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freezing-technologies

Freezing-technologies

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

Batch

Continuous

Food products such as berries and fries in large volumes may tend to stick and form clusters when they go to the freezer. These products must be frozen individually with uniform quality before preparing them for packing.


<h2>Freezing food products individually on perforated trays with pulsating air streams</h2>
The IQF freezer from Orange Freezing is a fluidized bed freezing system for food products. The system is equipped with food-grade perforated plastic tray bottoms with centrifugal fans and an agitation system that pulsates air. The process starts with the products being conveyed on a vibrating belt that makes them move and bounce around. While the products are moving, they are quickly frozen to avoid sticking to one another and to prevent dehydration. Then they are gently and uniformly frozen down to their cores as they move down the line and exit through a conveyor. The unit has a capacity range of 2 to 10 tons per hour.

IQF (Individual Quick Freezing) freezer

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

solid

<span style="font-weight: 400;">Remove the risks of cross-contamination and liquid nitrogen handling by adopting a freezer system that does not bring the coolant in direct contact with your samples. Increase storage space for the same footprint as a traditional freezer and improve access to samples without affecting the internal temperature and benefit from industry-leading temperature gradient.</span>


<h2><b>Liquid nitrogen freezer solution that removes risks of cross-contamination</b></h2>
<span style="font-weight: 400;">Suitable for a wide range of biotech and pharmaceutical uses, the Custom BioGenic Systems V1500-AB Isothermal Liquid Nitrogen Freezer provides nitrogen storage temperatures but without the need to bring samples into direct contact with the coolant. A patented jacket design means that liquid nitrogen surrounds the entire chamber whilst keeping the storage area completely clean and dry, allowing for exceptionally low temperatures throughout the unit.</span>

<span style="font-weight: 400;">As well as removing cross-contamination risk associated with collant contact, the V1500-AB also reduces health and safety risks associated with filling traditional freezers with liquid nitrogen as there is no splash risk.</span>

<span style="font-weight: 400;">Because the nitrogen is not introduced directly into the freezing chamber this allows the entire volume to be used for storage. The units will allow storage of a wide range of containers including aluminum and stainless steel square and vertical racks, mini racks, canister and frame systems, vials, boxes and canisters or cassettes.</span>

<span style="font-weight: 400;">The unit comes as standard with the respected Custom BioGenic Systems 2301 controller which handles auto filling and full monitoring of the unit, including alarms and data recording. The combination of controller and freezer design means the V1500-AB has an industry leading temperature gradient that averages -193°C inside the storage area.</span>

Liquid nitrogen freezer for safe and dry storage of your samples

Biotech equipment is used for cellular and biomolecular processing to develop products that improve our lives and the planet. With the help of specialized lab equipment, the active substance is manufactured or extracted from biological origin materials and typically produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Cell isolation, cultivation, cell banking, and culture expansion are called upstream processes. After harvest, the production process moves into a downstream process to meet purity and quality requirements which is divided into cell disruption, purification, and polishing. Biotechnology equipment makes use of various laboratory machinery such as bioreactors, centrifuges and incubators.

Biotech

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

liquid

As people become more health aware, frozen fruits and vegetables have become a popular customer choice. Thus, high-quality freezing without the loss of shape, aroma, or nutrition proves to be a vital aspect of production, making this system a great option for keeping the original characteristics of the product regardless of whether 700kg of strawberries are needed to be frozen or 14,000kg green peas.


<h2>Energy-efficient nitrogen-free fruits and vegetable freezer</h2>
The Easy Freeze by Pigo is a suitable system for high-quality and rapid freezing of fruits and vegetables without ruining their physical and nutritional properties. The fully controllable process of fluidization maintains the product above the belt in a cushion of air. This results in the immediate freezing of the crust and the core of the individual pieces, regardless of their type, shape, or current condition.

With the powerful ASR (Automatic Snow Removal) technology, the unit can operate for a few days without lowering freezing efficiency, eliminating the need of any defreezing related maintenance between employee shifts. Moreover, the nitrogen-free technology guarantees for cost-efficient operations. The nitrogen-free technology can also help in the restoration of misshapen products which improves the final quality of the packs.

