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Frozen pizza cooling Equipment

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Let's face it. No one can resist craving pizza for more than a couple of days. And in fact, cosmonaut Yuri Usachov didn't even make it while in orbit and received a pizza delivery through a rocket. Frozen pizza making process involves first creating the dough, allowing it to rise, and cutting it into the typical pizza shapes. After choosing sauces and toppings you prefer, you can let your pizzas cool in a spiral freezer.

Frozen pizza

Food freezers are often the last step in the food production chain. The design, materials, construction, and maintenance of freezers must follow the discipline of a hygienic design. Welded bonding, food product compatibility with the freezer material, and a welded stainless steel spiral system for effective cleaning are just a few examples to consider when contemplating a hygienically designed food freezer.


<h2>A fully-welded spiral freezes food products with horizontal air circulation</h2>
The Fully-Welded Spiral Freezer by ICS Spiral Freezers is a unique concept of fully stainless steel welded spiral modules (both inside and outside) that meet high hygiene standards. The Fully Welded system is hygiene-centric because the different parts of the system are not sealed with silicone but welded together. Silicone is more likely to wear and tear, over the years it can come off and can lead to the entrance of external substances. The machine modules consist of a stainless steel seamless welded insulating housing, equipped with a fully welded spiral framework, evaporator, and spiral conveying system. It is suitable for freezing typical food products including pizza slices, hamburgers, chicken nuggets, croissants just to name a few.

Intensive horizontal air circulation employed in this spiral system ensures the efficiency of the freezing so that products are being frozen equally and fast. With this technology, the air is evenly distributed across all tires, preventing the products from losing moisture, which keeps their weight loss at a minimum level. This freezing system can be equipped with a sequential defrost that guarantees a 24/7 production and consistently high-quality product with no defrost downtime.

The Fully-Welded Spiral Freezer has an internal cleaning system known as the CIP (cleaning in place) system that allows cleaning without removing equipment. The series of steps (rinsing, washing, disinfection and drying) can vary based on customer needs.

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Hygienic and fully-welded spiral freezer for food

Freezing is one of the most important industrial methods for the long-term preservation of food commodities. Many food products are sensitive to a freezing rate in that it can affect yield, quality, nutritional value, and sensory properties. Using a spiral freezing equipment with an efficient horizontal air flow and a sequential defrost can maintain product quality and reduce defrost downtime.


<h2>Freezing food products using horizontal airflow in a spiral system</h2>
The Spiral Freezer by ICS Spiral Freezers is a design based on two main spiral principles: the traditional (with or without DDS) and the self-stacker system. A self-stacker spiral freezer doesn’t require belt support, while the traditional spiral system needs support rings to hold the belt. Due to a compact design, the self-stacker spiral freezer has more capacity within the same height dimensions compared to the traditional spiral freezer. It is suitable for freezing typical food products including pizza slices, hamburgers, chicken nuggets, croissants just to name a few.

Intensive horizontal air circulation employed in this spiral system ensures the efficiency of the freezing so that products are being frozen equally and fast. With this technology, air is evenly distributed across all tires, preventing the products from losing moisture, which keeps their weight loss at a minimum level. This freezing system can be equipped with a sequential defrost that guarantees a 24/7 production and consistently high-quality product with no defrost downtime.

Additionally, the machine is easy to clean because it comes with a designed spray nozzle system, known as CIP (cleaning in place) system that allows cleaning without removing any equipment. The series of steps (rinsing, washing, disinfection and drying) can vary based on customer needs.

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High capacity freezer for food

Food manufacturers that produce ready meals such as pizza, burger patties, and bread require chillers as part of their cooling process before packaging. Chillers for large-scale applications help in making the most out of the space to accommodate these food products.


<h2>Cooling ready meals in an enclosed spiral setup</h2>
The Spiral Cooler/Chiller from Orange Freezing is an industrial-scale chiller for food products. The system has a spiral setup where the products to be chilled are loaded to save space. An evaporator is placed beside the spiral to remove humidity from the product. They are enclosed in a hygienic box consisting of stainless-steel walls and ceiling with insulated floors. For an increased level of hygiene, the bearings and drives are located outside the enclosure. This also simplifies maintenance. The box has adjustable feet which makes installation and relocation of the system quicker.

