MTX Ripening Technology

MTX were originally contracted by S H Pratt and Co (Bananas) Ltd to significantly extend the depot’s ripening capacity at which time MTX was also asked to future proof the new facility, considering the size of the pipework and the pump layout, in preparation for extending the depot in the future.

MTX were contracted to return to the facility to provide an additional 8 No. High Cube Ripening Rooms over a 2 phase project. Both phases were given a tight 8-week programme equating to approximately 2 weeks per room, and despite the facility running a 24-hour operation, MTX were able to maintain the users access to the entire depot throughout the full duration of the project, which was completed on time and on budget. Using this phased approach to the project proved extremely effective and provided the facility with a faster return on investment whilst ensuring disruption was kept to an absolute minimum.

Completing the final phase of the project MTX returned to the facility to install the last 4 No. High Cube 60 Pallet Ripening Rooms, and the installation of an additional pump, all of which was installed in just under 8 weeks with minimal disruption to the client.

Many of MTX’s clients are now opting for the High Cube Ripening Room design, as installed at Sovereign Park, as this incredibly efficient system allows end users to place an additional layer of boxes per pallet on each tier. This provides the client with the maximum amount of ripening capacity using the space available, with minimal additional cost to the overall scheme.

Owner and Managing Director Robert Wells said:

“We’ve worked with MTX for many years and have always been happy with the service they deliver. In my opinion, they offer the best product available in the marketplace, in terms of the range of room options available and overall performance. We have a large variety of orders coming through our facility on a daily basis and with the MTX room options we’re able to cater for all orders and, most importantly, achieve reliable consistency with the products we deliver to our clients.“

The Requirements

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 the designs had been finalised, MTX were able to start work on the installation and commissioning of 36no 60 pallet ripening rooms.

The construction programme 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 Solution

To deliver this project, MTX devised a uniquely phased construction programme:

The 1^st phase of the construction programme involved the installation of rooms 1-16 in the newly extended part of the facility. These 16 rooms alone provided the client with the same ripening capacity as the 40 rooms originally in operation at the facility. MTX also installed a state of the art central chilled water plant, which involved complex installation works across the entire facility.

During the 2^nd phase of the project, rooms 17-20 were completed. These rooms provided our client with a total of 20no fully commissioned MTX ripening rooms after only 20 weeks after initial works commenced and increased the facility’s ripening capabilities from 960 to 1200 pallets (or 51,840 to 64,800 boxes).

In the 3^rd phase MTX developed the temperature controlled loading bays and a state of the art packing and production area. The final 16 rooms (rooms 21-36) were also installed and commissioned at this time.

The 4^th and final phase of this project saw the installation of 2 large melon and pineapple chill stores.

Main Considerations

The 2^nd phase of the project provided the most significant challenges for MTX as the old ripening rooms had to be decommissioned and removed alongside the main production and packing area, which remained in full operation throughout the entire construction programme. During this phase 4 rooms (rooms 17-20) were completed and successfully handed over.

An expertly phased construction programme and careful co-ordination 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.

The enabling works for the project commenced with work on the 10 No. Ripening Rooms carried out over a strict 15-week programme. In addition to the primary contract works MTX were also contracted to supply and erect an additional office within the existing locker room.

MTX also installed new network cabling to the entire site including the new ripening rooms enabling them to be interrogated individually via the MTX state of the art ripening management system (RMS); a system that provides the ripener total control of each individual room, and each chamber, via its own control system located adjacent to each door.

Whilst the Ripening Rooms were installed as per the patented MTX design, the project design team delivered a bespoke design for the vertical baffles on this scheme to achieve increased efficiency from each room. Due to the success of the newly designed silicone rubber baffles, this modification will be carried forward for all MTX Ripening Rooms installed in the future.

The new ripening rooms were successfully completed on programme and within budget and feedback from our client has been excellent.

This was an extension to the clients current facility that already houses thirty 24 tonne Ripening Rooms previously installed in addition to a two storey temperature controlled packing facility and large store.

The rooms were constructed using 100mm thick insulated PIR composite panel. Within each of the rooms we have a complex steelwork arrangement which acts as pallet support.

Full design and installation including mechanical, electrical and refrigeration was carried out in house. Cooling to the rooms was provided by a series of DX packaged condensing units provided by Airedale. A sophisticated control system was installed offering accurate temperature control.

The timely completion of the project was vitally important as this was key to the clients operational requirements.

MTX were solely responsible for this project from conception to completion, the project brief was to fit-out an existing unit with a new banana ripening facility able to ripen 480 tonnes per cycle with the view for future expansion. The new facility was to include a Holding Area, Packing Area, Quality Control Office, Plant Room and Banana Ripening Rooms.

MTX constructed ten 36 pallet two tier and two 60 pallet three tier ripening rooms all fitted with the unique MTX pallet sealing system along with our reversible airflow ensures uniform ripening. All ripening rooms also fitted with a fan inverter drive, giving us variable airflow and reduced energy consumption.

The cooling media for the site is chilled water, the chilled water system comprises of 3no. 250kW free-cooling chillers controlled from a central sequence control panel, this allowing the client close efficient control of their plant.

Alongside this MTX installed an MTX Plant Visor, which via the internet gives you access to view the status of chilled water plant at any time.

MTX’s in house project teams were responsible for the full design, installation and commissioning package of the mechanical, electrical and refrigeration services. The installation conforms to all current legislations.

The new facility was fully operational within an 18 week programme.

MTX were awarded the contract as specialist turn-key provider and commenced work on site in to design and fit out 10 No. MTX Stone Fruit Ripening Rooms within a brand new 5,500m² building.

The extent of the contract also included the full mechanical and electrical installations for the entire depot which included two chilled water systems; one serving the new production area and the other serving, 10 No. Ripening Rooms, five new cold stores and a dispatch area.

The new purpose built depot features many state of the art advantages to help users with ease of access and energy efficiency. Furthermore all of the temperature controlled areas of the new depot are continuously monitored and controlled via the MTX Ripening Management System (RMS) providing complete control to the client at all times.

In recent years MTX has installed a number of additional facilities on this site including energy saving systems which have already resulted in savings of 100’s of thousands of pounds in electricity with payback periods of less than 12 months.

Winfresh approached MTX requesting an appraisal of their existing chiller plant and associated chilled water distribution system which resulted in proposals to replace 2 existing chillers and water circulation pumps.

The 2 new chillers, manufactured by Airedale of Leeds, are energy efficient free cooling chillers which use ambient air for partial or full cooling in conjunction with the refrigeration compressors as required. A sequence controller maintains a constant supply water temperature to ensure that the free cooling function of the new and existing free cooling chiller is maximised whilst still meeting cooling demand from the process.

The existing secondary water system has also been upgraded to provide energy saving inverter driven pumps to supply chilled water as required to the process.

This installation has been a huge success proving that inefficient facilities can be re-developed to become energy efficient providing the site with a new lease of life without the need for large scale replacement.