cold-storage room 46, 720 0.90 78, 230 0. 78 14, 070 0.71 Machine room and refrigeration. 22, 470 . 43 39, 720 Bey!) 2s 920 . 36 Packing room and office............. 56, 030 1.08 58, 930 . 58 105, 720 702 Heating, plumbing, and electrical equipment 16, 270 wa 21,620 ae, 27, 140 14 Goverédareasiiy.sscs sccecerseves Se tiscyseeess ss 9, 360 .18 14, 200 .14 27, 850 14 5, 550 antl 7, 000 .07 | 17, 500 .09 Motalerrersats terre tenet esss cere teeta oer a eee ae 156, 400 3.01 219, 700 2.18 395, 200 1.96 1 Based on index of construction costs in the Yakima, Wash. ?51,840-loose-box capacity. 3 100,800-loose-box capacity. 4201,600-loose-box capacity. , area, Jan. 1, 1961. 25 MODERN DESIGN, MATERIALS, AND BUILDING TECHNIQUES CAN REDUCE FIRE LOSSES In one recent year, in the State of Washington alone, 11 apple warehouses burned; this estimated property loss was over $3 million. Unfortunately, little can be done to hundreds of older warehouses that are counterparts of the buildings destroyed or damaged. Even with added fire-protection de- vices, careful operation, and a realization that plant watchmen are as necessary as cashiers in a supermarket, old and obsolete warehouses remain an industry problem. Old mistakes in construction should not be re- peated; a fresh look should be taken at the new con- struction techniques. The designs in this report can incorporate the safety equipment discussed below (appendix table 15). The way a plant is designed determines not only its efficiency, but also its fire insurance rate, its resistance to a fire, and even its probability of having a fire. The plant layout that requires storage of empty boxes next to the building, or that has open wooden platforms makes it easy to start a fire with a careless match. Such plants have proven easy marks for arsonists. Almost all plants require some shop welding work. The lack of a proper area for such work, with in- combustible floors and walls, invites a fire started by a welding torch. Insurance companies know that more obsolete plants burn down than do modern plants. It is only a matter of time before the high fire losses of apple warehouses will be paid for solely by owners of obsolete plants. Regardless of how high the total fire insurance bill is, the apportionment of premiums is based on the location and operational, structural, and fire-protective features of the in- dividual warehouse. The operator who plans construction with safety features pays only a frac- tion of the average premium. Fire-Resistant Materials Properly Installed Cost No More Regardless of the premium rates, the plant de- sign should be as fireproof as possible, within reasonable cost. Normally, it costs little more, if any, to build with Underwriters’ Laboratories (UL) approved materials. These materials have known resistance to fire, and usually provide a large bonus in reduced insurance premiums. 26 Some examples are: UL-approved masonry blocks for exterior walls and partitions are no more expensive than frame construction, and they pro- vide 4-hour fire resistance. Furthermore, the pumice block, readily available in the Pacific Northwest, has unusually good insulation qualities that are desirable in cold-storage construction. Incombustible insulation can usually be obtained as reasonably as the combustible type. Natural flues in walls and ceilings can be eliminated by attaching the insulation directly to the roof deck and walls. Such construction eliminates combus- tible studs and often eliminates combustible interior finish. Proper location and design of heaters and chimneys, machinery and boiler rooms, adequate electrical circuits, and incombustible storage facili- ties for supplies all aid in fire prevention and the cost is only foresight in planning construction. FIRE-RESISTANT Woop.—The wood roof deck and supporting trusses, normally vulnerable to fire, can be impregnated with a tested and ap- proved fire retardant that renders them incombus- tible. The treatment was only recently made available in the Washington State area. When the treated wood meets the specified UL require- ments, it has an insurance rate equal to unprotected steel. The process, at some Pacific coast plants, costs approximately $90 per 1,000 board feet. It will reduce annual insurance premiums when used in the 100,000-box apple warehouse design located in Class 9 (unprotected) areas,’ by $2,000 and for the same warehouse in a Class 3 town, such as Yakima, by approximately $300. It is important that the processed wood have a UL label, showing that the treatment is by impregnation, and that it has endured a 30-minute test with a flame-spread rating not over the equivalent of 25, and that there has been no evidence’ of significant progressive com- bustion. INCOMBUSTIBLE INSULATION.—Premium _ sav- ings are possible when incombustible insulation (see appendix) is used throughout, and is attached directly to the roof deck and walls. UL-approved insulation properly applied, results in a $300 annual saving for the basic 100,000-box warehouse in unpro- tected areas, and a saving of approximately $50 per year in a Class 3 town. “Classification is based on availability of adequate fire protection. Water Requirements on Site The major factor in selecting the plant site, from a fire-prevention standpoint, is proximity to adequate water supplies. For economies in insurance rates and water supplies, it is desirable to locate the warehouse near a good fire department. Adequate water supplies also facilitate the installation of fire hydrants and_ sprinkler systems, which are important factors in insurance rates. A secondary consideration is the nearness of other plants and operations; clear spaces should be maintained be- tween buildings. The clear-space requirements will vary with the size and height of the buildings and the type of occupancy. Sprinkler Systems The most efficient single mechanical device for industrial fire extinguishing is the automatic sprinkler system, yet it is seldom found in apple warehouses. This often reflects lack of foresight; the owner discovers, after the building is con- structed, that the installation of a sprinkler system would then be relatively expensive. Two major considerations in the design stage are that there must be an adequate water supply and adequate overhead space. Sprinkler systems can generally be installed at current costs for less than 35¢e per square foot of the building area. In the basic 100,000-box capacity apple storage and _packing- house for example, the actual cost estimate for a sprinkler system is approximately $12,000, or about 12c cost per loose box of warehouse storage capacity. Sprinkler installation companies usually arrange terms under which the actual rate savings will pay for the sprinkler system in a few years. The economic importance of sprinklers is shown by a premium saving of almost $5,000 a year for Class 9 unprotected locations, when sprinklers are included in the apple warehouse design. This assumes an adequate water supply for the sprinkling system of 1,100 gallons per minute at a pressure of 70 to 100 p-s.i. (pounds per square inch) and 3,000 g.p.m. (gallons per minute) at 60 p.s.i. for the hydrant system. For Class 3 protected locations the actual dollar savings are less but the premium is reduced some 50 to 70 percent. Other fire-protection devices are hand fire extinguishers (one is needed for each 2,500 square feet) and watch-clock stations that require the watchman to follow a predetermined path through the plant. Lower Premiums Cut Operating Costs Research was conducted on fire-insurance rates for various locations and construction alternatives for the 100,000-box plant, based on rates estimated by the Washington Surveying and Rating Bureau (see appendix, p. 42) which serves all fire-insurance companies in the State of Washington. The results indicate several direct ways to save on premiums. Aside from lower premiums and their effect on profits, the major benefit is that the business is much less likely to be permanently interrupted or lives lost because of a disastrous fire. By choosing a site for the basic 100,000-box warehouse (see appendix, p. 42) in an area with ample water source, clear surrounding spaces, and an efficient fire department such as a Class 3 city, versus a site in an unprotected Class 9 area, a premium savings of $3,800 per year, or 4c per box of apples, can be realized. WALL CONSTRUCTION.—By using reinforced concrete walls or UL-approved masonry block walls, instead of wooden wall construction, an owner of a basic 100,000-box warehouse almost anywhere in Washington State would save $2,000 a year on insurance premiums. MISCELLANEOUS Factrors.—Other factors affect rate and premium in a substantial manner. For example, the elimination of ammonium nitrate fertilizer storage in the apple storage or packing rooms eould eliminate a penalty of $1,500 per year. HAVE PLANS REVIEWED. —In summation, several premium-saving features have been presented. However, every prospective owner should have his specific plans reviewed by a fire-protection engineer who knows the insurance rating rules of his State. The items discussed above are only a guide, even for the State of Washington. Engineering service of the required type is often available through architects’ and engineers’ offices, insurance agents’ and brokers’ offices, and fire-insurance companies. BIBLIOGRAPHY (1) THE AMERICAN Society oF- HEATING AND VENTILATING ENGINEERS. 1960. HEATING, VENTILATING, AND AIR CONDITIONING GUIDE. Ed. 38, 1,264 pp., illus. New York. (2) THE AMERICAN SOCIETY OF REFRIGERATING ENGINEERS. 1957. ASRE DATA BOOK (DESIGN). Ed 10, 1,009 pp., illus. New York. (3) CARLSEN, EARL W., DuERDEN, RAOUL S., Hunter, D Loyp, and Herrick, JOSEPH Fe JR. 1955. INNOVATIONS IN APPLE HANDLING METHODS AND — EQUIPMENT. U.S. Dept. Agr. Mktg. Res. Rpt. No. 68, 89 pp., illus. (4) ———, DuERDEN, RAouL S., HunTER, D Loyp, and HERRICK, JOSEPH F., Jr. 1953. APPLE HANDLING METHODS AND EQUIPMENT IN PACIFIC NORTH- WEST PACKING AND STORAGE HOUSES. U.S. Dept. Agr. Mktg. Res. Rpt. No. 49, 302 pp., illus. (5) ———, DuERDEN, Raout S., Hunter, D Loyp, and SainsBury, G. F. 1954. METHODS AND COSTS OF LOADING APPLES IN THE ORCHARD IN THE PACIFIC NORTHWEST. U.S. Dept. Agr. Mktg. Res. Rpt. No. 55, 22 pp., illus. (7) Herrick, JOSEPH F., Jr. 1955. FLOAT ROLL SORTING TABLE. U.S. Dept. Agr. Mktg. Activities: 18(5): 6-8, illus. (8) ——, McBirney, STANLEY W., and CarL- SEN, EARL W. 1958. HANDLING AND STORAGE OF APPLES IN PALLET BOXES. U.S. Dept. Agr. AMS-236, 41 pp., illus. (9) Hunter, D Loyp and Herrick, JOSEPH F., Jr. 1955. CUTTING COSTS IN APPLE PACKING. U.S. Dept. Agr. Mktg. Activities 18(3): 3-6, illus. (10) MEYER, CHARLEs H. 1958. APPLE SORTING METHODS AND EQUIPMENT. U.S. Dept. Agr. Mktg. Res. Rpt. No. 230, 24 pp., illus. (1)) > 1958. COMPARATIVE COSTS OF HANDLING APPLES AT PACKING AND STORAGE PLANTS. U.S. Dept. Agr. Mktg. Res. Rpt. No. 215, 75 pp., illus. (12) SarnsBuRy, G. F. 1959. HEAT LEAKAGE THROUGH FLOORS, WALLS, AND CEILINGS OF APPLE STORAGES. U.S. Dept. Agr. Mktg. Res. Rpt. No. 315, 65 pp., illus. (6) ———,, and HERRICK, JosEPH F., Jr. (13): 1955. AUTOMATIC BOX FILLER. U.S. 1953. ROOF INSULATING METHODS. Refrig. Dept. Agr. Mktg. Activities Engin. 61(3): 286-290, 330. 18(6): 3-6, illus. APPENDIX Workers Required to Operate Packing Lines A time study analysis was made on the number of workers needed to operate the packing lines in the 50,000-, 100,000-, and 200,000-box-capacity apple packing and storage houses. The results of the analysis are in table 6. The figures are given by worker assignment. Packing and Storage House Designs Figure 29 is the site plan for the 50,000-box packing and storage house. It shows the location of the important features of the layout of cold storage and the packing room. Elevations are shown in figure 30 for this same plant. A scale model was constructed of this plant and figure 31 gives two views of this model. The site plan for the 100,000-box capacity packing and storage houses is shown in figure 32. Figure 33 shows the elevations for this plant. Figure 34 is the site plan for the 200,000-box-capacity apple packing and storage house. It shows two storage rooms, each with a capacity of 100,000 boxes. The packing room accomo- dates two packing lines—one for exact sizing and one for group sizing. Figure 35 shows the elevations for this plant. Figure 36 gives two views of a scale model of the 200,000-box-capacity plant. ROOF VENTILATOR ( STEELPLATE END SoS EE SY | CONNECTION AND IVAN ‘ 3L!2 LONGSPAN STEEL JOISTS Nf BUTT PLATE HH i) ‘ eS SCALE OF FI [25 o 5 10 1 = Nera ° | \ MAKE ABSORPTION TESTS 2 | EMPLOYEE PARKING AREA (ones FLL WITH 3" GRAVEL COTE wi / ” U — | ROLLED GRAVEL - 2" MIN \ WELL / Yop i0" WITH FINES | rt | & | 1-4"X2'-0" CONCR. TTT i! DISTR. AND CLEAN- sien at OUT BOX || | DRAIN FIELO 1 1 | 180! 4" TILE a aa 4 PACKING AREA eid $ ya a Lb 4 -¢y-1 DISTR.BOX = 1 64'-4 4+ 20'-0"be 72'-0' ole agate] Po PSTRBO Fe | ] }---Osepric Tank HH! ——— | ys | re 2° WATER SUPPLY LINE e an | ' be 2 if ' | : ig A | = 8 Ha | | Mt | | e Yds ! = oof ft RECEIVING > 2 im t= Sea AREA is ° H © ASPHALT PAVING rma (5 wu SLOPE COVERED Ii J att For EES a AREA ASPHALT } yds I PAVING | F=3 SLOPE | ' ' 7 . ht ee } : | | | | |! 4 pe A ——— yyy ! 1 It! ere" | 4 —— 50'-0' + yt | FUTURE EXPANSION AREA — = | | Wt | \ ' ' iy | | | | if neu | ht | | 1 we b | i) i | SITE PLAN | | Wh H SCALE OF FEET | Vt 0510 20 30 40 50 ' ; 7 ‘ | | £ ' H | +—— siope - | ' | \ L | ral H ——— <> BUILT-UP ROOF 1X8 WO. DECK (DIAG) \ 2X12 -12°O.C, JOISTS ~ 5" CLEARANCE Se FOR INSULATION. ae ions — BLOWER UNIT it z f ei ae i a vy BUILT -UP ROOF j “ ON 2X6 TAG DECK Ec | Sf MH CATWALK 1 | a 2000” ADDITIONAL D.L. ~-2X6 -16"0.C, JOISTS) |! |-— 1/4" PLYWD, FACE r SS Aue rooms =| Fal | = 2° RIGID INSUL. PAD if C ] [ J AROUND PERIM. OF | it COLD ROOM 2' wi LL Lill OLO ROOM 2'WiDE rena) SECTION X-X_ ag FLAPPER DOORS BOWSTRING TRUSSES, DESIGNED BY FABRICATOR AND SUBMITTED TO OWNER FOR APPROVAL £ SYMMETRICAL ee BY 51/2" CONCR. FLOOR ON 6" GRAVEL FILL HIGHWAY STATE | | | | | + — 21-0" — 24'-6" PNL.HGT, : FIGURE 29, —Site plan for the 50,000-box-capacity apple packing and storage house. 