The system features the Opti Flow horizontal airflow design, that the company created to maintain the temperature and air speed all throughout. This helps minimize loss of moisture and retention time for cooling of products. The capacity rate of the system can go as high as 4 tons per hour. Products with temperatures from 80°C to 90°C can be cooled down and ready for sealing and packaging.

Spiral cooler/chiller

Frozen food manufacturers with products such as chicken parts, fish, and convenience foods require freezing processes with good hygienic standards. Products must also be frozen in the shortest time possible with minimum weight loss for a better yield.

<h2>Freezing food products in a hygienic space</h2>
The Spiral Freezer from Orange Freezing is an industrial-scale freezer with good hygienic standards. The system is composed of a hygienic box with stainless steel walls and ceiling, a spiral belt for loading products to be frozen, and an evaporator to remove humidity from the products. Additionally, the bearings and drives for the system are positioned outside the box for increased hygiene level and easy maintenance. It is equipped with insulated floors and the box is mounted with adjustable feet for quick installation.

The system features Orange Freezing’s Opti Flow horizontal airflow design that keeps the temperature and air speed the same all throughout, which helps minimize loss of moisture. Retention time for freezing is also minimized as a result.

Spiral freezer

When processing heat-sensitive products such as coffee, fruits, vegetables, or meat, maintaining product quality during drying is essential. Traditional drying methods often lead to oxidation, flavor loss, and higher energy costs, which can be problematic for maintaining clean labels and product integrity.
<h2>Gently dries products with minimal flavor loss</h2>
The DryBand Lyo by Bucher Unipektin is a belt dryer designed for the continuous freeze-drying (lyophilisation) of pre-dried or frozen food pieces, as well as coffee. It handles free-flowing granular products, maintaining high product quality through non-oxidizing, low-energy drying. This system involves a series of belts that convey products in a controlled environment, using independent heating zones and patented radiant plates to optimize drying rates. Feeding rates range from 2 to 4000 kg/h, with heating and cooling surfaces from 0.2 to 325 m², and a heating range of 20 to 180 °C. The vacuum levels vary from 0.5 to 50 mbar, ensuring gentle, efficient product handling. Its closed system design ensures automated operation and cleaning, making it suitable for industries like coffee/tea, fruits and vegetables, meat or seafood, pharmaceuticals, probiotics, enzymes, and infant nutrition.

Continuous freeze drying solution for coffee and food pieces

When packing frozen foods into cartons, your packaging system should be cleaned by wash-down using corrosive substances or high-pressure water to clean the surfaces that contact the food.


<h2>Pack frozen foods in cartons with a smart hygienic system</h2>
The MAESTRO Cartoner, from Mpac, is an automated side-load cartoning system for packing frozen pizza, ice cakes, frozen fruits, and ice creams. It’s made of hygienic and corrosion-resistant stainless steel and equipped with a dedicated infeed system for bags, pouches, flow-wrapped products, and other tailored solutions. The system can accommodate a wide range of carton sizes and types, such as display cartons, flip top cartons and pre-glued sleeves and has Intelligent Machine Interface (iMi) in place for automatic changeovers and machine status information. Processes in the system include precise carton erecting, loading, transportation, and closing. The entire system is servo-driven and directly coupled to its components, reducing wear and prolonging operating life.

Washdown Cartoner For Frozen Foods

Adequately packaged frozen fries retain their original color, taste, and texture. And because frozen items like French fries are perishables, they need to be quickly packed and stored before they spoil. This is primarily why using a high speed frozen food automatic case packer can be effective and beneficial for mass production lines.

<h2>Quick, damage-free packaging for frozen French fries</h2>
The BluePrint Automation Cubemaster 300 offers a faster and more efficient solution to adequately pack frozen fries, utilizing all the box space and stacking the product vertically and horizontally. The Cubemaster 300 is a gravity case packer built for flexible frozen bag packing. It arranges the products on the belts, including a vibrating one that settles the bags before they are stacked on top of the other. They are then side-loaded into the carton packages with just the right speeds and precision, without damaging the fries inside.

Gravity packers don’t require a tool changeover as they function with handwheel adjustments. They pack different sizes of frozen fries and other frozen potato products such as service food bags or retail bags. They also rapidly yet delicately pack heavier frozen goods as well.

