MTX Ripening Technology

The extent of the contract included new: Chiller Unit, Buffer Vessel, Variable speed pump set, associated controls and modification of main water pipe work runs.

The key aim for the project was to undertake the works as quickly as possible with minimal disruptions due to the site being fully operation and with no opportunity to shut down.

This was done by strategic planning of the strip out and removal phase, new plant installation phase and pre-fabricated pipe work to minimise install time.

The plant was up and running again within 48 hrs with the project being fully complete within 5 days.

MTX Contracts Ltd were approached to assist in looking at ways of improving their existing ripening infrastructure. The existing rooms in use for this process were simple blast coolers and warming rooms with no forced air capability. This was having a detrimental effect on produce that in most cases was ripened unevenly.

After careful consultation with the Frutas Montosa team, we were able to establish that to increase product turn around and to ensure consistent ripening, 6 MTX ripening rooms would be required to meet with demand. However in order to achieve this, a number of challenges had to be overcome.

Frutas Montosa is very much at the forefront in Avocado production, supplying produce throughout Spain and around the world. In order to do this efficiently, they have introduced large perforated polypropylene bins, each capable of holding up to 300kg of produce. The bins once full enter the system and have individual barcode tracking devises fitted to each, allowing produce to be tracked throughout the process. The bins however do have inherent restrictions that had to be overcome in order to facilitate forced air ripening.

Each bin is 1200mm wide x 1000mm deep x 800mm high and have forklifting points that creates a gap in between stacks.  This creates air gap at each bin position allowing air to bypass. To overcome this MTX have created individual sealing flaps that are positioned at each bin location to prevent air leakage. There are 128 of these seals per room and have been proven to work extremely well.  Tests carried out have shown that within each bin random samples of fruit have reached and maintained set point much faster than expected.

The rooms were constructed in part by local Spanish contractors and by MTX’s specialist contractors who were on site for 7 weeks once the room shells were completed, to install equipment shipped from the UK.

Each room comprises of the following:

• 8 No pressure fans
• 2 No 22 kw evaporators
• Steam humidifier
• 1 No vent fan & damper
• 16 pallet dampers
• Co2 sensor
• Humidity sensor
• Temperature sensors
• High temperature cut out
• Room control panel
• Room control unit
• Specialist pallet sealing system
• Room lighting (PIR activated)
• Void lighting
• Sliding access door

The project was completed on time and on budget in just 8 weeks.  This project has been very successful and MTX have been asked to look at other areas within their facility to introduce additional MTX forced air ripening room systems.

An expertly phased construction program and careful coordination between the core project team allowed the client to successfully double their ripening capabilities in just 36 weeks while maintaining all existing ripening and production commitments.

Fyffes Group Limited had scope to enlarge and modernise their existing Banana Ripening facility and awarded MTX the design, supply and installation contract. Upon completion of the initial construction phase of the project, which included a 3750m² extension to the existing facility and once all designs had been finalised, MTX were able to start work on the installation and commissioning of 36 No. 60 Pallet MTX Ripening Rooms.

The construction program stipulated that the rooms were “to be handed over to the client on a uniquely phased basis throughout the construction period enabling the client to relinquish existing rooms for decommissioning and removal” with the aim of reducing disruption to staff and daily production schedules.

The installation was external to the main facility and required enabling works prior to commencing the room’s construction.

A concrete plinth was designed and installed by MTX to provide a base for the rooms. 3
fully weatherproof rooms were subsequently constructed on this base.

A fallow area was created outside the rooms to act as a link to the existing building. An opening was then formed by the client from the existing building to provide access to the ripening rooms. Refrigeration of the rooms was via externally mounted condensing units.

Each room also contained electrical heating and spray humidification to provide the optimum ripening conditions. The blast chiller room allows the client a rapid cooling option for up to ten pallets of produce over a short period of time. Each room also contained MTX’s unique pallet loading system to give the client the maximum flexibility possible.

MTX were contracted to supply, deliver and install the four pressurised ripening rooms after dismantling and removing existing internal facilities.