27 BUILT-UP ROOF G.I. COPING ‘ : ROOF VENTILATORS STEEL JOISTS PANELS. ALL PILASTERS |+—3"D.S | | CONCR. WALL 1+ 3/4" CHAMFER | 1 | i] ] NORTH ELEVATION CORRUGATED GALVANIZED __ ROOFING o es cir T az 5 T | 7 | T 2 Saeed iil | a T ta STEEL OPGN WEB JOISTS CONDENSER TH CROGS| BRACING = oe =] c STEEL H COL. == SS =I | _——) a ly = yh — —— — et = - EAST ELEVATION CONGR. CORBELS FOR FUT. EXPANSION SLOPE ROOF 1/2"-1' 4X6 CONT. SUTTER BUILT-UP ROOF ON U | — / PF 2x6 TAG DECKING > 5 — ———£ ae | POURED CONCR. eRe AD CONCR. TILT-UP PILASTERS — WALL PANELS POURED CONCR (Ot — PILASTERS —+} oe rf 3"DS. (a = : — = E _ i c== = car oF os ——=Ls = SSS = SSS CONCR. BLOCK PANEL SOUTH ELEVATION FOR FUTURE DOOR is ROOF VENTILATORS BUILT-UP ROOF G1. SCUPPERS AND | ea DOWNSPOUTS CORBELS ] H | SCALE OF FEET [3-5 = os o 5 10 15 20 28 WEST ELEVATION Ficure 30.—Elevations for the 50,000-box-capacity apple packing and storage house. TABLE 6—Numbers of workers required to operate three packing lines with different types and amounts of equipment Workers required on— Operation One line | One line | Double to do to do line to do exact group both exact sizing * sizing’ | and group sizing? Move unit loads of loose fruit, culls, empty boxes, and packed fruit by forklift truck... ...... 02.2.0... 1 1 2 Move loose fruit from pallet to floor chain conveyor by handtruck....... 1 1 2 Stack empty boxes on pallets, put boxes on monorail conveyor, and handle extra small fruit from eliminator. 2 18 Manual wrapping and packing 18 Mechanical tray packing......0.....0sbecceeeeeees 9 Bagmmrmponciertrctrin eres 6 Stamp and weigh packed boxes 2 Lid packed containers...........-s0sce00] 9 L beseeseaeeed 1 Tally. 2 sabelssecsersadaessesseeussttcessbanccresrre css] MOLap cect asec: 1 Segregate.. 2 Supply packing material 1 Supervise....... 1 Maintenance... 1 All opexationss..cc..c.ccnavecscaneese L 1The average capacity of the packing lines is 420 boxes per hour; the maximum capacity is 600 boxes per hour. 2 The average capacity of the double packing line is 920 boxes per hour; the maximum capacity is 1,300 boxes per hour. Estimated Electrical Load for the Plants The estimated electrical loads for the three plants are given in the following tabulations: 50,000-Box Plant Horsepower Watts Amperes Motors: Three-phase, 230-V: Compressor... 25 Compressor... 10 Evaporator condenser... 3 Circulator pump.. 1 Defrost pump 3 SLotal savisevnctsvuetececseseecescsas 42 95 Single-phase, 230-V: 8 blower units... 8 4 unit heaters. 1 3 ventilators... 1 Motal:seecscrssctseretetace terest 10 37 Motors for packing room equip- rile er haa canbe esaenciooasconcor ice 25 56 Pe: Lighting: Horsepower Watts Amperes Cold-storage floods (22 x 150- Waltemeretcemintentersarsines arco 3, 300 RLM reflectors (12 x 200-w.)..... 2,400 Packing room lights (29 x 200- We) scectreescverceeestdticsses:atsiaes 5, 400 Office (3 x 160-w.).. ee 480 Office (3 x 100-w.).. 300 sllOtal tseece ctrestsnstiesccrcdsrsac 11, 880 56 Additional packing room lighting..... 3, 300 15 Total electrical load............... 1259 ‘ Provide a 400-ampere main breaker. 100,000-Box Plant Horsepower Watts Amperes Motors: Three-phase, 230-y.: Gompressoticssssesesccesres ect as cee 50. GOMPLESSOL: ses eercc oscars scews conse 20. 2 defrost pumps (3 hp. each). 6. Evaporator condenser..... U5 Circulator pump KS photallrecasecy donestcers voess coeaese 85 192 Single-phase, 230 y. motors: 14 blower unit 14 4 unit heater: 1 iventilatorsesiescenssccscsuceesnss 1 TOtaliviiccssestocsesvsasceassssacchs 16 58 Motors for packing room equip- ment... ofAadnbacadd 25 56 Lighting: Horsepower Watts Amperes Cold-storage floods (22 x 150- Wa) sectter-ceeverene desweess 3, 300 RLM. (3 x 100-w. 300 RLM. (12 x 200-w.).. 2, 400 Packing room lights (33 x 200- Wa) itercdierecccdeterdeverserecaterseys 6, 600 Office (8 x 160-w.)... 1, 280 Office (1 x 200-w.)... 200 MVotalitcccccrsccsrsccvestvcnvestsers 14, 080 64 Additional packing room lighting... 3, 300 15 Total electrical load.................. 1 385 1 Provide a 400-ampere main breaker. 200,000-Box Plant Motors: Horsepower Watts Amperes Three-phase, 230-v.: Compressor... 60 Compressor... 50 Compressor sccscessssccescczsssstees 20 4 defrost pumps (3 hp. each)... 12 2 circulator pumps (1% hp. CACM sracescsareteecsentesVesits crs 3 2 evaporator condensers (7% hp. each)... 15 MOtalarscsstssesstressericr es ss 160 360 Motors — Continued Horsepower Watts Amperes Single-phase, 230-v. motors: 28 blower Units. + ...555s+20+0505008 28 5 unit heaters... 1.25 5 ventilators 1.75 Total rca seccnectceracet estes veceece aul 112 Motors for packing room equip- MeMtraeeccertecestiavetse otters cee 50 113 Lighting: Cold-storage floods (44 x 150- is ered recente a 6, 600 RLM. (3 x 100-w.). “t 300 REM: (18:x '200-w.);<:...ccosseeeses 3, 600 Packing room lights (52 x 200- We) sas + 10, 400 Office (8 x 160-w 1, 280 Office (3 x 200-w.). 600 iLotaltvieeaeestseasst esses seceeess 22, 780 104 Additional packing room lighting... 6, 600 30 Total electrical load............... 1719 ! Provide a 800-ampere main breaker. Insulation Requirements Storage Room VAPOR BARRIER. — The vapor barrier is on the outer surface of the insulation; the inner surface is vented, because, during most of the operating season, the vapor pressure inside is lower than the average vapor pressure of the outside air. In the Yakima region, the average outdoor vapor pressure for December and February is about the same as that inside a building. In Janu- ary, the average outside vapor pressure is 3.3 mm. Hg, and the indoor vapor pressure is 3.8 mm. Hg, or a pressure difference of 0.5 mm. For September and June, the warmest months in which it is likely that the storage will operate, the outside vapor pressure averages 7 and 7.3 mm. Hg, giving a difference of 3.2 and 3.5 mm. between outdoor and indoor vapor pressures. Roor INSULATION. —In storages with the bowstring truss roof, the general practice has been to apply the insulation either to the roof-deck itself or between the joists of the roof structure. Although this construction method subjects the insulation to higher outside surface temperatures from direct solar load, this can be alleviated by using heavier insulation. The cost of extra insulation is offset by elimination of ceiling structure costs within the building, and by making the truss space available for the re- frigeration system and air circulation. Tests show that, at an average daily outside temperature of 65° F., the average roof surface temperature will be about 75° F. when insulation is applied to the roof deck.2 When insulation is placed beneath a well-ventilated attic space, the top surface of the insulation will average about 68° F. With 32° F. inside temperature in each case, the temperature difference through the insulation will be about 20 percent greater in the case of the in- sulation applied to the roof deck. If 4 inches of corkboard, installed beneath a well-yented attic space, is taken as standard insulation for cooler service, the roof deck should be insulated with 5 inches of corkboard, to restrict heat flow to the same as that of standard. Because 5 inches of corkboard produces a U value (overall heat transmittance) of 0.056 B.t.u./sq.ft./hr./°F. Td. (temperature difference), this value is specified as representing maximum transmittance allowable for the various ceiling in- sulations considered. ° See Bibliography, reference 13. BN-14981 (above) BN-14982 (below) FIGURE 31.—Scale models of the 50,000-box-capacity apple packing and storage house. 29 1X8 WD, DECK (DIAGONAL) 2x12 12"0.C. JOISTS (are ROOF S"CLEARANCE FOR INSULATION DB BUILT-UP ROOF ON ls _7~ BLOWER UNITS BOWSTRING TRUSSES DESIGNED BY FABRICATOR PROVAL 2X6 TBG DECKING STEEL PLATE END CONNECTION AND "3212 LONGSPAN STEEL JOISTS Es | eal Hi 2O00"ADDITIONAL D.L. O|O _7~ 2° RIGID INSUL.PAD AROUND PERIM. COLD ROOM -2' WIDE }17'-1/2" C. ol AND SUBMITTED TO OWNER fa FOR API CATWALK BUTT PLATE if ¢ SYMMETRICAL 5 1/2" CONCR. FLOOR is 6" GRAVEL FILL /-—— 24"- 6" PNL.HGT. SECTION X-X SCALE OF FEET HAE i) 5 10 15 20 ~~~ See noTEd| CLEANOUT BOX cy be ——____—______ 9'-9* —_— $$ —-_____—_ + 16'-0"4 i Fae ° (ORY \ vt EMPLOYEE PARKING \ weer | ° SEE NOTE! uae’) COVERED AREA (COVERED | | AREA = i SEPTIC TANK < DISTR. BOX w NOTES au = ' H |-EMPLOYEE PARKING; ROLLED GRAVEL, ° H H i 2" MINIMUM DEPTH. 4 PACKING AREA i tit ' 2-DRY WELL; MAKE ABSORPTION TESTS rd ° atten TO DETERMINE SIZE REQUIRED. FILL WITH re Hata es 3" GRAVEL, COVER TOP 10" WITH FINES, ES = itt t eleLo rat 2" WATER SUPPLY LINE 'g = « is a = ‘ RECEIVING AREA Ee 5 ‘> ASPHALT PAVING SLOPE FUTURE EXPANSION AREA SITE PLAN SCALE OF FEET ESS 0510 20 30 40 50 SLOPE FIN. GRADE 75'-0" HIGHWAY BEAMS “ tee tog 2X6 DECK SPACED 1/4" 7] 8 2-6" are 2-6" ApaRT ON 2k4 NAILERS 4° WF-10 26 GA. GALV. ROOF- CORRUGATED 212K 21/272 PURLINS lot-20 — CONT. FIELO WELD TO C COL. 9°C-13.4 — SuI26 W JOISTS SLOPE ROOF 1/2"-1' an PLATFORM y~ BUILT-UP ROOF ON 1X8 DECKING G.I. COPING ON SI-13 2X8 NAILER —————- 2x6-I16 00 a a ZUNFIN. CEILING Xixa eracns =f ra > CONCR. BLOCK BOTTOM CHORD ON 3-2XI2 STRINGERS OF TRUSS ELEVATION SECTION FiGuRE 32.-Site plan for the 100,000-box-capacity apple packing and storage house. 30 CATWALK DETAILS SCALE OF FEET 8 o12 4 6 10 This additional insulation costs about $0.20 per sq. ft. In addition, there is approximately 8 percent more area to be cov- ered, and the cost for each sq. ft. is about ($0.80 + 0.20) x 8 percent = $0.08, for a total extra cost ot $0.28 per sq. ft. A ceiling to provide an attic and support the insulation would use 2.5 board feet of lumber per sq. ft., so the extra cost of insulation on the roof-deck is offset by the material cost alone in the ceiling. When labor to install the ceiling is added to the costs, it is esti- mated that the savings achieved by using roof insulation will amount to between $0.25 and $0.30 per sq. ft. of horizontal area. Table 7 is presented to compare a number of insulation treat- ments that have been used successfully on roof-decks or in the roof structure of apple storages. Costs per sq. ft. of roof were obtained from responsible contractors. U values were either calculated from published data in the ASRE Data Book or taken from tests of similarly insulated structures.!° From the comparisons given in table 7, it is apparent that the rigid insulation applied to the deck is considerably more ex- pensive. Five inches of this material would probably have been close enough to the maximum overall transmittance required (0.050). (The cost, however, would still have been between $0.90 and $1.) The various other insulators which are installed between the joists are not greatly different in cost per square foot, and the 12-inch fill of fiber glass was selected because of the lower U value obtained with this material. To use this information: Assume that the recommended in- sulating procedure is the 12-inch fiber glass fill, held in place with a sheet of 0.006-inch-thick aluminum foil, and is available at $0.46 per sq. ft. at the construction site. The U value is 0.0237 B.t.u./sq.ft./hr./°F.Td. This is to be compared with some other insulating procedure which, for the purpose of this example, will be assumed to be of equal durability but the cost at the site of the proposed construction is $0.35 per sq. ft. and the U value is 0.04 B.t.u./sq.ft./hr./°F.Td. TaBLE 7—Installation cost and overall heat transmittance (U value) of 4 types of ceiling insulation | cost per U value sq. ft. iE B.t.u./sq. Dollars St./hr[° F.Td. Description of insulation 12-inch fiber glass insulating wool be- tween joists with 0.006-inch aluminum sheet on bottom of joists...................4 0. 46 0. 0237 Rigid insulation on top of deck, 6-inch fiber glass roof deck (3 layers of 2 inches) with 15-Ib. felt slip sheet........... 1.17 . 0425 6-inches P.F.-612 semirigid fiber glass insulation between joists with 0.006- inch aluminum sheet on bottom of JOISES*cccanteeccasteseesterineanetereataipedtacees -49 . 0405 2 layers of prefabricated aluminum foil insulation having a total of 6 sheets of aluminum, between joists. Joists sealed on bottom with %-inch plywood... | 48 1.039 ' Determined by field tests. 10 See Bibliography, references 2 and 12. tak The annual cost differential for a U of 0.0237 is $12.10 and for a U of 0.04, $20.50. The difference between the two is $8.40, which is the annual difference in fixed and operating costs per 1,000 sq. ft. between the two insulations being considered. The insulation cost difference between the two methods is 1,000 x (0.46-0.35}=$110. The annual fixed charge on this investment, consisting of 5 percent depreciation, 2.5 percent amortized interest, and 2 percent for insurance and taxes, or 9.5 percent of $110, equals $10.45 per year per 1,000 sq. ft. In this case, the extra equipment and operating costs encountered with the sub- stitute insulation would be $2.05 per 1,000 sq. ft. less than the fixed costs on the heavier ceiling insulation and there would be an overall saying in using the hypothetical substitute. In addition to showing the method of comparing the various insulations that may be considered for an application, this example serves to show that insulation types 3 and 4 in table 7 would have to be available at about $0.36 per sq. ft., in order to be considered equal to the insulation selected. The slight differences in annual costs for several of the insula- tion materials that are similar in performance show the need for careful evaluation of the durability of material selected. To obtain firsthand information on the performance of the material selected for the storages in this report, tests of in-place heat transmittance and examinations of the condition of the insulating material were made at an apple storage plant. The roof was insulated with 12 inches of fiber glass between joists. The tests were made at the end of the second season's operations. Heat flow and temperature differences through the insulation were measured with a Gier and Dunkle heat flow meter, thermo- couples, and a recording potentiometer. The data were analyzed by methods described in an earlier work.!! The observed value closely approximated the value calculated from the ASRE Data Book.'