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spiral-cooler

Spiral-cooler

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 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

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.

Industrial

For manufacturers handling vast quantities of food products, maintaining optimal freezing conditions is essential. Consistent air temperature and speed are critical to minimize residence time and weight loss, ensuring a higher yield of quality frozen products.
<h2>Ensure uniform freezing with horizontal airflow</h2>
The Optifreeze™ Spiral Freezer from Dohmeyer is specifically designed for large capacity cryogenic freezing applications. With its unique horizontal airflow system, this freezer maintains consistent air temperature and speed across all levels, minimizing product residence time and reducing weight loss for higher yield. Its modular design enables custom-made solutions tailored to meet specific production requirements, ensuring maximum flexibility and efficiency. The Optifreeze™ is ideal for various food products, including convenience foods, ready meals, frozen snacks, chicken, fish, poultry, bread, bakery products, and fruits and vegetables. Additionally, the modular concept of the freezer minimizes installation time, further enhancing production efficiency.

Large capacity cryogenic spiral freezer

Freezing

solid

Efficiently freezing food products with high surface-to-volume ratios while minimizing dehydration and fitting into limited floor space is challenging for many industrial food processors.
<h2>Increase freezing capacity through high-velocity airflow</h2>
The High Performance Tunnel Freezer from Dohmeyer is designed to maximize freezing efficiency through its innovative use of high-velocity turbulence fans. These fans increase gas flow inside the freezing modules, effectively blowing away the insulating layer of air around the product. This results in the highest freezing capacity for a given floor space and the lowest possible residence time. The compact design makes it suitable for facilities with limited space. The freezer is ideal for products like pancakes, hamburgers, and pasta, where rapid surface freezing is crucial to reduce dehydration. Featuring patented control strategies for both temperature and gas flow, the Dohmeyer High Performance Tunnel Freezer is tailored to meet specific industrial requirements.

High performance tunnel freezer for industrial food processing

In beverage production, managing the temperature of packaged products is critical to ensuring quality and safety. Packaging beverages at either cold or hot temperatures can lead to microbial growth or structural integrity issues, making effective temperature control essential.
<h2>Efficiently regulate beverage temperature post-packaging</h2>
The heating and cooling tunnel from Co.Mac is designed to regulate the temperature of packaged beverages, bringing them to room temperature efficiently. Suitable for products like beer, wine, soft drinks, hard seltzers, ready-to-drink beverages, and energy drinks, it handles multiple container formats, including cans and glass bottles. The system features easy cleaning and maintenance, with each tank equipped with doors on one side and double panel filters that can be extracted from the pumps side. Available in sizes of 10 sqm, 25 sqm, and 36 sqm, the tunnels are capable of handling various production scales.

Heating and cooling tunnel for beverages

<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

liquid

When freezing large quantities of fruits, sauces, and vegetables efficiently, maintaining product quality while minimizing human intervention and operational costs is crucial. Traditional freezing systems often fall short, leading to inconsistent product quality and higher labor costs.
<h2>Ensure even and consistent freezing</h2>
The Spirafreeze system by CFT Group is a highly automated industrial spiral freezing system designed to handle various food products without continuous human intervention. With the spiral technology, this system ensures even distribution of cold across all products, maintaining consistent freezing quality. It boosts production efficiency by eliminating the need for constant monitoring and intervention. Constructed to reduce labor costs and increase operational cost-effectiveness, the Spirafreeze system is suitable for industries processing fruits, sauces, jams, and vegetables. Utilizing air technology, it has high capacities ranging up to 10,000 kg/hour, making it ideal for large-scale operations.

Industrial spiral freezing system

Continuous

In the production of wafers, maintaining product quality and ensuring proper cooling are essential. The cooling phase can present issues such as uneven cooling, product deformation, and hygiene maintenance challenges.
<h2>Facilitate consistent wafer cooling</h2>
The Franz Haas SPK Wafer Block Spiral Cooler from Bühler is designed to address the challenges faced in wafer production cooling processes. It features a modular design, allowing for customization according to specific customer needs. The fully insulated housing and optimized airflow system provide high energy efficiency and consistent cooling results. To maintain hygiene standards, the cooler includes accessible corridors within the housing and an optional conveyor cleaning device. This cooler ensures gentle horizontal handling of wafer blocks throughout the process, preventing product deformation. It's suitable for high-quality wafer production with minimal footprint and easy maintenance.