Industrial IQF freezer for fruits and vegetables

Proofing is a phase in the baking production line that can’t be rushed. It’s an essential process for well-risen, well-shaped baked goods with a good flavor. A quality proofer should provide the right conditions for rising dough; slow airflow, controlled temperature and time as well as right humidity level will make all the products rise evenly.


<h2>A Spiral conveying system industrially proofs pastry before freezing</h2>
The Spiral Proofer by ICS Spiral Freezers provides the right climate conditions for every proofing stage. The system is provided with an air treatment unit located on the top of the spiral, that can control temperature, moisture and air speed parameters throughout the whole proofing process ensuring evenly sized products. For large capacity proofers, its robust and site-built concept ensures a fast assembly and sound operation. The Spiral Proofer can process capacities up to 6000 kg/hour or more.

To prevent the slip and stick effect (when pastry doughs bump on each other, which leads to product waste), the Spiral Proofer is fitted with a Direct Drive System that allows the belt to go on without interruptions. With the DDS (Direct Drive System) manufacturers don’t have to worry that products will move on the belt and stick to each other– the belt engages the drum with special teeth which makes it unmovable. Thanks to this technology, products stay in the original position throughout the entire proofing process.

The Spiral Proofer ensures a hygienic design and accommodates easy cleaning and low maintenance. Easy cleaning comes with a spray nozzle system, known as a CIP (Cleaning In Place) system that allows a cleaning without removing any equipment. The series of steps (rinsing, washing, disinfection and drying) can vary depending on customer needs.

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High capacity spiral proofer for pastry

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

Cooling baked goods and food products can be problematic for sliced baked goods. A crusty texture can become leathery and tough. Crispness deteriorates if the goods are not cooled down properly. Having a sound cooling equipment will keep the quality and shelf-life of baked goods up to par.


<h2>A spiral conveyor cools down your baked products before packaging</h2>
The Spiral ‘Ambient’ Cooler by ICS Spiral Freezers, is a good solution to cool down produced and baked products (pancakes, loaves, doughnuts) to ambient temperature before freezing or packaging. The warm products will leave the oven chamber and travel on the continuous spiral conveyor which is driven by the Direct Drive System. With the DDS (Direct Drive System), manufacturers won’t have to worry about products moving on the belt and sticking or bumping on each other which could result in damage of the desired shape, even in the product waste. Thanks to this technology, products stay in their original position throughout the entire cooling process. Also, the system is equipped with height detection technology which checks product height, preventing a jam in the production process.

The Spiral Ambient Cooler can be designed as an up-going or down-going spiral. Additionally, the spiral systems are custom-made and can be designed for small places. For example, for manufacturers with low ceiling, the double (twin) spiral system can be applied. In such case, the up-going spiral and the down-going spiral are joined together by one belt.

The Spiral Ambient Cooler design follows the hygiene standard required by the food industry. Additionally, a belt cleaning system can be applied, making the technology even more hygienic.

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High capacity spiral cooler for food

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

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

Large food products, like whole chickens, may be packed in bulk or in large containers such as carton boxes or trays. These products can be chilled or frozen while kept inside the packages before storing or shipping out. But handling these  containers manually can be a difficult and costly task. By using a system capable of conveying large boxes for freezing, costs for manual labor are reduced while productivity increases.
<h2>Freezing bulk food products in boxes or trays</h2>
The Carton Box Freezer from Orange Freezing is a large-scale freezer for food products packed in large containers such as carton boxes, trays, and crates. The system is designed to convey the packed products into the Carton Box Freezer, where it is frozen using an horizontal airflow design called Opti Flow. Temperature and air speed inside the unit are maintained constantly to minimize retention time of the products and help save energy costs. After the freezing process, the products go out of the freezer through a conveyor ready for storage or shipment.

The system has a faster freezing time of about 6 hours compared to other similar systems, in which it varies between about 8 to 9 hours. Labor costs are also reduced as the system can be configured to convey these large containers into and out of the system. With its computer-controlled, fully automatic operation and a capacity of about 10 to 14 tons, productivity is marginally increased.

Carton box freezer

For quick freezing of food products like burger patties, bacon strips, potatoes, and fish, a cryogenic freezing process may be a solution. However, it is expensive to operate as it uses liquid nitrogen to quickly freeze the product. An alternative and cost-effective solution is to use air jets to freeze products just as quickly as a cryogenic process would and with the same quality.