* Duplicate samples of the insulation were withdrawn from three places in the roof, and moisture determinations were made. The insulation was exceptionally dry; all samples con- tained less than 0.3 percent moisture. Because of the dryness of the insulation and its ability to restrict heat flow after two seasons’ use, it seems reasonable to conclude that its characteristics and method of installation are adequate. More expensive insulation is unnecessary for the usual intermittent apple storage operations. WALL INSULATION.—The minimum requirement for wall in- sulation was set at a U value of 0.07, which is the equivalent of 4 inches of corkboard and is considered standard for 30° F. Table 8 shows the wall insulations that were considered, the installed cost (determined by responsible contractors who had used the material), and the U values, as determined either by calculation or by test. The built-up wall with reflective spaces and a mineral wool bat was finally selected because it combined low initial cost and good heat transmittance. Slight changes in contractor’s pricing could change the selection to either insulation 1 or 5 (table 8) because these three cost about the same. Evaluation of the differences in prices and performance can be made as described in the discussion on roof insulation. A heat flow test was made on the walls in a building whose construction was very nearly the same as that selected in this report. The U value for the wall was 0.034, compared with a calculated yalue of 0.038. ! See Bibliography, reference 13. '2 See Bibliography, reference 2. CONTINUE TOP CHORD OF SHORT JOISTS 2'-0" FOR OVERHANG> _7— PILASTERS POURED G1. SCUPP! BUILT-UP ROOF 4 WITH COLUMNS yr ROOF VENTS iesrcaiuahers G.I, COPING > FLASHING > SLOPE 1/2"-1' j-2X8 FACIA SHT.MET || COVER | [+ 3/4" CHAMFER ——~ EE DET" CONCR. WALL Seal PANELS NORTH ELEVATION y- ROOF VENTILATOR ZF STEEL JOISTS WITH CROSS BRACING an CORRUGATED SHEET METAL ROOFING _— ih Ses pee ON, Soest) s peal = -—— — _ — 4 EVAPORATIVE CONDENSER ecerron® CONT. REGLET STEEL — =| CAODER | — | ae | = = =| =| = | = pl ey —— — =4 ——— & ——_ 1, = c = == = = == ral === sats EAST ELEVATION 4 i2"xi2"xe" te Gl. SCUPPER ~ ont cnRee a SLOPE 1/2"-1"_ = = = 1 FOR FUT. EXPANSIO! ' a a nf PILASTER CORBELS | =| | CONCR, WALL, PANELS | es “WARP CONCR. = TO DOOR 2a SOUTH ELEVATION BUILT-UP ROOF SCALE OF FEET o 5 10 15 20 WEST ELEVATION FIGURE 33.—Elevations for the 100,000-box-capacity apple packing and storage house. 31 75'-0” ~ _/~ MAKE ABSORPTION TESTS \. TABLE 8.—Installation cost and overall heat transmittances (U values) of 5 types of wall insulation with perimeter insulation only. It was calculated that the benefits obtained from the pumice and concrete would not justify an investment of more than $0.13 per sq. ft. The cost of such a fill is several times this amount. 100'-o* I99'-0" eae TO DETERMINE SIZE REQ'D. ' ; Installation ie See — / FILL WITH ARGRAVEL: SS x Description of insulation ee per U value At the storage plant with the pumice-concrete fill a recently orrwel \ a added room had loose pumice rolled in place to form a 12-inch oso". ; 2 oe fill, for $0.35 per sq. ft. This material is somewhat superior to \ femme: | ieee ' 4inch P-F61: a : Dollars | fe.lhr.PF.Ta. the pumice-concrete. Heat flow rate measured in midwinter Se igre ik 200'oF "TILE a PF. He semirigid fiber glass in- was 1.4 B.t.u./sq.ft./hr. for the rolled pumice insulation and $2 Burton box ! ee pees ne, ipolidiag averaged 1.9 B.t.u./sq.ft./hr. for two locations on the floor with aaa : 1 word |! an cide finish a rnin rice pumice-concrete fill. During midwinter, a floor insulated with 3 ij Pitt elacernctide chumalcrial ecneee math 0.56 on0s7e inches of corkboard, situated on similar soil and with comparable RR. i | 14 \ dine sfibere plassstiaid’ ARS (asphalt: : fs drainage, showed a heat flow rate of 0.62 B.t.u./sq.ft./hr. The 12 ates | 1 | enclosed) board insulation (no in- inches of pumice do not seem to resist the heat flow nearly as ,' are — ' H ! “Hala OFx" OF An terior finish) applied in: well as the 3 inches of corkboard. Had the rolled pumice fill sine at | Ea orrice!| ¢O! Two 2-inch layers. 74 0642 resisted heat nearly as well as the corkboard, its use would seem eed ' AREA |[-"*7U--SEPTIC TANK | One 4-inch layer. i . 64 . 0642 justified, because its cost is slightly less than that for cork treat- | 4-inch _tigid foam-type insulation (no ment. i | SLOPE FIN. GRADE, a ney) pele’ in: From these comparisons, inorganic fill materials do not seem | A One Aainch ge paastedeesaseseatrs's.seens 1. ear promising for insulating floors of intermittently operated apple | Built-up wall with 9 reflective eiaces ve : storage rooms. Perimeter insulation only is specified because it 4'-0" CONC. WALK one 4-inch mineral wool bat and 4%. is assumed that ground water level is never within 12 feet of the | i sl inch fiber glass roof decking for in- floor level. Storages without floor insulation should be cooled | / = ES WATER SIERLNE terior finish............. Ree ee 50 0424 well before harvest so that the heat may be removed from the ope Two layers of prefabricated aluminum earth beneath the floor. | foil insulation having a total of 4 sheets For sites where the ground water level is within a few feet of MACHINE ROOM- of aleeintian, eredaged between studs, m ; the surface for any considerable period of time, insulation be- } pie ea ELON PAY OOGs retreats 52 - 0489 neath all of the floor surface with 3 to 4 inches of boardform in- | ' ! Determined by field tests. sulation, preferably of the type with closed cellular structure = that is impervious to moisture, is recommended. © GOLD STORAGE AREA EI | 5 * 5 iS i z Packing Room P Beene a FLoor INSULATION.—The selection of floor insulation is more Kovereo} AREA complex than wall and roof insulation. The extent to which a Because of the growing tendency toward packing to order 4 = floor should be insulated in this type of storage depends largely during the winter months, heat loss in packing rooms was studied ‘ upon the site. If ground water level is near the floor surface — to see if wall and ceiling insulation is necessary. SPUR TRACK SOLO STORAGE AREA ASPHALT PAVING SLOPE 1-0", HIGHWAY STATE FUTURE EXPANSION ___ SLOPE FIN. GRADE s SCALE OF FEET E 0510 20 30 40 FIGURE 34.—Site plan for the 200,000-box-capacity apple storage and packing house. within 10 feet for a substantial part of the season—some insula- tion should be placed beneath the concrete wearing floor. If the water level is lower than this, it is difficult to justify the cost of floor insulation, because dry ground is a fairly effective insulator. As a minimum, however, when the floor is not insulated, the wall insulation should extend down below the floor onto the foot- ings so that the concrete floor does not touch the outside wall. Where this precaution has not been taken, heat transmission rates at the wall have been observed during warm weather that are five or six times greater than at a distance of 5 feet from the wall. In the storage design in this report, the breaker strip of insulation is brought back under the floor rather than continuing down the footing; a perimeter ribbon of insulated floor is thus provided. If the insulation is extended down to the footings, the perimeter strip showing reduced heat flow is much narrower. The most economical width of the floor ribbon was not determined. A study, during the operating season, in two storages having only perimeter insulation indicates that the total fixed cost of added refrigeration equipment, because of additional heat leakage from the uninsulated floor, would justify spending 40 to 50 cents per sq. ft. to insulate the floor with the equivalent of 3 inches of boardform insulation. The cost of a subfloor to support the insulation, however, plus the cost of the insulation, would range between $1 and $1.25 per sq. ft. It therefore seems best to limit floor insulation to the perimeter in locations where ground water level is more than 12 feet below the floor surface. In addition to perimeter insulation, various types of inorganic fill materials, with sufficient compressive strength to be used beneath the floor were considered. Floor heat flow data from one storage built with a 9-inch layer of pumice and concrete beneath the concrete wearing floor was compared with that in storages The first step was to select a representative packing schedule and determine the number of degree-days that would be involved in heating during such a season. This step and the calculations leading from there to fixed and operating cost differentials are in the section on Economic Analyses of Wall and Ceiling Insulation. Data in that section give these differentials for overall heat trans- mittance ranging from 0.0 to 1.0 B.t.u./sq.ft./hr./°F.Td. The method of applying this information is essentially the same as that given earlier for similar data in the study of economic thickness ef insulation for the storage walls and roof. Also shown in this section are the calculations determining the selection of wall insulation and the calculations showing why roof insulation was not recommended. In order to make the wall insulation as simple as possible, a boardform insulation was selected that had a vapor barrier already applied to the warm side. In the packing room the vapor movement would always be-from inside to outside; therefore, the insulation selected must either have a vapor barrier applied to the inside face, or must itself constitute a vapor barrier. In addition to the economic reasons for insulating the packing room walls, there are also physical considerations. When the packing room is maintained at 60° F. and the outside temperature is —5° F., an uninsulated concrete wall would have a surface temperature of about 29° F, Besides large radiation transfers from the room occupants to this cold surface, the wall would frost whenever room humidity rose above 30 percent. At slightly higher outside temperature, and with room humidities of 35 to 40 percent, the walls would sweat. The uninsulated ceiling will have a surface temperature of about 48° F., at a 60° F. room and —S° F. outside temperature. Sweating will not occur until the humidity in the room rises to 65 percent. Because a considerable amount of dry outside air is brought into the packing room by the apple washer ventila- tion system, it is not likely that the humidity in the packing room will approach 65 percent. CORR. SHT METAL ROOF DECKING eTatanreEnea cians ON STEEL FRAME nok OUTS BUILT-UP ROOFING ROOF VENTILATOR jf CONT. REGLET A G.I. FLASHING aay i ON 2X6 T&G DECKING : /— om | pad 4X6 CONT. G.1. SUTTER 7 vi VAVAVAVAVAVAVS ———— : i ———— Yate ra ice = = B*x67e155 || “Su 167 W STEE 6" CONC. TILT-UP WALL PANELS| -3° 0.S. STEEL COL'S. || JOISTS - 5'-0' Insulation for walls and ceiling of the office was found to be justified, as shown in the section below. Because the office is occupied throughout the heating season, and higher temperatures are maintained there, insulation will obviously provide an even POURED PILASTERS- Sane itebe SEE DETAILS | 6" CONC. TILT-UP WALL PANELS, POURED PILASTERS - SEE DETAILS greater return per square foot of exposed area than in the packing room WEST ELEVATION Moreover, chilling by radiation to cold, uninsulated walls when outside temperatures are low would be more noticeable, because {TOP OF PILASTER CORR. SHEET METAL office workers are not as active as packing room workers. \ ao 8-0" FLOOR LINE - TO PLATE ] [ex Peel a aE EVAP. CONDENSER | <= ies PLATFORM > ik S9,0S, i| [ TILT-UP ya PANELS —— th : = a Economic Analyses of Wall and Ceiling Insulation SLOPE PAVING Cold Storage POURED WINDOW SILLS| Calculations for this economic analysis are based on the FINISH FLOOR LINE EAST ELEVATION “NFO STEEL LADDER - WELD 3/4” 1.0. PIPE fi 1] 1 <. H . ———— RUNGS 12°0.C. TO |-1/4"LO. PIPE STANDARDS - ollowing assumptions: ANCHOR LADDER TO WALL Average outside air temperature during operating period, September through May, is 45° F. Average roof temperature is 55° F. for season. Average wall temperature is 45° F. for season. Length of season is 9 months (270 days, or 6,600 hours). Roof temperature is 75° F. Wall temperature is 65° F. Refrigeration equipment cost is estimated at $600/T.R. Annual fixed charges on refrigeration equipment are 15 percent of initial cost of the equipment. Average power required per T.R. equals 1 kilowatt (kw.). Average power cost is 1.5¢ per kw.-hr. SOUTH ELEVATION. Total annual fixed charges on insulation are 9.5 percent of installed cost. - CEILING.—Heat leakage influences refrigeration capacity 7S THESE SECTIONS POURED 4 WITH PILASTERS- 3/4" CHAMFER a SLOPE - 2" PERI \ =| Ei cone comucis I avavava sees )-REMOVABLE FLAPPER STORM OOORS- 5 Ls- ef i SEE DETAILS ] —— OF SEE SCHEDULE BUILT-UP ROOFING TAPER FACIA nooIc| ooac looc WALL, PANEL }-— 24'-6" HIGH ——~ BOND BEAM 17-172" —+ SCALE OF FEET fish; a —————} o 5 0 20 required and, consequently, refrigeration investment. - - : Change in refrigeration capacity required by a change in ceiling ——$ =) | & | | | = ——————— insulation transmittance, U, per 1,000 sq. ft. of surface is deter- Teen = — — = — — —= = 1 mined by: BOND BEAM || er oe : } ! 75=32)x1,000xdU_3 58:dU T:R. H be ach cL 12,000 : Change in annual fixed charges on refrigeration equipment a2 provided to meet required capacity as determined by a change in ye A a z ie ae RT — ceiling insulation transmittance is: 3.58 dUX$6000.15=$322.00 NORTH ELEVATION Se : es. TT dU (per 1,000 sq, ft.) _ ao ‘7 SEE REFRIG, DETAIL Change in operating cost influenced by change in ceiling 3-6 CATWALK J) catwack insulation transmittance is calculated as follows: Average season's heat leakage per 1,000 sq. ft. is: = i BOWSTRING TRUSSES y DESIGNED BY FABRICATOR ANO SUBMITTED TO OWNER | € SYMMETRICAL, Esvuernical BOOD" ADDITIONAL FOR APPROVAL nyt amet ion (S5—32)X1,000*6,600XU in B.t.u.'s a [ olo Change in season's heat leakage per 1,000 sq. ft. with change Hop Lee _ 7 - =< in U is 151,800,000 dU B.t.u. hr., or in terms of ton hours: 14" 10. PIPE Ral E32" mGIO SUL PAD AROUND ey 2' WIDE 6" GRAVEL FILL a 151,800,000 dU — y5 659 qu SECTION _X-X 12,000 Change in operating cost with change in U is: 12,650 dU x1 $ kw./T.R. x 80.015 kw.