Wafer block spiral cooler

In the bakery industry, producing large volumes of consistent, high-quality English muffins poses unique challenges. This includes ensuring precise dough temperature, gentle handling, and efficient processing, all while maintaining energy efficiency and sanitation standards.
<h2>Produce large volumes of consistent english muffins</h2>
The English Muffin Production Systems from AMF Bakery Systems, developed in partnership with Sugden, Ltd., provide an optimized, turnkey solution. These systems can produce up to 26,000 units per hour, featuring an insulated griddle that reduces energy consumption by up to 20% and individual servo drives for better control. The MuffinFlex Divider & Rounder ensure accurate scaling, while the Open Frame Mixer maintains the precise temperature range needed for optimal results. Designed for ease of maintenance and sanitation, these systems include tool-less removal for certain components and flexible configurations. Additional components such as the Vesta Spiral Cooler and the VersaLoader Robotic Product Loader further enhance efficiency and product handling.

English muffin production system

Blending

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

A loading system feeds your continuous or batch processing machine with the specified material or item in line with the flow of production. Loaders transfer the articles from one stage of preparation to the next with uniformity and accuracy.

Loading

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

In large-scale baking operations, maintaining optimal cooling conditions for products like bread, rolls, and pastries is critical to preserving their quality and shelf-life. Overheating can lead to spoilage and inefficiencies in the baking process, necessitating reliable cooling solutions.
<h2>Custom-configured cooling for continuous flow</h2>
The Vesta Spiral Cooler by AMF Vesta delivers customizable and modular cooling solutions designed to enhance sanitation and efficiency in industrial bakeries. Its spiral configuration ensures continuous product flow, promoting uniform cooling across a wide range of baked goods. The system's modular design elements make it easy to clean and maintain, minimizing downtime. Trusted by the industry's top bakers, the Vesta Spiral Cooler supports seamless integration into existing production lines while ensuring consistent, high-quality results. With over 1,000 global installations, it stands as a proven solution for intermediate and final proofing, baking, cooling, and freezing applications.

Spiral cooler for industrial baking

Batch

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

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

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

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

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 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

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

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

Spiral coolers

The Roman quip “bread and circuses” says everything about the ubiquity of loaves through the ages. But although flour, yeast, and water are still the main bread recipe ingredients today, the baking process as well as the bakery equipment available, takes this basic formula to new avenues. From sprouted wheat challah to beetroot ciabatta and protein rolls, breadmaking has changed considerably since the time of the Roman empire.

Bread

Croissants have crossed global barriers to become a widely consumed pastry, unique for its rich buttery taste and crispy exterior. Regardless of location, the croissant production process involves creating laminated dough by repeatedly folding and rolling butter into dough. Temperature regulation is crucial to the croissant making process as too warm temperatures negatively affect the overall outcome.

Croissants

Dough

Only a few things are as attractive as a gorgeously glazed doughnut. Even when customers are not in the mood, that beautiful sheen will invite them to take a bite. To achieve this appearance, the two doughnut types, cake and yeast doughnuts, can use the help of appropriate doughnut making equipment.

Doughnuts

Thomas Jefferson served as the third US president, extended the country’s territory, and authored the Declaration of Independence. But his lasting impact on American society goes beyond politics. He is credited with introducing French fries after his stint as Minister to France. The tasty snack remains a global favorite, cut in all shapes and sizes and topped with imaginative condiments. But while the 19<sup>th</sup> century President had his potato chips prepared by his cook, serving the market demand today requires specialized French fry processing equipment.

French fries

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

They can be eaten with a sauce of choice, seasoned with various spices, even battered and deep-fried again, served for lunch or as bar food, but one is for sure - everyone is a fan of potato wedges! But how does a plain potato become a delicious wedge? Potato wedges are processed with the help of standard potato processing equipment and undergo processes of washing, peeling, slicing, and cooking.

Potato wedges

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