Food Storage

A concept to succeed

F o o d S t o r a g e U n d e r g r o u n d Wa r e h o u s e

Table of Contents

Future foood storage......................................................................3Going underground.......................................................................4 Why a shell structure?...................................................................5 Warehouse safety...........................................................................6 Automated design storage.............................................................7 A warehouse control system..........................................................8 Insipired by nature.........................................................................9 There’s no easy way........................................................................11 New future buildings.....................................................................12

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Providing food has been a major con-cern throughout history and developing solutions for producing, transporting

and preservation of food allowed civilizations to thrive and develop. Although major break-throughs in ensuring food came with the inten-sive mechanization and biotechnology of agri-culture, individuals all over the world still face problems accessing safe and nutritious food to meet their dietary needs and food preferences for an active and healthy life. Developing coun-tries face new challenges like land degradation, climate change, agriculture diseases, water crisis and a growing population whose demands must have to be meet. But also the mature countries in Europe and USA are focusing in developing new technology to tighten efficiency, provide bene-fits related to health and safety, energy efficiency and automation of services. Improving the pre and post-harvest condition and shelf life of raw

F u t u r e f o o d s t o r a g efood is clearly a critical dimension to be man-aged. While the ways to renovate and renovate are many in today’s industry trends show a clear preference in three key-areas, energy efficiency, labor efficient automation and the newest im-provement in facility design that provide fast and efficient packaging, storage and distribution of goods in the warehouse. The proposed develop-ment of the new design concept for a Food Stor-age Warehouse is occurring facing new concern related with sustainable development, energy efficiency and emerging building technologies in construction industry. We are in a point that will allow us to change the way building a struc-ture is seen driving be new development in areas like car-making, ship building, manufacturing industry and 3D printing. The aim of this project is not only to offer a sustainable design for food storage but also to put in question the emerging technologies for planning, building and maintain a new construction. In order to ensure food secu-rity and for all individuals more sustainable food storage warehouses must be develop.Technology advancements combined with the latest demands in the food and beverage supply chain are perpet-ual non-stop motion.

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Cellars and basement have traditionally been the storage spaces where per-ishable goods wine and ice could be

kept for long periods. That’s because earth of-fers a good insulation both on winter and sum-mer. These days basement are used primary for parking cars and transportation. Thus the main advantage of underground structures is ener-gy efficiency; preservation is a better deal than production. Underground buildings can help reduce the energy demand by using beneficial soil temperatures and large amount of earth cov-er as insulation. Studies have showed that un-derground buildings can almost be considered zero-energy buildings as the annual energy de-mand is near zero. Moreover, low annual energy demands for these underground building cases, can be seen in a range of climates with highest benefits in arid climates. Another factor in sav-ing energy through earth sheltering is the reduc-tion of infiltrated outside air; heat loss can often be attributed to air infiltration. Because of this the proposed the building design is an almost full underground structure where the air circu-lation is fully controlled and monitored. There are several drawbacks to underground storage warehouses such like; high ventilation, spatial orientation, evacuation problems or indoor air quality. Small room and narrow corridors un-

derground could contribute to many negative effects such as claustrophobia, lack of orientation and lack of connection with the outside world. This problems can be address be providing a better design solutions. Firstly the food storage warehouse will be fully automated requiring less personnel to be operated and maintain locat-ed in the upper levels of the building facilitat-ing easy access to evacuation zones in cases of emergencies. The sense of space created by high ceiling and glass partitions as well as providing natural light proves the basic framework for the interior design elements. Secondly, high venti-lation demand can be seen like an advantage in controlling the temperature of the storage ware-house and providing a tool for a better managing the climate conditions. Another main advantage of using underground structures is preservation of surface spaces by requiring small footprint. In many cases underground spaces results from lack of surface spaces or location problems. This can be the case in newly urban conglomerates forming in developing countries as well as de-veloped countries. The challenges for mature markets are labor rates still relatively high and unavailability of land especially in Europe. Fur-thermore with the rise of land price using under-ground structures always a good choice.

G o i n g u n d e r g r o u n d

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W h y a s h e l l s t r u c t u r e ?