-hr. = $189.80 dU. Total of changes in ; : — ~ fixed charges and operation costs per year per 1,000 sq, ft. FicurE 35.—Elevations for the 200,000-box-capacity apple packing and storage house. _ tequired by a change in ceiling insulation transmittance equals > $511.80 dU. Change in annual fixed charges, change in annual operating charges, and total of these two vs. change in U for U values from 0.01 to 0.1 are given in figure 37. 33 These total cost differentials arising from a change in U value may be balanced against the change in annual fixed charges per 1,000 sq. ft. of the insulating material, taken at 9.5 percent of installed cost of the material, to determine which insulating pro- cedure offers the lowest overall cost. Watt.—The same general approach is used to determine total cost differentials arising from a change in U value of the wall insulation; however, the actual differentials determined are not the same as for the ceiling because the outside design and outside average season temperature are different. Change in refrigeration capacity required by a change in wall insulation transmittance, U, per 1,000 sq. ft. of surface is deter- mined by the formula: (65 — 32) x 1,000 x dU 12,000 Change in annual fixed charges on refrigeration equipment provided to meet required capacity as determined by a change in U is: 2.75 dU x $600.00 x 0.15 = $247.50 dU (per 1,000 sq. ft.) Change in operating costs influenced by change in U: (45 — 32) x 1,000 x 6,600 x $0.015 dU 12,000 Total changes in fixed and operating costs per 1,000 sq. ft. required by a change in wall insulation transmittance equals $354.70 dU. 34 =2.75 dU T.R. $107.20 dU. BN-14980 FIGURE 36.—Scale model of the 200,000-box-capacity apple packing and storage house. Figure 37 gives the fixed charges for U values varying from 0.01 to 0.1. The foregoing analysis should be applied only to those insula- tion procedures deemed to have adequate performance for the duty involved and to remain efficient throughout the period set up for depreciation of the material. Packing Room Calculations for this economic analysis are based on the follow- ing assumptions: Average inside temperature is 60° F. and outside temperature isi—9> Bz Gas heating equipment cost is estimated at $400 per 100,000 B.t.u./hr. output. Annual fixed charges on heating equipment are 15 percent of initial cost of the equipment. Fuel cost is $0.10 per therm (100,000 B.t.u. input). Heating equipment efficiency is 80 percent. Total annual fixed charges on insulation are 9.5 percent of installed cost. Degree-days during packing room operating season equal 1,667. The number of degree-days estimated for the packing room operating season involved a number of assumptions and the final figure was derived as follows: For a 60° F. inside temperature, the fuel consumption is esti- mated from the number of degree-days, using 55° F. outside temperature as a base. The data in the section “Use of Re- jected Heat from the Refrigeration System,” were used to determine degree-days below the base. Experience shows annual degree-days are apportioned as shown below. Deneedaye Packing room _Degree-days during Month at 55° F. operates— operating period 10 Entire month..........- 10 160 Entire month... a 60 483 2 weeks.. 225 739 2 weeks.. 334 841 2% weeks..... 508 566 2 weeks.. 283 326 2 weeks.. 147 - 1,667 Sept. to Mar......55--— O : Oi 1053: “014 ":0.5 06.07% TORRY “U"-THERMAL TRANSMITTANCE (B.t.u./SQ. FT./HR./°F. Td.) U. S| DEPARTMENT OF AGRICULTURE FIcuRE 38 treatment and a U of 0.086 for the second. Cost of the first treatment was estimated at $110 per 1,000 sq. ft. and for the second, $210 per 1,000 sq. ft. A study of the justification of these insulating treatments is tabulated below. Adding I-layer 4dding 3-layer reflective material assembly reflective material AU geecetretitegs carers oss 0. 32—0. 193=0. 127 0. 32—0. 086=0. 234 Annual fixed and oper- ating cost differen- tial/1,000 sq. ft........ $11. 30 $20. 80 First cost of insula- HOM ss2+e--eccsee-222:- fea 110. 00 210. 00 Annual fixed cost o! insulation....... Aire 10.45 20. 00 Net annual savings/ 1,000 sq. ft ......-..e-e 0.85 0. 80 The costs of these treatments were so close to the break-even point that it did not seem worthwhile to recommend either. Either treatment could be installed after construction. If it is found that the operating season is actually much longer than estimated in these calculations, or that the cost of installing the material is less than estimated, an insulated ceiling could be justified. NEG. 130-61 (11) AGRICULTURAL MARKETING SERVICE Office Calculations for this analysis are based on the following assumptions: Equipment selection is based on 70° F. inside temperature and —S° F. outside temperature. Gas heating equipment cost is estimated on the basis of $400 per 100,000 B.t.u./hr. output Total annual fixed charges on heating equipment are 15 percent of the initial cost of the equipment. Fuel cost is $0.10 per therm (100,000 B.t.u. input). Heating equipment efficiency is 80 percent. Degree-days per year equal 5,585." This analysis is based on office occupancy throughout the heating season, which would be normal; the number of degree- days in the office operation —5,585 — contrasts with the number for the packing room operation — 1,667. The change in heating equipment annual fixed charges as influenced by a change in U value is as follows: _ (70—5) x 1,000 x $400 x 0.15 dU _ aU d fixed charges 700,000 $45 13 See Bibliography, reference 1. 35 The change in operating costs per 1,000 sq. ft. of surface varies with change in U values as follows: 5585x24x 1000xdUx$0.10 100,000X0.8 elev 0ldl) Total of the changes in fixed charges and operating costs per year per 1,000 sq. ft. of surface caused by a change in U=$212.50 dU. These values are shown in figure 38. WALL.—The possibility of using 1", 144" and 2” thicknesses of foam-type insulation (K=0.25) was considered. This material will take an interior plaster coating. Material cost is $0.17/sq. ft. in 1” thickness; $0.255/sq. ft. in 144" thickness; and $0.34/sq. ft. in 2" thickness. Labor to install was estimated to be $0.15/sq. ft.; two coats of plaster, $0.28/sq. ft. U for uninsulated wall is 0.79 B.t.u./hr./sq. ft./° F. Td. d operating costs Insula- Total Fixed tion dU from unin- annual charges on Annual net thickness U value sulated wall cost diff.* insulation® savings® Me 0.19 0. 60 $126. 50 $57. 00 $69. 50 1%" 0. 138 0. 652 137. 50 65.10 72. 40 Pe 0. 108 0, 682 144. 00 73. 20 70. 80 *Per 1,000 square feet. The 1%" insulation provides the greatest net annual savings and an acceptable degree of insulation. CEILING.—For the ceiling, 6" of fiber-glass blowing wool, placed between the joists, is recommended. Uninsulated ceiling has U value of 0.32; insulated ceiling has a value of 0.04. The dU occasioned by the treatment is therefore 0.28 (0.32 — 0.04). The cost of this treatment will be about $0.24 per sq. ft. Total annual cost differential is $59.50 per 1,000 sq. ft. Fixed charges on the insulation amount to $22.80 per 1,000 sq. ft., leaving a net saving per year of $36.70 per 1,000 sq. ft. to justify the use of this insulation. Typical Refrigeration Load Calculation The calculation to determine the refrigeration load for the 100,000-box storage is typical for all of the storages, and the as- sumptions are given in detail below. Interior dimensions, 135 x 98 x 21 ft. high under the trusses. Outside measurement of storage room— 137 x 100 ft. Floor area, about 14,000 sq. ft. Ceiling insulated for U=0.0237. Walls insulated for U= 0.043. Uninsulated floor has a heat flow of 4 B.t.u/sq. ft./hr. during the receiving period. 7,000 field boxes per day are received. Allow 8 percent extra area on roof, because width actually is an Pa of a circle having a chord of 100 ft. and rise of about 12 ft. Heat leakage from conduction: aA B.t.u.|de Ceiling= 14,000x1.08x0.0237(75 —32)x24......., : 370, 000 Walls=480 x21 0.043 x (65—32)x 24. 344, 000 Floor=14,000X4X24.00 0000. 1, 344, 000 Total heat leakage from conduction............ 2, 058, 000 Heat due to infiltration: Lights, equipment and men working (75 percent of total heat leakage from conduction).................. 1, 544, 000 Fan motor heat equivalent 12545224 eeraecccaniors 1, 070, 000 Total fixed loads... 4, 692, 000 36 Receiving load: Cooling apples =7,000X0.9x34x(65—32)............ 7, 066, 000 Cooling boxes and pallets =7,0000.5x7x(65 — 32) 807, 000 7,000*34*9,000 Respiratory heat of fruit 2,000 1, 072, 000 Total:daily load ices: ccs .<32c0:0351 asevarsescsetee 13, 637, 000 Refrigeration capacity (T.R.) required, based on handling load with 22 hours of operating time per day: 13,637,000 _. 72,000x22 21-6 TR. For this storage, 52 T.R. capacity is recommended. Similar calculations can be made for the 50,000-box and 200,000-box capacity plants. Determining Performance of Refrigeration Systems When Receiving Bartlett Pears Because many apple storages are used to cool and store pears before apples are harvested, it is important to know if the storage can cool pears and hold them for shipment or sale. The average daily outside temperature and initial fruit temperature is assumed to be 85° F., and the average daily roof temperature is assumed to be 95° F. The capacity required is to receive and cool a ton of pears from 85° F. to 30° F. Cooling fruit=2,000X0.9X(85—30)................ Cooling boxes & pallets=507x0.5x(85—30).: Respiratory heat=18,000 B.t.u./ton of fruit... . Total! (periton: Of fruit)isc.-cccc-ccceesscessosessceseavs ee Calculate fixed loads encountered during the warmer recoiving season, deduct these from system capacity, and calculate how many tons of pears per day the remaining capacity will handle. Heat leakage: B.t.u./day Ceiling=14,000X1.08x0.237x(95—30)24... 559, 000 Walls=480X210.043x(85—30)* 24... 572, 000 Floor=14,000X4X24....0...0.000..0000.. ... 1,344, 000 Total heat leakage by conduction................. 2, 475, 000 Heat due to infiltration: Lights, equipment and men working (75 percent of total heat leakage by conduction)..................... 1, 856, 000 Fan motor heat equivalent: tia panes Soisheiee turer ianceesementeneratiees i seve see ne ree 1, 070, 000 0.8 Motal\ fixed'loads<..cssesseesecoskererecentececs cece oeece 5, 401, 000 System capacity on 22 hr. basis=52X12,000X22...... 13, 730, 000 Wess ifixediloadinrs sitar masieetreeeiaten ni 5, 401, 000 Available for GOoling pears -si1..scsteseserreesees eee 8, 329, 000 This will handle 8370. 000 65, tons of pears per day, or 3,290 lugs per day. In anormal 15-day season, the plant could receive and cool 49,350 lugs which would fill about 50 percent of the available space in the storage. Heating Load Calculations PACKING Room. —Calculations for the heating of the packing room for the 100,000-box plant are given below. Except for allowing for different size and arrangement, the calculations are similar for the other two packing rooms. Assumptions are: The room is 60 x 190 x 17 ft. under the roof deck. 149 ft. of wall adjoins cold storage and compressor rooms. 60 ft. of the front wall length is office partition, but the upper 7 ft. are exposed to the outside. The packing room volume is 193.800 cu. ft. Inside design temperature, 60° F. Outside design temperature, —5S° F. Storage temperature, 30° F. Ground temperature, 52° F. U for storage room wall=0.0424 U for ground=0.10 U for outside packing room wall with 1-in. insulation=0.19 U for uninsulated packing room roof=0.32 U for 2-8 x 10 ft. doors =0.69 Ventilation — one 5,000-c.f.m, fan is used in cold weather to vent fumes from washer. Heat leakage by conduction: B.t.uJhr Ceiling =60190*0.32*(60— —S)..020.0.0000000.. siaseas 202, 000 Storage room wall=17x149x0.424x(60—30)............ 3, 220 Floor=60190x0.1x(60—52).......... 5 9, 100 Doors = 2X8x 10X0.69%(60 — —$)..... : 7, 180 Outside walls: : =17X291=4,950 sq. ft. =7x60=420 sq. ft. Less doors =2x8x10=—160 sq. ft. 5,210x0.19x(60— —5).......... Sestienwactstnticn 64, 400 Total conduction loss... .......00....00c..c00ceeec0eeee. 320, 900 5,000x60*0.24x(60——5) ac Ventilation = py 132 saessasinateieras oO as UU Total heating load...............0..... ELE edtailes cout . 675, 600 OFFICE.—These caiculations show the heating load for the office, rest rooms, and shop space in the 100,000-box plant, and are typical of the calculations for all of the storages. As- sumptions are listed below: Office and other service space 60 x 16 x 10 ft. high. Office volume is 9,600 cu. ft. One wall adjoins packing room. Inside temperature, 70° F. Outside temperature, —S° F. ; Packing room temperature during nonoperating periods, 40° F. Ground temperature, 52° F. U for partition=0.30. U for outside walls —with 1-in, insulation=0.19. U for 156 sq. ft. of office windows=1.13. U for insulated office ceiling=0.0395. Heat leakage by conduction: Ponte Windows = 156X1.13X(70 — —5)...-.-..000e0es+ ... 13,200 Outside walls = [(10*92)— 156] x0.19x(7 10, 900 Inside walls = 10*60x0.3x(70—40).. 5, 400 Ceiling =60x160.0395x(70— —5) 2, 850 Floor=60x16x0.1(70—52) 1, 730 Total conduction loss....... eeapigeyacrceees: ifeieeeas . 