Influence of pallet height on energy consumption and cooling effectiveness in an apple cold storage

This study investigates the influence of pallet height on energy consumption and cooling effectiveness using a validated cold storage model based on CFD simulations. The model was validated against experimental temperature data, with a maximum normalized root mean square error (NRMSE) of 4.57%, indicating good agreement. Four pallet height configurations namely No pallet (0.0 m), 0.3 m, 0.6 m, and 0.9 m were assessed over a 40-hour cooling period. Temperature distribution within apple-filled crates was used to identify the locations of hot and cold spots, and performance metrics such as compressor energy consumption, specific energy consumption, mean crate temperature, thermal heterogeneity, and cooling effectiveness were analyzed. The results indicate that the No-pallet configuration disrupts airflow resulting in insufficient cooling, as evidenced by lower cooling effectiveness, while larger pallet heights (0.6 m and 0.9 m) introduce excessive air spacing resulting in higher thermal heterogeneity. The 0.3 m pallet height exhibited best performance such as lowest mean crate temperature of 4.7 °C, (8.7% lower), lowest thermal heterogeneity of 3.29 (14.42% lower), lowest compressor energy consumption per kelvin of 1.474 kWh/K (0.5% lower) and highest cooling effectiveness of 0.4 (5.37% higher). These findings provide practical insights for optimizing pallet configurations in cold storage, aiding energy-efficient operations in commercial refrigerated warehouses and post-harvest supply chains.