<h2>Freezing food products by directing air jets on the products’ surfaces</h2>
The Impingement Freezer from Orange Freezing is an air jet system for freezing food products. This system creates a freezing environment based on the speed of air blown into its pressure chamber. Multiple high-velocity air jets are used to direct the air at the top and bottom surfaces of the products, which creates an implosion and removes the layer of heat around them. The system is best suited for thin and fragile products, and for applications that require freezing of the outer layer of the product. This method results in freezing speeds and quality that are close to cryogenic freezing.

There is also less dehydration from the products compared to cold storage freezing. The system has flexible configurations that fit different production setups using 7 available conveyor belt widths up to 6 feet (1800mm). It can also be configured to accommodate up to 4 different products simultaneously using 4 separate conveyor belts of 1.5 feet (450mm) width. The freezer is ideal for crust freezing applications where the outer layer of the food product is frozen.

Impingement freezer

Frozen food manufacturers may require pre-freezing processes as part of their production steps before conveying their products to the freezer. One such application is for meat products where part of the product surface is frozen to improve handling and to minimize sticking and drip loss. Products like fruit pulps also require surface freezing before cutting.


<h2>Partial surface freezing of food products for easy handling and preparation</h2>
The Contact Freezer from Orange Freezing is a surface contact freezing system that can be used for a preliminary freezing process or as a single solution for preparing food products. The system is equipped with a refrigerated plate and a Teflon belt that runs over it. The products are conveyed on the belt until they get a stable frozen crust on the contact surface. This method allows minimal drip loss and reduces dwell time in the final freezing process. The unit is also equipped with adjustable feet for quick installation and easy relocation. The material construction of the equipment is stainless steel, which meets the highest hygiene standards.

Contact freezer

<span style="font-weight: 400;">For biotech and pharmaceutical cryopreservation, liquid nitrogen vapor storage provides a cost-effective and efficient solution where shorter-term storage is required. Vapor phase freezers provide easier access to the stored samples and provides higher levels of user protection from contact with the liquid nitrogen.</span>


<h2><b>Superior temperature stability with ease of access</b></h2>
<span style="font-weight: 400;">The Custom BioGenic Systems EV10 EcoVapor Liquid Nitrogen Freezer provides access to cost-effective and efficient liquid nitrogen vapor storage. Liquid nitrogen is pooled in the bottom of the freezer and a patent-pending custom engineered vapor insert enables superior temperature uniformity in the -180°C range. Because there is no liquid in the storage area it minimises risks involved with contact with liquid nitrogen.</span>

<span style="font-weight: 400;">The unit is controlled by the Custom BioGenic Systems Model 2200 controller. This unit features a dual temperature display and auto-fill capabilities that is fully software driven for automatic operation.</span>

<span style="font-weight: 400;">The EV10 features a lightweight, lockable, lift-off lid for easy unrestricted access to samples. The unit offers a capacity of 45 litres, with a maximum usable internal storage height of 737mm and internal diameter of 559. This generous sizing combines to enable the storage of up to 10,725 2ml vials using 5 mini racks.</span>

Liquid nitrogen vapor storage freezer

<span style="font-weight: 400;">For safe and convenient delivery of liquid nitrogen a robust and portable solution is paramount. This wheeled transport tank provides ease of use and operator safety for the supply of liquid nitrogen as a cryogen for long-term storage of samples in cryogenic freezers.</span>


<h2>Portable and robust storage tank that’s simple to use</h2>
<span style="font-weight: 400;">With a large 230 litre capacity, the CC230LP-SB liquid nitrogen supply tank is suitable for use in a wide range industries.</span>

<span style="font-weight: 400;">Featuring a robustly constructed wheeled platform with integrated handle, the unit is easy to move to exactly where it’s needed by only one operator.</span>

<span style="font-weight: 400;">Operating at 22psi (151.7kPa) this insulated unit has a class-leading evaporation rate of only 2% per day, reducing wastage and improving your operational efficiency.</span>

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Cryogenic industrial gases transportation supply tank

Handling

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

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

Connect directly with world leading manufacturers of Freezing equipment and find technology to build or improve your production line.