34,080 Ventilation load based on one air change per hour: __ 9,600X0.24x(70— —5) 13, 100 [= nao lo = 47, 180 Total heating loud ’ss...ccscseneseaceescsscs cecseeeetes Use of Rejected Heat from Refrigeration System In connection with the heating requirements for packing rooms and offices, a study was made of the possibilities of using heat rejected from the refrigeration system for this purpose. Because the 200,000-box plant has the most favorable relation- ship between the size of the storage and the size of the packing room, the study was made for this plant. The available rejected heat in the 50,000-box storage and the 100,000-box installation is roughly 25 percent and 50 percent, respectively, of the amount available for the 200,000-box’ plant. At the same time, the heating requirement is about 70 percent of that of the large plant. So, it does not appear that the use of heat from the storage rooms is practical in these smaller plants. The amount of heat available from cooling the storage in the 200,000-box plant in the winter was calculated for outside conditions of —5° F., the normal outside design temperature for Yakima, Wash.; for +12.5° F., which is the coldest average monthly temperature recorded for January; and for 27.7° F., which is the normal average monthly temperature for January. When outside temperatures are lower than normal storage temperature, heat is lost to the outside through the ceiling, outside walls, and air leakage. The floors and wall between the storage and packing rooms conduct heat. Also contributing to the heat gain is the heat from fan motors, lights, men and equip- ment working, and respiratory heat from the fruit in storage. In making the calculation for January, which is the critical month of the year for heating, it has been assumed that the storage will be two-thirds full of fruit. A number of midwinter heat flow observations from uninsulated floors indicate that 1.25 B.t.u./sq. ft./hr. is average heat leakage through floors for this time of the year. The heat available from storage has been plotted on figure 39, showing how this quantity varies with outside temperature. Also shown is the relationship between total heat requirement of the office and packing room, and outside temperature. These curves show that the heat from the storage rooms is not adequate to handle the office and packing room needs below a 46° F. outside temperature. Reflective insulation for the ceiling of the packing room would just pay for itself ‘by off-setting the cost of heat lost. Because savings are so little above the break-even point, it is not recom- mended where gas heating is to be used. However, when the use of heat from the storage is planned, insulation on the ceiling is recommended because it reduces the load on the packing room to the point where heat from the storage can be used a greater portion of the time. Because the saving in fuel consumption with gas will just justify the insulation investment, a comparison will be made with use of heat from the refrigeration system for a packing room with an insulated ceiling. Figure 39 shows the heat requirement for the packing room, with a ceiling insulated with a three-layer assembly of reflective material, that gives an overall ceiling U value of 0.086 B.t.u./sq. ft./hr./°? F. Td. Also shown is the combined requirement of the office and packing room after insulation of the ceiling. In addi- tion, there is plotted the combined heat requirement of the office and packing room when the ventilation fan is not operating, which would be the case at night. Because the ventilating fan operates only 8 hours a day, the average operating period load has been calculated and is shown as condition 3 on figure 39. Finally, the heat requirement for the office plis the heat required to maintain the packing room at 40° F. without the ventilation fan HEAT LOADS AND HEAT AVAILABLE FROM REFRIGERATED SYSTEMS UNDER VARIOUS CONDITIONS HEAT LOADS 1,000 B.t.u.’s PER HOUR eeccee Office and packing room load x=—xk=—=—x Packing room load 1,100 BS - —--= Total heat from cold storage o—o-o Net heat from cold storage —— Office load only 1,000 Condition #1 CONDITION #1~-PACKING ROOM CEILING UNINSULATED, VENTILATING FAN ON, PACKING ROOM TEMPERATURE 60°F. CONDITION #2--PACKING ROOM CEILING INSULATED, VENTILATING FAN ON, PACKING ROOM TEMPERATURE 60°F, CONDITION #3--PACKING ROOM CEILING INSULATED, VENTILATING FAN ON 1/3 OF TIME AND OFF 2/3 OF TIME, =I PACKING ROOM TEMPERATURE 60°F. CONDITION #4--PACKING ROOM CEILING INSULATED, VENTILATING FAN OFF, PACKING ROOM TEMPERATURE 60°F. CONDITION #5--PACKING ROOM CEILING INSULATED, VENTILATING FAN OFF, PACKING ROOM TEMPERATURE 40°F, 900+ 800 + ~S 700 500+ Condition #3 9 400K Sf — Fen 300 F Office load only -5 0) 5 10 15°) 20°" 25.) 30° 35° “40>. (745 OUTSIDE TEMPERATURE (°F.) U.S. DEPARTMENT OF AGRICULTURE NEG. AMS 131-61(11) AGRICULTURAL MARKETING SERVICE FIGURE 39 tet in operation is shown. This last line represents the heating re- quirements for the plant when the packing room is not in operation. The curves show that the heat from the refrigeration system is adequate to handle the office and daytime packing room load down to an outside temperature of 40° F., to handle the average operating period load down to 35° F., to handle the office and nighttime packing room load down to 26.5° F., and to handle the office and nonoperating packing room load down to 7.5°F. The heat available is adequate to handle the office load at all times. There are several possibilities for making the best use of the heat from the storage and these possibilities shall be designated as Systems A, B, and C. System A discharges the heat from the refrigeration system to the packing room only, through an air-cooled condenser coil, and would allow the eKmination of one gas heater. The other heaters would be used during periods when maximum heat was required. Although this system is quite simple, one very major change from the system originally specified is required. Ammonia refrigerant in a condensing coil that discharges air into a space where a number of people are at work creates a serious hazard. This can be avoided by the use of a Freon-12 refrigerating system. System B uses the heat from the cold storage to heat the office and as much of the packing room as possible, with supple- mental packing room heating by fewer gas heaters. System B would use panels heated by pipes in the floor and in the partition wall between packing room and offices. A comparison was made for performance and installation costs when the pipes carry either the refrigerant condensing directly in the pipes, or water which has been passed through a Shell and tube condenser, to transfer the heat from the condensing refrigerant to the water, which eventually conveys the heat to the panels. The panels are adequate for all heating in the offices. In the packing room the panels are located beneath the packing and sorting stations only. System C is similar to system B, except that supplemental heat is secured by operating idle portions of the refrigeration system on a reverse-cycle or heat-pump system. All heat will be discharged through the heating panels. When supplemental heat is required, the smallest compressor is all that is needed to refrigerate the storage. The two larger compressors and the evaporative condensers will be idle. They can be used as a heat pump to pick up heat at a low temperature level from the outside air and discharge this heat at a high temperature level inside to provide the required supplemental heat in the packing room. It was found that at an outdoor temperature of —5° F., there is sufficient capacity for the average 24-hour needs in the packing room. Since a floor-panel system has a large heat storage capacity, it seems reasonable to balance the system capacity against the average 24-hour period of 8 hours operation with the ventilating fan on, and 16 hours with it off. When the outside temperature is +10° F. or lower, the system will operate on compound compression using the middle-size compressor as the second-stage machine, which will handle the discharge from the first, or low-stage, machine or machines. This compressor will also handle the refrigeration of the storage, because the interstage pressure will be very close to the suction pressure required for the storage rooms. Above 20° F. outside temperature, the low-stage machine can be cut off, and the heat pump system operated on simple compression. A condensing coil in the defrost water tank will heat the defrost water. As in system B, a comparison was made for the performance and installation costs when the pipes in the heating panels carry either the refrigerant condensing directly or water that has been heated in a shell and tube condenser (i.e., an indirect system). In systems B and C, where direct condensing is used, ammonia has been retained as the refrigerant because, with the refrigerant carried in full-weight iron pipe encased in concrete, the leakage hazard was slight, and the safety hazards were similar to those encountered with a direct-expansion ice-skating rink. A number of such rinks have been built. To investigate the economic feasibility of these systems, an analysis was made of the cost of heating the packing room and office with gas. The packing room heating cost was based on actual days of operation, p. 34; office heating cost was based on the full season (September to March). These costs were then compared with the cost of heating with heat rejected from the refrigeration system, supplemental gas heat for systems A and B, and for supplemental heat from the heat pump for system C. Under systems A and B, the refrigeration equipment operates at somewhat higher condensing temperature than when operated as a straight refrigeration system, and requires more horse- power per ton of refrigeration. The cost of the heat derived from the refrigeration of the storage has been calculated by charging the extra power requirement against the heating operation. Using 80° F. condensing temperature as a normal average winter condensing temperature, operating at 96° F. condensing tempera- ture for the direct condensing systems involves an increase of 0.24 brake horsepower (b. hp.) per T. R. Operating at 105° F. condensing temperature for the indirect systems necessitates an increase of 0.35 b. hp./T.R. In addition, the indirect system must bear the cost of operating pumps to circulate the heat transfer medium. To estimate the cost of supplemental heat for systems A and B. and to estimate the cost of producing heat from the heat pump with system C, it was necessary to use some weather data that is not available from the Heating, Ventilating, Air Conditioning Guide (see Bibliography, reference 1). Fortunately, weather data for more than a 40-year period is available for Yakima. To minimize the\labor of developing this data, a record for the given month was selected that most nearly approximated the average temperature and number of degree-days for that month. Records for typical months from September through March were analyzed. The temperature scale was divided into 5-degree increments from —10° to 65° F. The average temperature for each day during the month was calculated as the average of the maximum and the minimum and the number of days with average temperature in each 5 degree division of the temperature scale was noted for each month. From this, the percentage of time ina given division of the temperature scale was calculated. Also the number of degree days below any required temperature base could be calculated. This latter information was used in deter- mining the amount of supplemental gas heat required for systems A and B. For system C the equipment balance points for output, heat requirements, and power requirements were determined for outside temperatures at —5°, 10°, and 20° F, and the cost of heat per 100,000 B.t.u. was determined at each point. These values were plotted on figure 40 to form a curve that showed a cost that decreased as outside temperatures increased until a minimum was reached at the point where heat from the storage was ade- quate to handle the load. At temperatures above this point, the cost of heat produced was constant. From this curve, the average cost of heat was determined for each temperature increment that had been used in the weather analysis. This cost was multiplied by the percentage of time in the increment and the sum of these products for each month yielded an average cost of heat for a particular month. This type of analysis was applied to both the direct and in- direct condensing systems and the values are plotted on figure 41. Also shown on this figure are costs for a direct condensing system during December, January, and February when the weather is colder than average. The January values are for the coldest month on record in this locality. These calculations are for January 1950, February 1950, and December 1951. 37 COST OF HEAT FOR SYSTEM C With Indirect and Direct Condensing Systems and Outside Temperature Range from -10° to 40° F. COST PER 100,000 B.t.u. OF OUTPUT (DOLLARS) -10 O 10 Indirect system Ve fe Direct condensing system 20 30 40 50 OUTSIDE TEMPERATURE-°F. U., S| DEPARTMENT OF AGRICULTURE NEG. AMS 127-61 (11) AGRICULTURAL MARKETING SERVICE Ficure 40 These values indicate just how severely the cost of producing the required heat would be affected by “unusual” weather, but for the purposes of this analysis the figures from the normal months are used. The heating cost per season was determined as shown in the calculations below by using the average cost of heat for a given normal month from figure 41 and the number of degree-days for the month. The difference between the heating cost for the season with gas and for heating with the various other systems has been cal- culated. This difference has been divided by 15 percent to determine investment that may be justified by the annual saving of operational costs. This percentage has been used previously to represent the total of fixed costs on refrigeration and heating equipment. The cost of gas heating equipment eliminated by each system has been added to the investment, justified by savings, to give the total investment allowable for each system, and these total figures are shown in table 9. Included in the table are the figures for the design arrangement where natural gas is the fuel, and figures for installations remote from gas service where LPG would be used. Table 10 estimates the cost of installing the major items of additional equipment required for each of the various systems. 