A shell structure is a particular and interesting structure from several points of view. Because of their free space that they provide shells are highly efficient and architecturally pleasing

structures. There are lots of possibilities and freedom regarding the de-sign of the interior spaces of the building. The main advantage that sell structure possess is that shell resist loads mainly through their geometry, the most structured system is one that counts both horizontal and verti-cal elements. Grid shell are also inexpensive construction solution, since less material is used, a grid shell is a less expensive structure offering possibilities regarding operation of the building. Typically price is close-ly related to the size of the members used and the choice of section. The price is a determining factor to assess the constructability of a structure. Furthermore the erection of the building is extremely rapid since no ad-ditions need to be done to the primary structure. Unlike typical buildings where the horizontal beams and vertical columns provide both support for structure’s weight and the strength and stiffness needed to resist later-al forces the shell structures can carry loads mainly through membrane

tension with no need by any additional structural elements therefore per-meating large open spaces and facades. Nevertheless, shell structures are not a common architectural choice for buildings. That is because the grid system must be flexible enough so can deform during the construction phase. The most largely used materials in construction industry, concrete and steel cannot bend easily. To allow the transformation to take place, the grid surface must be deformable. The erection process of the grid shell entirely relies on the quality of the nodes. The development of more performing computers programs, the growing interest in 3D printing technology and accessibility of new materials can make shell structures to be a common choise.

It is remarkable to notice how one structural concept can lead to so many innovations in terms of design methods, material, use , construc-tion technology. After over forty years of under representation in the building environment, the development of grid shell structures has taken a shift.

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Never forget earthquakes

Underground structures have several intrinsic advantages in resisting earthquakes motions as they are less affected by seismic wave. In general inertial forces (acceleration) are lower for underground structures. Seismic vulnerability is better correlated with ground velocity than peak ground acceleration. The response and the seismic vulnerability of an underground structure is controlled by the imposed seismic ground

deformation and not by the inertial forces. The structural oscillation effects are limited since they are constrained to move with ground motion. Besides, as they are designed to support important ground loads, they often can better resist earthquake loadings.

Wa r e h o u s e s a f e t y ; k e e p t h i s p l a c e c l e a n a n d o r d e r l y

Every year accidents occur while goods are being stacked or destacked. Many of these accidents are being serious-some even fatal. Is a real need to develop safe and efficient methods

for stacking and storage. A safe, orderly, efficient warehouse is a key to a successful operation. The warehouse plays an essential role in the way goods are sent, receive, stored and circulated throughout the facility. With so much going on and so much to keep track of, a warehouse also have more potential for accidents than areas with more limited func-tions. So it’s important to pay close attention to safety. To completely eliminate this problem the food storage must be fully automated. The vision is that of an warehouse system where humans interacts with robots in achieve a more productive and intelligent way of delivering food.

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A u t o m a t e d d e s i g n s t o r a g e

The food storage (warehouse) has long been a key component of the supply chain. Food storage is important not only for providing better con-ditions conserving food but also the capacity to fill orders in a timely manner. The ideal is to design every possible ordering request. Packing and stacking has long been a teasing problem for the mathematicians who somehow fail to capture much certain knowledge. The problem arise

from the question how can you find the optimal solution in arranging most densely in space an infinite number of equal solids of a given form. The question must sound trivial but the solution is far more complex. This frustration was not shared by computer scientists, whose more rough-and-ready tactics have found many practical results. The use of mathematical algorithms is key to finding a correct solution. Even if we find the correct mathemat-ical solution the reality is more complex. The warehouse food storage is dynamic with the need to adapt to changing market opportunities, competitive pressures, technology and others variables especially those unforeseen. Using an automated system will guarantee that the final requirements will be achieved. The system envisioned is an automated system operated by robots. The diagonal wooden grid that stores the pallets accessible only be the ro-bots thus make it safer to operate. The robots pick, organize and store the pallets in logical system. One of the key factors to reduce the picking-time per unit for the system is that the robots always make sure that high-runners(often used pallets are place at the top levels) of the grid, whereas low-runner(-less used pallets) are placed at the lower level of the grid. Another factor that the robots consider in organizing the grid are the conditions necessary

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A Wa r e h o u s e C o n t r o l S y s t e m

for preserving the food. Therefore the frozen food is stored at the low levels of the building in contradic-tion to dry and fresh food which is stored at higher levels. The system also consists of conveyors that make easy the transport and sorting of the bins. The grid is a wooden structure organized diagonally for more energy efficiency and flexibility in use. Wood is used as material for building the grid because is accessible, ecological material and offers sufficient resistance for supporting the pallets. The stiffness of the structure is provided by the compact overall design. In spite of the fact that the food storage warehouse will be fully auto-mated with picking robots coordinated by complex al-gorithms for more productivity the warehouse will still be planned by the working staff who will be the brain of the operation. The Warehouse control system will be located at the top level of the building by facilitating an easy way for carriers to deliver and shipping the food. The area above the warehouse will be a parking lot for better use of the land.