The ripening room is designed to expand Winward Isles current banana processing volume by providing flexible loading capabilities for the end 10 pallets of each room. The reversible air flow process ensures an even flow is directed through the fruit and therefore more consistently ripened fruit.

The current chilled water installation feeding the existing banana ripening rooms was expanded to allow for the new rooms.

The bespoke designs for this project are carried out in house, along with the complete project management of all construction aspects.

As with other recent MTX fruit ripening projects, a system of inverters will be used to enable variable control of the fans in the ceiling voids. This can significantly reduce client operating costs and reduce energy consumption.

We completed the installation of a new cold store facility that will increase the capacity to a further 163 pallets. This is an extension to the facility which is already one of the largest facilities within the United Kingdom.

The new area has been constructed using 150mm PIR composite panels along with 150mm mineral fibre panels that have formed the new fork lift charge area.

Above the new charge area, we have installed a mezzanine floor area that is capable of holding a further twenty pallets of packaging materials which has also freed up much needed floor space for fresh produce.

The design and installation of these areas has been undertaken by our in house team, including all mechanical and electrical works. Cooling to this area is via existing chilled water systems that have been extended.

This scheme has been such a success that we are now proposing a new scheme to install an additional mezzanine at the other end of the warehouse, giving a further 50 additional pallet spaces.

MTX completed the installation of 6 No. 24 Pallet Random Access Ripening Rooms for Chingford Fruit Limited based in Kent.

The new MTX Ripening Rooms were installed to replace their existing facility which was in need of modernisation. According to the clients’ request, the project was to be completed in 2 phases to ensure normal production could be maintained alongside construction works.

Phase 1 required the removal of two of the three existing rooms so that 3 No. 24 Pallet rooms could be installed. By maintaining close communication with the customer, MTX successfully overcame the challenges that arise when major construction works are being carried out alongside normal production.

Upon completion and handover of Phase 1, work was able to commence on Phase 2 – the installation of the remaining 3 no. 24 Pallet rooms. The rooms were supplied by the existing DX pack systems that supplies the entire site maintaining cooling requirements within the facility. Each room contains 2 No. 24KW evaporator coils allowing the rooms to operate at around 0°C. Each evaporator in each room was fed from 1 of the 2 pack systems allowing energy saving during part loading conditions with only 1 evaporator being operational whilst still maintaining the correct temperatures within the rooms.

Energy management systems were incorporated into the design allowing the fan speed to automatically adjust whilst maintaining the correct pressures throughout the pallet stack. This has already provided significant energy saving since the facility became fully operational.

The entire project was managed in house, from conception to completion, in only 17 weeks including installation, mechanical, refrigeration, electrical and commissioning.

Since the installation of the new MTX Ripening Rooms, the facility has doubled its ripening capacity whilst still maintaining the same size footprint within the warehouse, where space is at a premium. Furthermore, since its completion the client has commented on how pleased they are with the completed facility and have noticed significant improvements in the quality of the product coming out of the new MTX Rooms.

In September 2007 MTX completed the installation of five new pressurised ripening rooms within a new depot at Mack Multiples Division in Bishops Stortford.

An open-plan warehouse was purchased by Mack Multiples and MTX designed a layout of the warehouse based upon a specific number of pallets required by the client. All plant items were also designed including the new installation of a sufficient electrical feed for the entire warehouse including future expansion.

Upon approval of the design, MTX removed all redundant services within the facility. A concrete plinth was constructed adjacent to the building in order to house two new air-cooled chillers and a buffer vessel including all associated pipework.

Consideration was taken when at the design stage for future expansion of the facility with additional space allowed on the concrete plinth and all mains pipework suitably sized to allow for additional increase in duty.

The newly installed chillers operate a free-cooling option. This results in cooling of the media not using any energy when the external ambient conditions are below a certain temperature. This has proved to be a very cost effective, energy saving, option over past projects.

This project saw MTX install a new control system complete with touch screen controls. This system is both stylish and easy to use with the added advantage of allowing remote access, via the internet, to the ripening room control.