38 A comparison of the equipment estimates in table 10 with the amounts justifiable in table 9 shows that when natural gas is available the indirect condensing system connot be justi- fied, the direct system using the heat pump for supplemental heat cannot be justified, and the investments and benefits for systems A and B are only a little better than break-even. When LPG is used, system C will break even on a direct condensing system, but is not justified on an indirect system; systems A and B offer substantial savings. The annual net savings, over and above fixed charges, are calculated in table 11 for the circumstances where there will be a net saving. From this tabulation it appears that where LPG is the fuel, direct condensing, with system B is the best selec- tion. It offers the greatest annual return on the net investment. The comparison between the direct and indirect versions of system B is also of interest. The indirect system requires more equipment and has a higher operating cost, because of the higher condensing temperature required for its operation. Although the first handicap is the more serious, both cut the net annual savings to a quarter of that of the direct condensing ar- rangement of system B. When natural gas is available, it does not appear that even the saving available with system B operat- ing on direct condensing is sufficient to recommend its use in the standard plant layout. COST PER 100,000 B.+t.u. OF OUTPUT (DOLLARS ) 10 Indirect system - .08 normal weather \ .06 Direct condensing system- normal weather 04 \ 02 SERIA “OCT. NOV, U.S DEPARTMENT OF AGRICULTURE AVERAGE COST OF HEAT FOR EACH MONTH OF HEATING SEASON WITH SYSTEM C NEG, AMS 128-61 (11) AGRICULTURAL MARKETING SERVICE Direct condensing system- extreme weather conditions we FIGURE 41 Calculations determining the feasibility of using heat rejected from the cold storage in the 200,000-box plant are based on: Storage rooms—2 each with inside measurement 135 x 98 x 21 ft. under trusses and outside measurement of 199 x 136 ft. Floor area=28,000 sq. ft. Cubic content beneath trusses=570,000 cu. ft. Ceiling insulated for U=0.0237 Walls insulated for U=0.043 Floor uninsulated having heat flow 1.25 B.t.u./sq. ft./hr. during January Figure 8 percent extra area on roof Figure storage 34 full during January Figure fruit respiring at the rate of 660 B.t.u./day/ton of fruit Figure annual fixed charges on refrigeration equipment=15 percent Figure average power cost at $0.015/kw.-hr.—subject to 14 percent discount for months when maximum plant demand is over 100 hp. Figure natural gas cost at $0.10/therm (100,000 B.t.u. input) Average seasonal efficiency of gas heating apparatus 80 percent Cost of heat per 100,000 B.t.u. output=$0.125 Figure oil cost at $0.165/gal.; 140,000 B.t.u./gal. Average seasonal efficiency of oil heating apparatus 70 percent Cost of heat per 100,000 B.t.u. output=$0.168 Figure LPG at $0.18/gal.; 92,500 B.t.u./gal. Average seasonal efficiency of heating apparatus 80 percent Cost of heat per 100,000 B.t.u. output=$0.243 Heating load design conditions as set forth earlier in the ap- pendix in the section, “Economic Analyses of Wall and Ceil- ing Insulation in Packing Room and Office Space.” Size of packing room 99 x 220 x 17 ft. under roof deck. Size of office 99 x 16 x 10 ft. under roof. Packing room ventilation fan capacity 6,000 c.f.m.—operated during working hours only in winter. During non-working hours figure infiltration at rate of 200 cu. ft./hr./ft. of crack around a total of 92 ft. perimeter for 3 doors=18,400 c.f./hr. Calculations to determine heat available under winter design conditions with outside temperature to —5° F., outside design condition; to +12.5° F., lowest average January temperature on record; and to 27.7° F., average January temperature are given in the tabulation below: TABLE 9.—Investment that can be justified to heat packing room and offices in winter with heat rejected by refrigeration system and from reverse cycle operation of idle refrigeration equipment for the 200,000-box storage TABLE 10.—Estimated cost of additional equipment required for heating packing room and offices of a 200,000-box capacity apple storage and packinghouse with heat rejected from the refrigeration system Direct condensing | Indirect heating (96° condenser (105° condenser System temperature) temperature) Nat. gas Nat, gas | L.P. gas 4 Dollars Dollars | Dollars A—Heating packing room only by using air cooled condenser to reject heat from storage...... 2,520 | 4,490 [......... Re ater B—Heating office and a portion of packing room by panel heating to reject heat from storage only and other part of heat in packing room sup- plied by gas heaters............... 4,540 | 7,350 | 4, 100 | 6,900 C—Heating office and packing room by panel heating to re- ject heat from storage and heat from reverse cycle oper- ation of refrigeration equip- ment normally idle in winter. No supplemental gas heat required... ie | 5, 640 ie 670 | 4, 733 | 7, 767 Direct Indirect condensing} heating System Dollars | Dollars 2, 000 500 2,500 B—7100'-1” piping @ 50c per ft 3,550 3,550 Controls... J 750 750 Condenser UNG R: 1, 600 200 ; 6, 100 C—12500'-1" piping @ 50c per ft.. 6, 250 6, 250 Defrost water heating coil 150 150 Controls D. X. gas cooled and alteration to evaporative condensers........ Condenser 2, 000 2,000 N. R. 4, 000 350 1N. R. means “Not Required” TABLE 11.—Annual savings from use of heat rejected from refrigeration system Costs | Net System Fuel compared Net investment Gas heat annual cost savings Fixed! | Operating Total Dollars Dollars Dollars Dollars Dollars Dollars PAT (direct)istsecsecsseccscct 2,500-800 = 1,700 255 384 639 937 298 B (direct). 4,300-2,100 = 2,200 330 150 480 937 457 B (direct). 4,300-2,100 = 2,200 330 116 446 482 56 B (indirect). *100-2.100 = 4.000 600 216 816 937 121 C (direct) Riera 4.960 744 152 896 937 41 1 Assumed to be 15 percent of net investment. Heat available per day at— Heatavallabletpendeyats —S°F, 12.5° F, 27.7° F. °F. 12.5°F. 27.7°F. Heat loss and gain from Bitte Hees ree Respiration of fruit Btu, Buu. Btu. conduction: 200,000*0.67*35x660 Ceiling=199136X1.08 = 2000. 1,480,000 1,480,000 1,480,000 X0.0237X24x(to—30)... 584, 000 292, 000 38, 250 Net heat available from Outside walls=21x520 evaporators —(at 96° F. X().043X24x(to 30)... — 394,500 —197, 250 —25, 900 camipresson Gnneratnre Part walls=21150 and 25° F, evaporator *0.043*24(60—30) 97,500 97,500 97,500 temperature, 236 B.t.u./ Floor=199X 1361.25 , : min./ton is rejected at QM ceeeecereeeteeeeene 812,500 812,500 812, 500 condenser)................. 3,180,500 3,862,750 4,455, 450 ah Add 18 percent for heat of Total transmission —68, 500 420,750 845, 850 COMPTESSOF..--..eeeesees ess 573,000 695,000 802, 000 Air leakage 570,000*0.24x(to —30) = by hae — 386,000 —193,000 —25,400 Lights=1 ,400x8x3.415...... 38, 200 38, 200 38, 200 Trucks working=4 hr.x10 hp'x25 do stereeecmre enero 101, 800 101, 800 101, 800 Fan motor load 28X2545x24 = Og te 2,015,000 2,015,000 2,015, 000 Total heat available per Cay) sect ccsssusacsastacotvesse 3,753,500 4,557,750 5, 257,450 hOUfssetissvecessstresen tees ees . 156, 500 190, 000 219, 000 Calculate heat required for defrosting—heat four tank loads per day from 40° to 55°=4x224 cu. ft. X62.4 (55—40)=839,000 B.t.u./day On average hourly basis=35,000 B.t.u./hr. Deduct this from values calculated for heat rejected from cold storage refrigeration system and plot as net heat available from cold storage (fig. 39). At —5° F. outside; net heat =156,500—35,000=121,500 B.t.u./hr, At 12.5° outside: net heat =190,000—35,000=155,000 B.t.u./hr. At 27.7° outside: net heat_ =219,000—35,000=184,000 B.t.u./hr. Calculation of heat required by packing room with and without ventilating fan in operation for outside temperatures of —5° and +25° F. is: Heat required per hour at — -s° F +25° F Bru Baw Conduction losses: Ceiling=99X220*0.32*(60— to)... 453, 500 244, 000 Floor=99X220x0.1X(60—52)...........- 17, 500 17, 500 Storage room walls=17*150x0.043 MOU — SU) ecueeciecrevestaescs SSEROO 3, 200 3, 200 Outside wall: 17*389=6610 7x 9V= 693 7303X0.19X(60—to).....00.- 90, 200 48, 600 Total heat loss by conduction 564, 400 313, 300 Infiltration during non-working hrs. 18,400%0,24x(60— to) am OPEL OL 21, 700 11, 700 13.2 Total load during nonworking Htsens ee Infiltration when ventilating fan is op- 6,000x60x0.24x(60—to) 586, 100 325, 000 erating=————q3 5S Mech 426, 000 229, 000 Total load with ventilating fan OPEratin genset: eeteececatsnerees 990, 400 542, 300 Average daily load with ventilating fan operating 8 hours —off 16 hours......... 720, 600 397, 500 If ceiling is insulated with 3 layers of reflective material to attain U=0.086, then the above calculated loads are revised as follows: Heat required per hour at— —Surs +25°:F; Btu Btu Deduct from above calculations: Ceiling loss = 99x220x(60— to)x(0.32 — 02086). st esfscsctasscenatsssecsuestas sat —332,000 —178, 500 Revised total heat loss without venti- lator fan ci 254, 100 146, 500 Revised total heat loss inc tilation(etsssceeesistevsecsanseossvesacters 658, 400 363, 800 Revised average daily heat loss with fan operating 8 hours—off 16 HOLS etre aeercoeeneee castes scmecerrcecres 389, 000 218, 900 Calculate heat requirement for packing room when it is not in use and is maintained at 40° F. and ventilating fan is off, for to =—5° and to=+25°F. vv Heat required per hour at— —Sc.F. +25° F. Btu, B.tu. Conduction losses: Ceiling=99X220X0.086(40— to) 84, 400 28, 100 Floor=99X220x0.1X(40—52).........600 —26,100 —26, 100 Storage room walls 17x1500.043 x(40—30)...... HoDneRS baoxcidrorcneracodtic 1, 100 1, 100 Outside walls=7303X0.19X(40— to) 62, 400 20, 800 Total conduction loss............... 121, 800 23, 900 ; 18,4000, 24<(40— to) Infiltration=——{, —- ——_ Ticats 15, 100 5, 000 Total heat loss........ : 136, 900 28, 900 Calculation of ofice heating load when outside temperature drops to =—S° Ff. 25° F. and 60° F. Heat required per hour at— OU. 25° F. 60° F. Conduction losses: Batu Batu. Btu Ceiling=16*99X0.0395x(70— to) 4,700 2,820 630 Floor=16X99X0.1X(70—52)........665 1,600 1,600 1,600 Windows=11¢x1.13x(70— to) 14,740 8,850 1,970 Outside walls=10*131= 1310 174 1136X0.138X(70— to) .......ceecceees 13,350 7,060 1,570 Inside walls=10*99X0.3x(70—40) 8,900 8, 900 Total transmission...............55 43,490 29,230 5,770 Ventilation (1 air change per hr.) 15,840x0.24«(70— eo LOOT ITE 21,600 12,950 2, 880 Total heat requirement 65,090 42,180 8,650 On figure 39 are plotted five conditions: Heat available from the storage vs. outside temperature; the heat requirement of the packing room without ceiling insulation and with ventilation fan in operation vs. outside temperature; the heat requirement of the packing room with ceiling insulation with and without the venti- lating fan in operation vs. outside temperature; average heat load of the packing room when ventilating fan is on one-third of the time and off two-thirds of the time vs. outside temperature; and the heat requirement of the packing room maintained at 40° F. without the ventilating fan in operation ys. outside temperature. Also plotted is the heat requirement of the office vs. outside temperature, and to each of the foregoing curves for packing room heat requirement, the office heat requirement was added and plotted as total heat requirement vs. outside temperature. Total heat available from storage balances the combined office and packing room load at 46° F. outside temperature, when the packing room ceiling is uninsulated and the ventilating fan is in operation (condition 1 in fig. 39). This balance point drops to 40° F. when the packing room ceiling is insulated (condition 2 in fig. 39). Because both of these loads would occur only in the daytime (the load is considerably reduced at night), the defrost water would be heated at night, when extra heat is available. When panel heating is used, a large amount of heat is stored in the panels; so the balancing of the weighted average of the night and daytime loads against the net heat available from the system is reasonable. The net heat available and the total office and packing room load for condition 3 balance at 35° F. outside 39 temperature. When the packing room is not in operation, but is held at 40° F., the net heat available to heat the office and maintain this condition in the packing room balances the load at 7.5° F. (condition 5 in fig. 39). Cost Comparison WiTH NATURAL GAs.—Base consumption of heat in the packing room on the number of degree-days for the operating season is based on assumptions given in the section, “Economic Analyses of Wall and Ceiling Insulation.” Weighted average of day and night design loads were used for figuring fuel consumption costs given below: Office heating cost was computed as follows: $0.100,0043%0.09375%5,585X65=$146 (formula from Heating, Ventilating, Air Conditioning Guide, Bibliography, reference 1, applied to design load of 65,000 B.t.u./hr. and 5,585 degree-day season) Packing room heating during operating period was computed as follows: 389,000%24%1,667X0.10 389,000%24x1,6670.10_ 65x0.8%100,000 300. Packing room heating during nonoperating period calculated on the basis of heat loss per degree Td. times the difference between 40 and the average monthly temperature times the number of nonoperating days in the month. Months are November, December, January, and February. Td. for Nov.=40—39=1; Number of nonoperating days=16 for Dec.=40—31.3=8.7; Number of nonoperating days=17 Td. for Jan.=40—27.7=12.3; Number of nonoperating days=13 Td. for Feb.=40—35.2=4.8; Number of nonoperating days=14 Cost of heat= 136,900%24%[(16% 1} 178.7}4+-(13X12.3}114%4.8)]x$0.10 (40—5)x0.8100,000 Total season’s gas heating costs $146+$300+$36=$482. 0.243 With LPG the cost equals 0.195% 2482=$937 Calculate cost of season's heat system A, which discharges heat from storage through an air cooled condenser in the packing room. The office is heated by gas, and gas heaters supply sup- plemental heat in the packing room. The air-cooled condenser capacity was selected to equal the balance point of the daytime packing room load and the total heat available from this system. In figure 39, this capacity equals 240,000 B.t.u./hr. output =e T.R. from the evaporator. A condenser suitable for a 17-ton system with 60° F. air and 96° condensing tempera- ture was selected and cost approximately $2,000 installed. The net heat available from the system balanced the average packing room operating load at 30° F., and it balances the packing room nonoperating load at —2.5°. In figuring heating costs, it was assumed that all of the nonoperating period would be handled by the heat from the refrigeration system, and that heat- ing down to 30° in the operating period would be delivered by the refrigerating system, Cost of heat rejected from the refrigeration system is the extra Power cost occasioned by operating at a higher condensing tem- perature than is normal for the winter operation. Use 80° C.T. (condenser temperature) as normal winter operation. For direct condensing systems, use 96° C.T., and for indirect heating systems use 105° C.T. On the winter load the evaporators in the room will balance out the room load with approximately 30° room and 27.5° E.T. (evaporator temperature). Determine the capac- ity, b. hp. and b. hp./T.R. for this small compressor at 27.5° E.T. and the various condensing temperatures specified above to establish the extra b. hp./T.R. occasioned by the higher con- densing temperatures. These are listed in the following tabulation: 40 Normal Heat by refrigeration direct Indirect system condensing heating 80°F. 96°F. 105° F 18.9 17.4 16.8 Condenser temperature (C.T.).. Tons of refrigeration (T.R.) behpsesne 15.5 18.45 19.6 b. hp/ton F 0. 