Refrigerated bodies are used in a wide range of industries. These bodies are designed to maintain a constant temperature which is critical for preserving the freshness and safety of food and pharmaceutical products.
Vapour tightness of such bodies is essential to keep operating costs to a minimum. Water penetrating the body will result in higher service frequency for cooling units, increase the risk of cooling unit breakdowns (with a chance to spoil the loaded goods), reduced payload due to “heavy” water replacing “light” foam and increase the operational life time of the body. To achieve vapour tightness, bodies are constructed using a variety of carefully selected materials and components.
One of the critical components of a waterproof refrigerated box, according to Coldstores Group of Saudi Arabia (CGS), is its assembly by gluing. This process involves bonding the different parts of the box together using an adhesive. The glue creates a watertight seal that prevents water from entering the box and damaging the contents. The glue used for this purpose is specially formulated to withstand extreme temperatures and humidity levels, ensuring that it maintains its strength and integrity over time. Glue plays also a key part in structural integrity of a body.
Waterproof rivets are another important component of a waterproof refrigerated box. These small metal fasteners are designed to secure the different parts of the box together. They are usually made from stainless steel and are specially designed to resist water penetration when the body is washed out. Waterproof rivets ensure that the insulation material remains in an optimal condition and can withstand harsh conditions, such as exposure to saltwater or extreme temperatures.
Metal skins are another important component of a waterproof refrigerated box. They are used to provide strength and durability to the box, making it capable of withstanding harsh conditions. The metal skins used for this purpose are typically coated with a layer of paint and protective material to prevent rust and corrosion. Metal skins are especially important for refrigerated boxes that are used in outdoor environments, as they provide protection against weathering and other external factors. They are also more impact resistant than other skin materials.
Rubber seals for door leaves are also an essential component of a waterproof refrigerated box. These seals are designed to create a watertight seal around the door of the box, ensuring that water cannot enter the interior. The rubber used for these seals is specially formulated to withstand extreme temperatures and humidity levels, ensuring that it remains flexible and does not crack or break over time.
A thermal barrier around the doors is typically achieved by using a combination of insulation material and wood. Without a thermal barrier, condensation can cause damage to the loaded goods. The barrier is installed between the steel skins of the box and the interior liner and is typically glued or sealed in place to prevent any air or moisture from entering the cavity.
When installed, a GRP strip creates an additional barrier that helps to prevent condensation. The strip acts as an additional layer of insulation around the doors, reducing the amount of heat that can penetrate the body structure.
Finally, the GRP floor is another component of a waterproof refrigerated box. GRP stands for Glass Reinforced Plastic, and it is a type of composite material. It is not as strong as other floor types but cost effective for floor applications A GRP floor is designed to withstand loading by forklifts and resists water penetration, ensuring water cannot reduce the life expectancy of the floor structure (wood can rot away) and that the floor remains in good condition.
In conclusion, a waterproof refrigerated box is a crucial piece of equipment for many industries. Its components, including its assembly by gluing, water-proof rivets, steel skins, rubber seals for door leaves, and GRP floor, are all carefully designed to provide strength, durability and protection against water penetration and therefore reduce total cost of ownership. When purchasing a waterproof refrigerated box, it is essential that all of these components are of the highest quality to ensure that the box is capable of withstanding harsh conditions and keeping its contents safe and fresh.
CGS is using state-of-the art design and production technologies and processes to enhance the quality and performance of its products. Material characteristics and physical laws guide CGS in the appropriate material selection for its products to optimise total cost over life time.
To reduce production timeframes and deliver quality products, CGS relies on modern fabrication processes like robot welding.
- Speed and efficiency. Robot welding is much faster than manual welding since robots can perform welding tasks continuously without the need for breaks or fatigue. This can significantly increase production speed, which can be especially beneficial for companies that need to produce large volumes of welded products quickly. The speed of robot welding can also help businesses to meet tight deadlines and respond quickly to changes in demand.
