Guaranteed Cold Chain — Maruka’s High-Capacity Charging Solution for Cargills Magic
Project Overview: Powering the Mobile Cold Chain
The reliability of a national frozen goods chain depends entirely on the integrity of its logistics. When Cargills Magic Ice Cream required a centralized, high-efficiency charging infrastructure for its freezer lorry fleet, the mandate was simple: install a system that guarantees continuous power to the mobile cooling units, ensuring zero thermal disruption from factory to consumer.
Maruka Technologies (Pvt) Ltd. was selected to design, fabricate, and commission a complete system tailored specifically for this critical application, providing the robust control and charging capacity required for 24/7 cold chain logistics.
The Engineering Challenge
The challenge was twofold: to provide simultaneous high-amp capacity to a large fleet while ensuring the main power supply offered seamless redundancy.
- High-Density Charging: The facility required power management for 36 dedicated charging ports—each feeding a lorry’s cooling system—demanding meticulous load balancing and distribution safety.
- Critical Redundancy: The system needed a robust solution to manage power from the grid and an auxiliary source, protecting the 800 Amp main distribution circuit from any unexpected failure.
Maruka’s Solution: Precision Distribution and Hardened Durability
Our team developed a multi-stage power solution, starting with the primary distribution and extending to specialized cable protection.
- Main Distribution and Redundancy Control
The core of the system is the power intake and distribution spine:
- 800 Amp ATS Main Panel: We fabricated an 800 Amp Automatic Transfer Switch (ATS) Main Panel to ensure seamless power redundancy. This control panel automatically monitors the primary grid supply and executes a safe, rapid transfer to a standby generator source in the event of a failure, thereby guaranteeing power continuity to the entire charging fleet.
- Charging Distribution Panel (CDP): Power is routed to secondary 160 Amp Sub-Distribution Panels dedicated to managing the 36 charging ports, ensuring localized protection and efficient power scaling across the complex.
- Durability and Enclosure Integrity
Given that significant portions of the charging infrastructure were external and exposed to industrial washdowns and weather, the enclosures required superior protection.
- Outdoor Protection: All outdoor panels were constructed using Cold-Rolled Galvanized Steel with an advanced powder coat finish. This choice of material and coating system significantly reduces corrosion risk and increases durability against environmental exposure, guaranteeing component lifespan.
- Enclosure Finish: The use of durable white steel coupled with a professional powder coat was specified to reflect solar heat and maximize longevity.
- Underground Installation Protocol
To ensure the safety and longevity of the high-capacity cabling, we implemented a rigorous underground laying protocol, adhering to the highest international standards for cable containment and protection.
The entire route was secured using a multi-layer trenching method:
- Trench Preparation: Cables were laid within a prepared trench, preceded by a 50mm base layer of sand to provide a consistent, cushioned bed.
- Layered Protection: Following the cable installation, a subsequent 50mm layer of sand was added, followed by concrete tiles laid directly over the cables.
- Warning and Backfill: This hard protection was topped with a 300mm layer of soil before the final warning tape was installed and the trench was backfilled.
This meticulous, layered protocol ensures the cables are protected from abrasion, physical impact, and future excavation risks.
Outcome: Guaranteed Performance and Operational Certainty
The entire system was successfully commissioned and handed over to the client’s operational team. Maruka Technologies (Pvt) Ltd. confirmed system reliability by providing full testing and commissioning documentation, followed by a one-year warranty.
Furthermore, reflecting our commitment to superior customer service, a pre-installation free service check was scheduled one month prior to the start of the warranty, ensuring the site environment and foundation were perfectly prepared.
Cargills Magic now operates with the power certainty required to maintain the integrity of its cold chain, demonstrating that Maruka provides enduring, engineered solutions where continuous operation is non-negotiable.
Does your critical operation require guaranteed power certainty? Partner with an engineering firm that commits to technical excellence and meticulous execution.