82 1. 06 117, Added b. hp./T.R. due to higher | SCR errr ret RIGS EEEPPERST Neca oes nt 0. 24 0.35 Cost per 100,000 B.t.u. output with direct condensing is: 100,000*0,24x0.746*$0.015 60X236x0,85 $0,022. Cost of season’s heat with system “A” are: Gas heating of office as per previous calculations............ $146 Supplemental gas heat in packing room for 129 days in operating season below 30° base __389,000x24129x0.10 23 ~~ 65X0.8X100,000 ee senses seceseccesces beens cescaseccnes Heating by refrigeration system in operating period for 1538 degree-days above 30° base _ 389,000*24«1538x0.022 65X100,000 tte tee cteeeeeeteeteeeneeees Heating by refrigeration during non-operating period 136,900%24x[(16X1)}H17x8.7}4{13X12.3H(14*4.8)]x$0.022 45x 100,000 49 With LPG for supplemental heat: Cost of season’s heating= __(146+23)x $0,243 Ce=— 20,125 Refrigeration=49+6 $384 Annual savings compared with all LPG heat=$937—384 =$553. This installation also will eliminate one large gas heater in packing room and save $800. Investment justified when natural gas is used 258 | =9,15 + $800=1720+800=$2520, Investment justified when LPG is used = 772+ 800 =3690+800=$4490. Calculate the cost of a season’s heat with system B, direct condensing, which discharges heat from the storage through panel heating coils in office and packing room floor and in a partition between office and packing room. Gas heaters supply supplemental heat to the packing room in extreme weather. The net heat available from the system balances the average daily operating load down to 35° outside temperature for office and packing room, and balances office and nonoperating packing room load down to 7.5° outside temperature. Capacity of gas heaters for supplemental heating will equal approximately 330,000 B.t.u./hr. Capacity required for all gas heating is 660,000 B.t.u./hr. Savings in heater investment = $1,300 in packing room and $800 in ofice — $2,100. Cost of heating office entirely by rejected heat from refrigeration: 65,090*24.x5585x$0.022 $26 (75) 100,000 Heating by refrigeration for 1,484 degree days above 35° base during operating season in packing room: 389,000X24x1484x$0.022 G5X100,000 9 tteestteeesceeeeestesteeeeeseeereees Heating by refrigeration during nonoperating period (from previous calculations)... 2... eeeccescscees, $6 Supplemental gas heating for 183 degree-days below 35° base during operating period: 389,000*24x183x$0.10 : SeEGSXUERIOD VUDMES TE et ee $33 Supplemental gas heating for the packing room during the nonoperating season estimated at 10 percent of all gas heating for this portion of load Total season’s cost with natural gas for s hGH ssrtitres cer er eee le ete If LPG is used for the supplemental heat, the gas heat (33 +3)x0.243 — 0195 cost required = = $70. Total season’s heating cost with LPG supplementing=$80 +$70=$150. Annual savings in fuel cost compared with natural gas = $482 —$116=$366. Annual saving in fuel compared with LPG =$937— $150 = $787 Investment that can be justified when natural gas is available = $366 + 99 .100=$2,440-+ 82,100=84.540. Investment that can be justified when LPG is to be used as a fuel = $757 4 §2.100=$5 250+ $2,100= $7,350. To discharge the heat rejected by the refrigeration system approximately 920 ft. of l-inch condensing coil in partition wall, 1,500 ft. in office floor, and 468 ft. in the packing room floor for a total of 7,100 ft. of l-inch pipe are required, To calculate the cost of a season's heat with System B— indirect heating, circulating warm water through the pipes in the floor panels and heating the water by condensing the re- frigerant in a shell and tube condenser—select condenser to balance total heat rejection at 35° F. outside temperature= 233,000 233,000 B.t.u./hr. =o a = 16-ton condenser; select condenser for average water temperature of 96° F., cir- culate 5 g.p.m./ton, and 6° F. temperature range (or 80 g.p.m. of water on at 93°—off at 99°): select condenser for leaving ter- minal difference of 6° F=105° C.T.; and size of 8 sq. ft./ton or 128 sq. ft. Increased hp. above normal refrigeration system operating in winter—0.35 b. hp./ton; and also required is the operation of 1%-hp. water circulating pump. Compressor operating cost per 100,000 B.t.u./output _ 100,000*0.350.746x0.015 ere 0.0317. 60x242x0.85 yl Pump operating cost per 100,000 B.t.u./output — 1.5x0.746x0.015 Total cost per 100,000 B.t.u. outpute.....cccccccceeceeee. -0.0402. To obtain cost of season’s heating with system B indirect 0402 : heating apply factor of oe 1.82 to costs for portions of heat furnished by refrigeration system calculated for System “B” direct condensing: With natural gas for supplemental heating season’s heating cost = ($801.82) + $36 = $182. With LPG for supplemental heating season's heating cost = $146 + $70= $216. Annual saving in fuel consumption compared with natural gas = $482.00 — $182.00 = $300. Annual savings in fuel consumption compared with LPG = $937.00 — $216.00 = $721. Investment that can be justified when natural gas is available: ms $2,100 = $2,000 + $2,100 = $4,100. Investment that can be justified when LPG is to be used as fuel: _ 8721 0.15 With system C, reverse-cycle operation of idle refrigerating equipment is used to obtain the required supplemental heat from the outside air. Evaporative condensers are used as dry coil evaporators to pick up heat from outside air. Capacity of each unit is approximately 10 T.R. at 20° F. Td. between air and re- frigerant. Using compound compression arrangement with largest and smallest compressors on low-stage duty and middle- size compressor to handle second stage duty, plus the load from the storages, under design condition of —5° F. outside tem- perature, the equipment balances out at —29° F. evaporator temperature with 24.5 T.R. from the evaporators. With heat of compression, this amounts to 28.7 T.R. for the second stage compressor. Add to this 11 T.R. from the storage, at this outside design condition, giving a total load of 39.7 T.R. for the second stage compressor. Balance point between low and high stages approximately 20° F. intermediate temperature, Heat rejected per hour from second state = 39.7X236x60 = 562,000 B.t.u./hr. From figure 39 the average hourly heat requirement for office and packing room at — 5° outside temperature is 454,000 B.t.u./hr. The capacity is such that 35,000 B.t.u./hr. defrost heating re quirement can be met and also allow 2 to 3 hours shutdown time for defrosting reverse cycle evaporators. Two tanks of defrost water are used. Heating coil fed from discharge line for defrost water heating is used. At 10° outside temperature, operate the reverse cycle system on compound compression, but let storage operate independently on small compressor. Operate evaporative condenser fans at low speed. Let large compressor run at 50-percent capacity and balance evaporators at — 12° F. evaporator temperature to pick up 15 TLR. which will constitute a load of 18 T.R. on the sec: ond stage machine. Let second-stage compressor run at one- third capacity at 30° F. intermediate temperature for its suction, At 20° outside temperature, operate the reverse cycle system on simple compression; the middle-size compressor at one-third capacity will produce 9.5 ton at 7,5° E.T. where it balances the two evaporators. The heat produced by the system, the hp. and the various com- ponents, the power chargeable to the heating operation, and the cost per 100,000 B.t.u. output at the foregoing balance points are tabulated below. The condition for 35° F. outside temperature, where the heat from the refrigeration system is adequate for the heating duty, is also shown. +$2,100 = $4,800 + $2,100 = $6,900. Outside temperature... —5° F. +10° F. +20°F. +35°F. Total heat from refrig- eration system — B:tiu./ hits s.crayscreserecs 156,500 186,000 204,000 233,000 Heat from reverse cycle operation— B.t.u./hr 255,000 134,000 ........... B.t.u./hr 562,000 441,000 338,000 233, 000 Deduct heat to defrost storage room evaporators and reverse cycle evaporators — Bittu./hicee-er street 52,000 52,000 43,000 35,000 Net heat available for load —B.t.u./hr........, 510,000 389,000 295, 000 198, 000 Calculated average hourly load—B.t.u./ 454,000 357,000 292,000 197, 000 Hp. on auxiliaries for heating system —h.p.. 15.0 5.0 OD Obeeesseceess Actual hp. on refrigera- tion system—hp....... a 14.2 16.2 18.4 Hp. on low stage compressor—hp....... 28.9 14s Optreccsier sand teretesssees Hp. on high stage compressor —hp....... 49.7 18.0 14.5 sesseeeeeee Motaliipascvcsscoiscee 93.6 Dle2 Bos, 18.4 Deduct hp. required for refrigeration at normal operation...... 9.0 11.0 13.0 14.3 Net hp. for heating — 84.6 40.2 22.7 4.1 Cost per 100,000 B.t.u. produced............... 230.188 20.117 0.101 0. 027 ' Included in high-stage compressor hp. ? For conditions of 10° F. and lower, figure 14-percent discount on power rate as total load will put power consumption into a different discount bracket. Cost per 100,000 B.t.u. output at —5° F. outside temperature. 84.6x0.746%0.0150.86* 100,000 0.85510,000 =$0.188. These values are plotted on figure 40 and, with the weather data on table 12, determine the average monthly cost of heat delivered with system C. Typical average monthly cost of heat calculation is given below for typical month (January 1951 in table 12). Cost of — Percent of Product of Average daily temperature heat | time? col. 2&3 SitoelOsmerenaieaeycatacinssecnedscses cies si $0. 129 9.7 $0.0125 0.113 3.2 0.0036 0. 105 3.2 0.0034 0. 0875 6.5 0.0057 25 to 30.. 0. 0625 22.6 0.0141 30 to 38 0. 038 32.3 0.0123 35 to 40. 0. 027 19.4 0, 0052 40 to 45, 0, 027 3.2 0.0009 Average monthly cost/100,000 B.t.u................ 0.0577 ‘Taken from figure 40. 2 Taken from table 12. Values similarly determined for other months are plotted in figure 41. The season's heating cost with system C, direct condensing, is given below. Packing room —operating period—use heating costs from figure 41 and number of operating degree-days assumed in sec- tion, ‘Economic Analyses of Wall and Ceiling Insulation.” 389,00024(10 + 160)$0.027 Sept. & Oct. 65x100000. $6. 60 Non, BLOODLINES 0.50 Dec, < LANDS. 21.10 Jan ee Mat teee eae 42.20 Fel ae 15.80 Ma oe) at a $0.02 EE ee ee a 5. 80 Total for operating season................00.0 000.0000 102. 00 For nonoperating period practically entire load will be carried by heat from refrigeration system only—use same figures as for system B. Total packing room heating cost...................05 108. 00 Office heating cost—figure months of Dec., Jan., Feb., and Mar., at average cost of heat prevailing for each month. Figure rest of heating season at $0.027/100,000 B.t.u. since heat from storage is adequate for the requirement in other months. 65,090*24x 1050*0,0439 Dec 75x100,000 rites $9. 60 J 65,090*24x1125x0,0577 13.50 an.= T5x100,.000 ite tttetitteeeetesteses Bb 65,090*24837x0.0388 a Feb. = ——75x100,000 retrecseeeee 6.50 _ 65,090*24-*624x0,0273 Mar = ~"75%100,000 ane 1949 65,090*24*(5585 — 3636)0.027 Other months 75x100000...° 11.00 Total office heat cost ba Total packing room heating cost.... 108. 00 Total season's heating CoSt...........c0scsseessseeeneee Annual savings compared to natural gas = $482.00 —$152.00= $330.00. Annual savings compared to LPG =$937.00— 152.00 = $785.00 Use of system C eliminates $2,640 from packing room heating investment and $800 for office. Total = $3,440. Investment that can be justified when natural gas is available: _ 330 0.15 + 3,440 = 2,200 + 3,440 = $5,640. Investment that can be justified if LPG is to be used: = 82. + 3440 = 5230+ 3440= 88670. To operate as outlined for system C requires the installation of a direct-expansion gas cooler between the low and high stage machines, a suction trap, float valve, connections and valves. The two evaporative condensers may be operated as evaporators when required. Also needed are a control system to actuate the proper portions of the machinery when supplemental heat is required, a water heating coil in the defrost tank, and condens- ing coils in the floors of the office and packing room totaling 72,500 ft. of l-inch pipe. For system C, indirect heating, a shell and tube condenser is installed to condense the refrigerant and heat the water circulated through the floor panels. The condenser selected for the system output at — 5° F. outside temperature = 562,000 B.t.u./hr. which represents 39.5 tons input to second stage. Using 8 sq. ft./ton will require approximately 320 sq. ft. of surface. Circulate 5 g.p.m./ton—or 200 g.p.m. on at 93° F., off at 99°—leaving terminal difference of 6°, condensing temperature = 105°. A 5-hp. circulation pump was selected for 200 g.p.m. at 50 ft. head. Average monthly output costs are obtained in the same manner as with the direct condensing system. The amount of heat pro- duced at the various balance points is about the same as for the direct condensing system but the power inputs are high due to higher condensing temperature and more auxiliary power being required. In the tabulation below are listed heat outputs and require- ments, power requirements, and cost of heat production at various outside conditions for system C, indirect heating: Outside temperature — elves Total heat from re- frigeration system — Bitiui/hirereccesceacsoseee 156,500 186,000 204,000 233,000 Heat from reverse cycle operation—B.t.u./ ite fcssscattngestaceeredastt 417,000 259,000 137,000 ........... bi) +10 +20 +35 TABLE 12.