Delivering fast food

An important part of the food industry fac-es problems not only in the producing and preserving the food but also in distribution

segment. Rising costs, changing consumers habits, le-gal and environment pressures are driving people to implement new processes simple to keep up. Because the warehouses are a critical component of the supply chain, they require a detailed planning process to en-sure clockwork operation. Collecting data quality and accurate trading will lead to an efficient material flow of food increasing the speed and material handling combined with less manpower reducing the number of shifts in the operation. The easy way in planning and supervision, allowing tracking and tracing current lo-cation and status of the food in the supply chain will lead to fewer added costs by speeding and anticipating the demands of the market. It makes great sense to cut waste and shorten the time between production and consumption.

The Brain of the Operation

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I n s p i r e d b y n a t u r e

The development in industrial refrigeration has always been with the important objective of reducing electric power consumption. Optimal temperature range for perishable food storage is 3 to 5 oC. Unfortunately this meant using refrig-

erants with negative impact concerning the environment. Fluorocarbon refrigerants im-pact the environment by ozone layer depletion and global warming. In spite of the fact that in resents years many researchers developed a new range of refrigerants with min-imal environmental impact this remains a concern especially in the developing coun-tries. Perhaps we must find different solutions for keeping a low temperature for storing food, a cleaner, safer, performance way of doing things. Nature has always proved to be a better architect, providing with better solution than humans. Consider this example: termite mounds such as those of the Macrotermes michaelseni exist in environments where the external temperature varies from 35°F at night to 104°F during the day, but the mounds themselves maintain a constant internal temperature within one degree of 87 °F, day and night. Hundreds of thousands of years of evolution perfected the mounds tunnels and air conduits to create a self-cooling ventilation system. This may be a model to follow. It turns out that termite mounds operate on a system of convection currents that suck air at the lower part of the mound down at the button and then up to the top. The ducts are open and closed by termites digging new vents and plugging up old ones. A system of channels and ducts circulates air through the mount. The passages run

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through area of the mount that have walls that are porous or have tiny ventilation holes. The pores act as fresh air ventilation and stale air exhaust. The supply and return system performs solely on heat and gravity with no moving parts. Underground wells supply the termite mound with source of water and a source for cooling the interior. The peaks and towers of the termite’s nest act as lungs that expel rising hot air, which is generated by the breaking down of the fecal comb by the fungus. The air then rises via a large cen-tral air duct, and moves up through the long porous chimneys. The carbon dioxide in the air then diffuses to the outside, while oxygen diffuses into the chimneys. The oxygenated air eventually loses its heat to the cooler outside air and cools sinking down into the cel-lar. Such an ingenious HVAC system is necessary for the survival of some three million termites to a single colony.

This principles are used at Eastgate building in Harare, Zimbabwe, the country’s largest office block and shopping center fallowing the same air-vent strategy as the ter-

mites. At Eastgate fans on the first floor suck in outside air and the push it up along a central spire, venting it through chimneys at the top. The building also introduces a principle that we have seen in previous case studies such as German Reichstag. All of these de-signs utilize the principles of thermal movement in order to create cross ventilation which can naturally cool a building. The result is a building that needs no air conditioning, minimal heating and a reduction on construction and maintenance costs.

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T h e r e ’s n o e a s y w a y

Although mechanism of which termites self-regulated nest works might be explained us-ing a thermosiphon model in which the heat produced by the metabolism in the mound produces a buoyance effect within the nest and that flow was induced by the wind pass-

ing over the open chimneys and drawing air in from openings nearer the base of the mound, this is not completing completely true. The same model using passive system for climate control based on gradients was used in designing the Eastgate building. However this simple model proved to reduce the cost with ventilation and energy use is not adequately describes the ventilation and gas exchange processes in a termite nest. The Eastgate is not equipped with porous walls or vents that open and close depending on the fresh air required. The proposed new model describes the mound as an or-gan for the exchange of respiratory gases. Ventilation in the nest is driven by the tempered variation in wind so is “tidal not circulatory”. Instead of designing for a standard natural ventilation strategy such as cross-flow or single-sided ventilation, we might design a wind capture device that acts as a gas exchange system, so that stale air and fresh air mix within a chamber that is connected to the oc-cupied space, surface conduits and a porous outer membrane. Fluctuations in wind speed and direc-tion then produce tidal flow. Conduits of varying sizes could be included so that the system is tuned to varying wind frequencies. The device could be shaped so that wind is captured in all directions.