The Cubemaster 300 can be applied by manufacturers of other food products, for instance grated cheese.

Frozen food automatic case packer

Mpac Group is an industry leader in packaging automation, cartoning, and case-packing technologies.

Frozen pizza has come a long way since the Celentano brothers first commercialized it in 1957. To completely grasp how much this comfort food has taken over, consider that Italy, the country where fresh pizza originated, is now the third-largest player in the frozen pizza market in Europe.

To learn more about the challenges of mass-producing frozen pizza, we spoke with pizza cartoning experts Luc Smeets and Michael Weber from the <a href="https://mpac-group.com/" target="_blank" rel="noopener">Mpac Group</a>, specializing in packaging automation.


<h2>Mastering the art of handling large pizza cartons</h2>
Frozen pizza is produced on an industrial scale and at high speeds to keep up with the vast market demand. An industrial pizza oven operates continuously at 350 °C and can produce 10,000–15,000 pizzas each hour. Can you imagine what would happen if, right at the end of the line, your pizza cartoner gets stuck?

Pizzas piling up everywhere. An industrial oven this size is not so easy to switch off to stop production flow. So, how to make sure even the end-of-line cartoner will run reliably?

One of the key challenges in the cartoning step is keeping the pizza carton intact while moving at such high speeds.

"<em>A pizza carton is 300 mm by 300 mm and controlling the movement of these big-sized cartons at higher speeds is not easy at all</em><em>. Our rotary system can gently erect the cartons by placing them on the conveyor belt, aligning them perfectly to receive the frozen pizzas</em>" explains Luc.

Also, keep in mind the pizza cartons often come in eye-catching branded designs<em>.</em>

<em>“You</em><em> need to check</em><em> and guarantee</em> <em>that each pizza box looks </em><em>exactly </em><em>the same while running 180 pieces per minute</em>”. Michael points out.
<h2>Equally important is keeping the pizza itself intact</h2>
When the pizza comes out of the freezer, you want to minimize the time the pizzas are exposed to warmer temperatures and pack them within a few seconds.

"<em>To prevent damaging the pizzas, we have a special infeed. One or more pizzas are </em><em>placed</em><em> in a bucket by a conveyor system</em><em>, which </em><em>retracts once the bucket </em><em>is full of pizza and</em><em> moves on to the next bucket. Instead of shooting them in, the system follows them and gently pushes them sideways in the cartons</em>" Luc highlights.

And what about pizzas with toppings? Apparently, frozen toppings like mushrooms are hard as stones, and if your pizza is forced into a carton that doesn’t match in height, the toppings will spread irregularly and may even damage the carton itself.

<em>"Our cartoner can control the pizza carton in such a way that it is still possible to push in the pizza without damaging the carton or pizza, even if the pizza is a little higher than the carton. In case of a clear height difference, the intelligent software identifies the height difference and sorts the pizza out to avoid stopping the machine and damaging the pizzas so as not to waste," </em>Michael claims.

As Michael reminds us, pushing the pizza into the carton with too much force makes it act like a frisbee. And even though it may have the same disc shape, this tasty food is not designed for outdoor play.

The need for speed - Let's pack 180 frozen pizzas a minute

Food

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Freezing ready foods is a science in its own right. The process must be performed quickly to retain the quality, but decreasing temperatures too fast forms crystals, reducing shelf-life and distorting organoleptic properties. Apart from industrial freezers, frozen food production technology specialized packaging equipment that protects the items from freezer burn and cold chain degradation.

Frozen food

A snack is a small portion of food ready to eat and simple and fast to prepare. People usually consume snacks during the day between traditional meals such as breakfast, lunch, or dinner. Snack foods include simple products such as nuts, dried fruits, peanuts as well as packaged and processed foods. Puffed corn products made by extrusion or flavored potato chips are examples of processed foods.

Snacks

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Frozen pizza cooling

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Frozen pizza cooling Equipment

Which frozen pizza cooling technology do you need?

Hygienic and fully-welded spiral freezer for food

High capacity freezer for food

Spiral cooler/chiller

Spiral freezer

Continuous freeze drying solution for coffee and food pieces

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