—Analysis of weather data at Yakima, Wash., to determine normal number of days and percentage of time in each month during packing season in average temperature brackets of 5 degrees progressing from —10 to +70 ° Normal months Average daily Lower than normal months temperatures Sept. 1951 Oct. 1947 Noy. 1950 Dec. 1952 Jan. 1951 Feb, 1951 Mar. 1949 | Dec. 1951 | Jan, 1950 LE Days Days) Pct. -10 to —5 Re es 6 Ads —5 to 0. Oto 5... 5 to 10.. 10 tol5... 15 to 20 20 to 25 25 to 30... 30 to 35 35 to 40. 40 t0 45. 45 to 50. -4 : : d 50 to 55. : : Bed tea be 55 to 60. i 5 60 to 65. 65 to 70... HK ASrNeE Hw Pet, |Days) Pct. |Days| Pet. |Days} Pct. |Days| Pct. Ae plbas a cedescoacsra| iL 2 Recorded degree- Gays.i sec: csesssceese 125 Normal degree- GAYS te sieeasscoris 125 Recorded average temperature (°F).. 61.6 Normal average temperature (°F).. 62.6 Total heat available — Bitau/ bers eeteaiserserase 573,500 445,000 341,000 233, 000 Deduct heat required to defrost storage room evaporators and re- verse cycle evapora- tors—B.t.u./hr......... 52,000 52,000 43,000 35,000 Net heat available for load—B.t.u./hr....-.... 521,500 393,000 298,000 198, 000 Calculated average hourly load —B.t.u./ Wiriscreccees ronerdusrasaane 454,000 357,000 292,000 197,000 Hp. on auxiliaries for heating system — 1 Sheceeasareerers i 20.0 10.0 10.0 5.0 Actual hp. on refrigera- tion system—hp....... .....06- 15.1 16.6 19.0 Hp. on low stage com- pressor —hp...........- 28.4 GEA De covece ce cmitsesset ees: Hp. on high stage compressor—hp....... pe | 20.7 15.5 se-seeeee Total hip:. :e.cs:-sscccssesaa 103. 5 60, 2 42.1 24.0 Deduct hp. required for refrigeration at nor- mal operation—hp.... 9.0 11.0 13.0 14.3 Net hp. for heating — Hpi cepesianasvassteeunscsos 94.5 49, 2 29.1 9.7 Cost per 100,000 B.t.u. produced............++.- 80.205 $0.142 380.129 30.064 These values are plotted on figure 40 and then in the same manner as used for system C for direct condensing; the average monthly cost of heat delivered by the system was determined and plotted on figure 41. Season's operating cost for indirect heating with system Cc was calculated by adjusting previously obtained monthly costs in proportion to cost of heat for the month for the two systems. Packing room Ruereune period: Sept. & Ger = PPE 6.60=815.60 Nov= 2070X10.50=22.60 Dee. = Ter x2 10=38.40 Jan =2-0277 <42,20=67.00 Feb 20754 <15.80=30.70 “Mar = 6H x5, 80 13.70 188,00 Packing room nonoperating, period: 0.064 =9.007%0.00= 14.00 Total packing room heating cost=$202.00 Office heating cost: Dee. =< 9.60= 17.50 Jan = 00271 x13.50=21.50 Feb =O 6.50 12.60 Maret <3.40=8.10 Other months 0.064. 71 .00=26.30. 0.027 Total office heating cost=$86. Total season's cost of heating $288. 41 Annual savings, compared to natural gas: $482—$288=$194. Annual savings, compared to LPG: $937—$288=$649. Investment that can be justified when natural gas is available: 194 3440= 1293+-3440=$4733. 0.15 Investment that can be justified if LPG is to be used: 649 0.15 3440=4327+3440= 87767. Construction Cost Estimates for Three Packing and Storage Houses The estimated construction costs of the 50,000-, 100,000-, and 200,000-box packing and storage houses are given in table 13. These costs include lot and site preparation, construction costs, and installation of heating, plumbing, electrical, and refrigera- tion equipment. These estimates are for the Yakima, Wash. area, and could be materially changed by individual require- ments and location. The cost of the land is not included. These estimated costs are based on the construction cost index for Yakima as of January 1, 1961. Fire Insurance for Apple Packing and Storage Houses Fire insurance rates for the 100,000-box apple packing and storage house are listed in table 14, There is little difference in rate for a building with outside walls of certified hollow concrete blocks (8" thick or greater) or with walls of reinforced concrete (6" thick or greater). Minor rate differentials result when sub- stituting masonry walls of one type with masonry walls of another TABLE 13.—Estimated construction costs for three different size apple storage and packing houses type; great differences may occur when combustible walls (i.e., frame) are substituted for masonry. Assumptions are: Apples in storage valued at $3.75 per box. Storage capacity equal to 100,000 standard boxes having a total value of $375,000. Length of storage period is assumed to be 6 months. Insurance on packing and storage house worth $200,000; this represents 80 percent of insurable value. Rates are for State of Washington only; promulgated by Wash- ington Surveying and Rating Bureau and based on its review of drawings and specifications for a 100,000-box storage and packinghouse. Bureau rates are tentative only and for the facilities under assumed conditions only. The premium calculations were performed for the above con- ditions and following Washington State rules for rating the build- ing with 80-percent coinsurance clause and the contents at 100 percent of value en a monthly reporting form basis. The fore- going allows 50 percent of values to be prorated and 50 percent to be short rated developing approximately 55 percent of the an- nual content premium for a 6-month storage period. Other monthly storage periods would not necessarily develop propor- tionate premium savings and would have to be calculated for each storage period. Fire insurance premiums based on the above assumptions are developed and presented in table 15 for class 3 and 9 locations and for different types of construction. Location, has a very significant influence on the size of pre- mium. The annual difference in premium for a 100,000-box plant is $5,600 minus $1,700 or $3,800 or approximately 4c per box saving by locating in a class 3 town as compared to a class 9 unprotected town. Comparison of the figures for the frame construction plant and the basic (masonry) plant indicates that, in a class 3 town, saving with masonry construction is $3,900 minus $1,700 or $2,206 1 i Item 50,000-box house 100,000-box house 200,000-box house Dollars Dollars Dollars Lot and site preparation: Site grading 150 150 300 Excavation and back fill. 300 350 490. Gravel fill.......... 700 970 1, 250 Asphalt paving... 2,370 2,530 8, 620 Rolled gravel (parking lot). 600 1,270 3,550 Septic tank and drain field 450 550 630 Dryiwellictviiscastesis ess 50 50 90 2" water tap and meter 170 170 170 Taxes, insurance, margin, etc., at 16 percent... 760 960 2, 400 5,550 | ———— 7,000 | ———— 17,500 Packing room: Foundation, walls, pilasters, floor, roof construction, roof ventilators, in- sulation, millwork, and painting, plus taxes, insurance, margin, etc., at 16 DENCENiscassosscanrcacererre nn sacvaraene cabs tats secisiece araianccechapvesturvestetss prssecteeet 53, 450 51, 490 93, 420 Office (floor cost included above) Walls, ceiling, millwork, painting, and vents plus taxes, insurance, margin, etemratelGjpercenthrencrt ccvce ccm stcscaver cee cacesencertarseracccistatapdedesseiseeseess 2,580 7,440 12, 300 Cold-storage room: Foundation, walls, pilasters, floor, roof construction, insulation, painting, doors, and catwalk plus taxes, insurance, margin, etc., at 16 percent......... 46, 720 78, 230 144, 070 Machine room: : Condenser platform, doors, machine mounts, painting, plus taxes, insurance, Marginwet Ce satel Ospercentirec: erences tevsicerstcecccssancsecccd sarees tsccreeccerescaeecss 1,770 1,770 3, 230 Covered area: Concrete floor, foundations, and steel work 9, 360 14, 200 27, 850 Heating 6,550 7, 820 8,970 Plumbing 1,900 2,070 2,530 Eee 7, 820 11, 730 15, 640 efrigeration. 20, g i 700 37, 950 69, 690 eR Ot alse steeser terns es en Ue esa rere ace ce coe pene ce fe wen Soe sae 156, 400 219, 700 395, 200 42 and in an unprotected town is $7,900 minus $5,600 or $2,300. The annual saving possible by using masonry construction in preference to frame construction is $2,000 in Washington towns. Use of an approved sprinkler system probably offers the greatest possible annual monetary saving. For example, savings in a class 3 town are $1,000 ($1,700-$700) and in an unprotected area savings amount to $4,800 ($5,600-$800). Using treated lumber roof construction in a class 3 town will save $400 ($1,700- $1,300) and in a class 9 area will save $2,000 ($5,600—$3,600). If incombustible insulation is applied directly to the roof deck and walls, the savings al a class 3 location amount to $50 ($1,700— $1,650) and at a class 9 location amount to $340 ($5,620-$5,280). It should be understood that to realize the savings indicated above, additional expenses may be incurred. Plant operators will need to make their own determinations as to whether the saving in premiums justifies the expense. Plant operators contemplating constructing a new packing and storage house or remodeling older houses should consult with their insurance company representative and have him review the plans for modification and a resulting lower insurance rate. TABLE 14.—Tentative insurance rates for building and contents per $100 for 100,000-box capacity apple storage and packinghouse for three risk categories, Washington State, 1960 Basic? Roof type for building and risk category ! B13 Bes B35 B4e Bldg. Contents Bldg. Contents Bldg. ~ | Contents Bldg. Contents Bldg. Contents. Building with combustible roof: 380% rates) isa. .tnesseccsesseaceder --| 0.264] 0.637 | 0.264) 0.637 | 0.262] 0.637] 0.247 | 0.628] 0.255 0. 637 6th (80% rates). 9th (flat rates)... A Building with incombustible roc .555 . 846 .555 . 846 555 . 846 .519 . 819 537 - 828 1.37 1.47 1.37 1.47 1. 36 1. 46 1. 28 1,41 1.32 1.44 3d (80% rates)... . 174 . 573 - 159 - 564 . 144 955 . 152 . 564 6th (80% rate - 328 - 683 . 229 - 701 . 269 . 64 . 286 - 655 Oth:(80% ‘rates):...:....--+0<. -919] 1.10 - 883 | 1.07 - 837 | 1.04 - 865 1. 06 ' Risk category is based on availability of adequate fire protection. * This is the plan of the 100,000-box capacity plant as indicated in the text of this report. * The basic plan, except that combustible insulation is used in roof space and combustible insulation is used in walls and partitions. *The basic plan, except that incombustible insulation is used combustible insulation is used in walls and/or partitions. 5 The basic plan, except that incombustible insulation is used incombustible insulation is used in walls and/or partitions. on roof deck and there is to be no roof space below roof deck and on roof deck and there is to be no roof space below roof deck and ® The basic plan, except that incombustible insulation is used on roof deck and there is to be no roof space below the roof deck and combustible insulation board is-used in walls and/or partitions with no interior sheathing or air space. 7 Roof is of wholly incombustible construction. Incombustible as referred to herein is a roof deck of unprotected metal supported by unprotected metal girders, beams, trusses, etc., and either masonry or unprotected metal vertical supports. In addition, the term incombustible includes a roof deck and all supporting members of fire-retardant impregnated wood. TABLE 15.—Comparison of tentative annual premiums for fire insurance for a 100,000-box capacity apple packing and storage house located in Washington State by the type of construction and class of protection! Type of construction and class of protection? Town Basic (masonry): ClassiNOn reece ences 02" Peel GV AKIIMNE) yen seteecisensenen sea GlassiNon Garcnesc: seceded: soceares= .| Unprotected..... Frame: Class:No. discs: Class No. 9.. Unprotected..... Basie with sprinkler: : Class No. 3.. [GNA Iria) eaestenseenines sea GlassiNonOseretesctasdsessecacaaczsuers .| Unprotected.. Basic with treated lumber roof Class No. 3..... Class No. 9.. Basic with incomb rectly to roof deck and walls: Class No. 3..... Class No. 9..... :| Unprotected .| Unprotected... (SNeakima)sroess see escenceeess (Wakimia)icrsseatseoee (Makima):coeanets.atecs Building * Contents * ———— — = Total premium Rate ® Premium Rate* Premium Dollars Dollars Dollars Dollars Dollars 0, 264 528 0. 573 1, 180 1, 708 ents 1.37 2, 740 1.40 2, 880 5, 620 . 946 1, 880 1.05 2, 160 3, 940 jeecdaatacnes 19% 3,940 1.90 3, 950 7, 890 . 160 320 . 190 390 710 . 190 380 - 216 425 805 . 144 288 . 500 1,030 1,318 . 837 1,674 - 970 2, 000 3, 674 . 247 495 - 565 1, 160 1,655 1. 28 2,560 1.34 - 2, 720 5, 280 'The rates and premiums shown here are tentative and are given for comparison purposes only. They are applicable to the specific building under consideration and are not necessarily the rates and premium which would be charged for any other building. from data supplied by the Washington Surveying and Rating Bureau. 2 Yakima and other fire-protected towns are rated as class No. ‘Building valued at $200,000. 4 Contents value based on 55 percent annual content. 5 Rates are per $100 value. Prepared 3, unprotected areas are rated as class No. 9, U.S, GOVERNMENT PRINTING OFFICE . 1963 OL—686-765 The marketing research in this report is part of a broad, continuing program of USDA’s Agricultural Marketing Service to bring marketing services to farmers, industry, and consum- ers. The seal shown below is the symbol of the 50th year of organized marketing service. In 1913, the first marketing agency, the Office of Markets, was established in USDA. It was the predecessor of the Agri- cultural Marketing Service. This report is one of a group that has helped to improve the marketing of apples. It sum- marizes research that will help bring reasonable returns to the producer, help hold down mar- keting costs, and give the con- sumer a product with less decay and fewer bruises. In the last decade alone, the Agricultural Marketing Service has been instrumental in de- veloping mechanized and auto- mated equipment for packing and sizing, a new type of bag- ging chute, cull chutes, a high piler for boxes, new packing sta- tions, mechanical handling of fruit boxes with forklift trucks, a loose box filler, and the re- cently developed and patented automatic _pallet-box _ filler. Continued research is planned.