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Let's make frozen foods

Your cooked foods are typically exposed to high heating conditions and could take a long time to drop to the right temperatures for further processing or packaging. Cooling tunnels consist of a series of blowers and exhaust hoods that rapidly extract the heat from your products as they travel on a conveyor belt.

Cooling tunnels

Chemical products engineered at high temperatures require specialized cooling techniques that transfer heat off free-flowing materials in a homogenized manner and at a fast rate. Drum coolers spread your material into smaller volumes and pass it through a series of cooling chambers that force temperatures down using counter airflow or water-jacket technologies.

Drum coolers

Drying cabinets consist of an enclosed chamber where products to be dried are placed on stainless steel trays. These drying systems reduce the relativity humidity allowing the moisture to evaporate quickly. Cabinet dryers are widely used for reducing the moisture content of sensitive products.

Drying Cabinets

Flow Pack Machines

It goes by many names. Freeze drying, lyophilization, or cryodesiccation is a form of dehydration that involves freezing the product to remove its water content and then removing the ice by sublimation – this means going from the solid to the gaseous state without going through the liquid phase. Freeze dryers are widely used in the pharmaceutical industry to increase the shelf life of products such as vaccines and other injectables. Due to their ability to best preserve the flavors, freeze dryers are used for food preservation in the food industry by dehydrating high-value products such as seasonal fruits or coffee. Industrial freeze drying systems are usually comprised of multiple components including vacuum pumps, stainless steel condensers, some form of heating and lastly, a chamber for drying where the materials are placed and processed.

Freeze dryers

Your processed foods are passed through a spiral cooler to quickly freeze them down and maintain a uniform temperature between defrost stages. Products are loaded onto a coiled conveyor surrounded by evaporators that draw out the moisture from your items. Meanwhile, large flow fans circulate cool air  at a controlled temperature.

Spiral coolers

Vacuum dryers are typically used to dry fabrics that are sensitive to heat. They find application in the production of active pharmaceutical ingredients, fine chemicals, and food products. Contact us to find out which vacuum dryer is most suitable for your specific application.

Vacuum dryers

Cartoning involves erecting a folded carton, filling it with the product, closing the flaps, or applying a lid and sealing with glue or adhesive tape. Choosing a cartoning solution involves, considering the type of primary packaging, the production volume, the size and count of the product in a carton, and the desired level of automation.

Cartoning

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

Freezing

Labels provide customers with important information about both your product and your brand. Different labeling technology attaches the printed film to the packaging using a range of methods such as shrink wrapping, side sealing, and adhesives. For added traceability and protection, you may also use serialization coding equipment and anti-tampering labeling systems.

Labeling

The Pasteurization process is the method of subjecting liquids to mild heat at a specific temperature and time, and quickly cooling them down again in order to destroy pathogens in your fermented or semi-fermented products. Thus, increasing the shelf life of the manufactured products. Untreated microorganisms may lead to diseases, spoilage, or unwanted fermentation. Most pasteurization equipment operate in a continuous method using plate heat exchangers to keep a uniform level of high efficiency sterilization.

Pasteurizing

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.

Continuous

Mass-producing french fries from raw potatoes requires a series of steps and various equipment for cleaning, drying, peeling, cutting, and frying, each presenting its own technical challenges. Bringing together all these processes involves the integration of multiple machines into a unified system, requiring effective communication among them to ensure a seamless and efficient operation.


<h2>All-in-one processing system for turning raw potatoes into French fries</h2>
The French fries plant from Kuipers is a complete turnkey solution for producing a range of potato-based products, including French fries, potato wedges, skin-on fries, and pomme Parisienne, starting from raw potatoes. The plant encompasses essential processes such as washing, peeling, cutting, sorting, blanching, drying, and frying.

The washed potatoes undergo initial cleaning in a rotating cage to separate soil and sprouts. A cyclone destoner with adjustable water flow removes stones that can create damage downstream. Next, a rod washer eliminates mud before the potatoes are exposed to high-pressure steam, which minimizes product loss during peeling. Subsequently, rotating nylon brushes remove the potato skin without the need for water. Roller inspection visually examines potatoes for defects that can be manually trimmed. Kuipers introduces a smart integration of hydro and mechanical cutting systems, enabling the production line to handle various cutting shapes and sizes efficiently with rapid changeovers.

Blanching uses a two-stage blancher. The first stage pre-gelatinizes the starch, inactivates enzymes, and opens up the starch cells. The second stage completes gelatinization and releases as much reducing sugars as possible. SAPP (Sodium Acid Pyrophosphate) solution is added to the product to prevent discoloration at later stages. Drying the potato strips is essential for proper product texture and lower oil absorption during frying. Additionally, the drying process plays a significant role in determining the moisture content of the end product.

A continuous fryer with adjustable temperatures and retention times handles the frying step. Additionally, a de-fatting shaker uses specific vibration movements to remove a significant amount of frying oil while keeping the bottom pan heated to recover the used oil easily.