Back to the basics

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N e w F u t u r e B u i l d i n g s

Building a shell structure with porous wall is a challenging task even impossible regard-ing today’s building technology. For a shell structure the components must be flexible enough so that can deform during the construction phase. Materials like concrete and

steel cannot bend easily. Construction industry, buildings and infrastructure remain to be the most expensive and slowly produced goods in our society. Nevertheless new rapid manufacturing and free-form fabrication techniques make it feasible in the near future for this kind of structures to be build. 3D and small robots used to manipulate small prefabricated elements will be a major innovative step for sustainable building providing architects and engineers new radical tools for questioning the codes and practices.

“Buildings may be constructed by swarms of tiny robots”

Neri Oxman, Associate professor of media arts and science

Construction technology

The new building technologies will be the next tool for build-ing more efficient, fast and in-

telligent. Throughout the history since romans invented roman concrete, many architectural and engineering achieve-ments have come after the advanced in construction building technology. With today’s methods is extremely difficult to build shell structures and even more inter-connected porous shell frames. That’s why I believe in new opportunities that 3D printing will offer.

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How far since judgment day?

Together with development in 3D printing new possibilities will arise to adopt new structural systems in codes and guidelines, like shell structures. Shell structures will require less manpower and skilled workers to the point that most of the work will be performed by tiny robots. Even though is still unclear who printing the building will de-

velop, like giant 3D printings or like swarms of tiny robots I incline to believe that the future homes will be build be armies of small, practical, useful robots. The food storage will be made of small frames that will be assembled by robots more like a lego building but unlike the frames that compose curtain walls there will have an important structural and functional role.

The porous surface

The porous surface will be a game changer feature of the build-ing allowing two main functions. Firstly it will allow expelling of rising hot air. Secondly it will suck air from the outside for

evaporative cooling the building. More like as human skin the porous surface will play an important role not only protecting the building against outside loads but also regulating the temperature. The simple principle that evaporative cooling works is that while water is evapo-rated, energy is lost from the air, reducing the temperature. The inside shell membrane will act like an evaporative pad that will cool the inside air keeping the food fresh and humidity at levels desired. The evapora-tion of water will require a large quantity of water provided by borehole drilling. A water reservoir will be located at the top levels for a better circulation of water. Unlike typical buildings where ventilation ducts are located in the ceilings the storage food warehouse ventilation will be achieved through ducts carved in the porous structure of the frame shells. Warmer air will be push through a central spire.

For finding a better solution by problems that we are faced we must adopt a new more complex design principles. Using and improving staking algorithms or by printing a range a new ma-

terials it will help us breaking the boundaries in building ones again after industrial revolution this time assisted by technologies like ad-vanced computers design software, 3D printing or automation. The ear-ly adopters of these technologies will be the ones will benefit the most

One last final thought

References

Bejan, A., 1997, Advanced Engineering Thermodynamics, 2nd

Chappels, H., 2010, ‘Comfort, well-being and socio-technical dynamics of everyday life’, Intelligent Buildings International

Mark Worall ,2014, Intelligent Buildings International, Homeostasis in nature: Nest building termites and intelligent buildings

J. Scott Turner*, 2001, On the Mound of Macrotermes michaelseni as an Organ of Respiratory Gas Exchange

J Scott Turner and Rupert C Soar, 2008, Beyond biomimicry: What termites can tell us about realizing the living building.

Henrik Holmberg, 1990, Analysis of Geo-Energy System with Focus on Borehole Thermal Energy Storage

Jens Petter Røyseth, Geir Fjermestad Rolandsen, Jonas Lye Scheie, Preben Grøssereid and Zheng Lee, 2012, Bachelor Thesis - AutoStore

Gontikaki, M., Trcka, M., Hensen, J.L.M. & Hoes, P. (2010). Optimization of a solar chimney design to enhance natural ventilation in a multi-storey office building. Proceedings of 10th International Conference for Enhanced Building Operations, Kuwait: ICEBO.

Shan K. Wang, Handbook Of Air Conditioning And Refrigeration

Chris van Dronkelaar, 2013, Master’s thesis Underground buildings

Thomas Bock (Prof. Prof. h. c./SRSTU Dr.-Ing./Univ.Tokio), Christos Georgoulas (Dr.-Ing.), Thomas Linner (Dipl.-Ing.) “Advanced Construction and Building Technology for Society”

Celine Paoli, 2007, Past and Future of Grid Shell Structures

Kyriazis Pitilakis ,Sotiris Argyroudis and Grigoris Tsinidis, Seismic Design and Risk Assessment of Underground Long Structures

The 3D model was design in Revit 2013