- Precision and consistency. Robots can be programmed to perform welding tasks with a high degree of accuracy and consistency. This is because they can precisely control the speed, angle, and position of the welding tool, resulting in consistent and high-quality welds. In contrast, manual welding can be prone to inconsistencies, which can lead to defects, rework and a decrease in product quality.
- Safety. Robot welding can improve safety in the workplace by reducing the need for manual welding, which can be a hazardous job. Robots can perform welding tasks in hazardous environments, such as high heat, toxic fumes, and confined spaces, without putting human workers at risk. This can help to reduce workplace accidents and injuries.
- Cost savings. Although the initial cost of implementing robot welding can be high, it can result in significant cost savings in the long run. Robot welding can reduce labour costs by decreasing the number of workers needed to perform welding tasks. It can also improve product quality and reduce the need for rework, which can result in cost savings related to material waste and labour hours.
- Flexibility. Robots can be programmed to perform different welding tasks and switch between them quickly, making them highly flexible in a production process. This can be especially beneficial for companies that need to produce a variety of products or adapt to changes in demand. Additionally, robots can be easily reprogrammed to perform different tasks as production needs change, providing even more flexibility.
CGS also uses 3D scanners for reverse engineering and software to build complex geometries while boosting production time.
A 3D scanner typically captures the shape and surface geometry of an object by projecting light or lasers onto it and recording the reflections. The resulting data is a point cloud or a mesh of triangles, which can then be converted into a 3D model using specialised software. By using a 3D scanner to capture the geometry of a physical object, it is possible to create a digital model of the object that can be used for reverse engineering purposes. The digital model can be modified and refined to create a new product or to improve an existing one.
This can be particularly useful in industries such as automotive, aerospace, and consumer goods, where reverse engineering can be used to create replacement parts, improve product performance, or reduce manufacturing costs.
The OEM is also using the latest Finite Element Analysis (FEA) software for design validation of its products according to internal standards.
- Cost-effective. FEA can be much more cost-effective than physical testing. It is much faster to run simulations using FEA than to build prototypes and test them in the real world. This can save companies a lot of money and time in the design process.
- Accuracy. FEA can provide accurate predictions of how a design will behave under various loading conditions. By analysing the behaviour of individual elements within the design, FEA can provide a detailed picture of how the entire system will perform.
- Optimisation. FEA can help engineers optimise their designs. By running simulations with different parameters, engineers can identify the optimal design for a given set of requirements.
- Flexibility. FEA allows engineers to test a wide range of scenarios and loading conditions. This makes it possible to identify potential failure points in the design and make changes before the design is built.
- Risk reduction. FEA can help reduce the risk of design failure. By analysing the design in detail, engineers can identify potential weaknesses and make changes to strengthen the design.
CGS has developed customised structural testing jigs to validate different design aspects before commencing production. Customised testing jigs are crucial for structural testing of products because they enable precise, repeatable and consistent testing of a product’s structural integrity.
These jigs are designed specifically to simulate the forces that the product may encounter during its expected use so that the theoretical calculations can be verified in a real life environment.
Here are some of the key reasons why customised testing jigs are so important for structural testing of products:
- Consistency. Customised testing jigs ensure consistent testing conditions, which is critical for producing reliable test results. By holding the product in place in a consistent manner, the testing jig eliminates variability in the testing process that could affect the results.
- Accuracy. Customised testing jigs enable precise testing of a product’s structural integrity by simulating the forces that the product may encounter during its expected use. This enables manufacturers to identify any weak points in the product’s design and make necessary improvements.
- Efficiency. Customised testing jigs can be designed to allow for high throughput testing, enabling manufacturers to quickly and efficiently test large quantities of products. This can be particularly important for manufacturers that produce products in high volumes.
- Safety: Customised testing jigs can help ensure that products are safe for consumers to use by identifying any potential structural issues before the products are released to the market.
- Cost-effectiveness: Customised testing jigs can help manufacturers save money by reducing the need for expensive prototype testing or product recalls due to structural issues.