French fries processing line

Frying was an early method for preserving food. The most common technique, immersing foods in boiling oils, dehydrates the items and decreases microbial growth. But even with alternative decontamination and preservation methods, frying remains a popular cooking technique. The oils add complexity to the natural flavors and textures of foodstuffs. One of the main challenges of fried products is maintaining oil freshness. Industrial frying equipment processes large volumes of food homogeneously by strictly controlling the temperatures in the frying chamber. However, oil efficiency is also crucial, and temperature control must balance oil levels in the line.

Frying

Accuracy is a primary concern for case-packing pre-packaged foods such as milk or preserves. But in order to position items into large cases at high speeds, the infeed system must quickly adjust to different packaging options, including cartons, cans, pouches, and doypacks.


<h3>Pack foodstuffs automatically in RSC and WA cases at high-speeds</h3>
The ALISIO, from Mpac, is a side-load case packing system for a range of pre-packaged formats. Snacks, beverages, and foods may be loaded into regular slotted cases (RSC) or wrap-around (WA) cases. The high-speed system reaches a maximum output of 25 cases per minute. At the same time,  the intuitive, user-friendly controls with Intelligent Machine Interface are designed for automatic changeovers of less than 10 minutes.

The system supports small batches allowing operators to switch between RSC and WA cases. Its open and robust construction makes all components accessible and easy to clean. The case magazine can be adjusted to accommodate up to 300 cases. The ALISIO is servo-driven and directly coupled to its components to minimize wear and improve operating life. A modular infeed design makes handling bags, pouches, cartons, and other types of packaging easy. The unit is designed to operate continuously with fewer stops for maximum productivity and is rated at 98% efficiency.

Side Load Case Packer For Packaged Food

<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

Batch

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

solid

Bakeries that serve products like croissants, pastries and other baked goodies need to maintain constant temperature and humidity during proofing or final fermentation process. This allows all the dough to rise evenly before loading it to the oven.


<h2>Controlling temperature and humidity for even proofing of baked goods</h2>
The Spiral Proofer from Orange Freezing is a system for proofing baked products in a precisely controlled temperature environment. The system features Orange Freezing’s Opti Flow horizontal airflow design that maintains the temperature and air speed all throughout the proofing process. It is composed of a hygienic box with a spiral assembly and an evaporator inside. The baked goods are loaded on the spiral assembly, where temperature and humidity are controlled until the entire proofing process is completed. The box has stainless steel walls and ceiling with floors that are insulated. The bearings and drives for the spiral assembly are placed outside the chamber for hygienic purposes and quick maintenance. The box is also equipped with adjustable feet for quick installation.

Spiral Proofer

For high speed palletizing, palletizing high payloads, or just where greater flexibility is required, introducing a high level of automation can prove very beneficial.


<h2>Anthropomorphicc palletizer for bags bundles and boxes</h2>
Paglierani's Anthropomorphic palletizer is a great choice for in-line packing of varied loads. Suitable for all sizes of bags, bundles and boxes, the anthropomorphic arm's versatility and flexibility provides a solution for almost all palletising situations.

Made with Italian precision and built-in monitoring and control, this modular equipment can easily be integrated into a production line.

Palletizing robot arm

If storing and transporting products easily is a problem for your industrial production, then you need palletizing solutions. A pallet is a flat structure, on which containers of the packaged products are stacked to consolidate the product and to make it easier for a forklift to lift the goods for warehousing and transportation. A palletizer is a machine that automates or simplifies the process of stacking product containers onto a pallet. The choice of an industrial palletizer depends on the type of product packaging such as bags, drums, or boxes, the level of automation required, and the in-feed to the palletizer. Palletizers find applications in all major industries including food, chemical, and pharmaceutical.

Palletizing

Frozen food

A frozen cake can last up to 6 months before the texture begins to change. But if the freezing process isn’t carried out correctly, ingredients start reacting sooner. Cool the cake down in a cooling tunnel before flash freezing them to avoid crystallization. Finally, wrap the products to limit contact with air before loading them into their cartons. Whether sheet or layered, making frozen cakes is no piece of cake.

Frozen cakes

A juicy piece of fruit evokes images of sunlight and warmth. But manufacturers take the reverse route and freeze the harvested products to keep their nutritious mix of minerals, fibers, and vitamins intact. Frozen fruit processing equipment takes temperatures down to around -18 °C, giving the foods an extended lease of life. Many smoothies, jams, and purees we consume are the fruit of frozen labor.

Frozen fruit

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

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

Find manufacturing technology for frozen food products and connect directly with a global network of leading machine suppliers.

Let's make frozen foods

Which frozen food equipment do you need?

French fries processing line

Side Load Case Packer For Packaged Food

Washdown Cartoner For Frozen Foods

Spiral Proofer

Palletizing robot arm

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French fries processing line

Side Load Case Packer For Packaged Food

Washdown Cartoner For Frozen Foods

Spiral Proofer

Palletizing robot arm

Stories about frozen food

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

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