We were approached by a client working in the berry processing industry. The company was expanding, and at a certain stage, it became clear that the existing freezing capacity was no longer sufficient. It was necessary to increase the volume of finished frozen products without compromising quality and with the ability to operate stably during peak seasons.
The customer decided to install a berry blast freezing tunnel that would operate on a CO₂ refrigeration system.
Initial conditions and tasks
Before launching the project, we worked with the client to define the main objectives:
- increase the volume of shock-frozen berries so that the company could produce more finished products per unit of time;
- integrate the tunnel into the existing processing line without stopping production for a long period;
- implement a CO₂ refrigeration system as a more modern and environmentally responsible solution;
ensure stable operation of the complex in continuous freezing mode throughout the shift and season.
Implemented solution
We took on the entire scope of work: from equipment selection to installation and commissioning.
1. Delivery of an OCTOFROST quick-freezing tunnel
An OCTOFROST quick-freezing tunnel was selected and delivered for this facility, designed for:
- freezing up to 3700 kg of berries per hour in a continuous flow;
- careful handling of the product to preserve the shape and appearance of the berries;
- uniform freezing of the entire mass, which is important for the stable quality of the finished product.
As a result, the customer achieved a significant increase in the actual throughput capacity of the freezing line.
2. Design and installation of a CO₂ refrigeration system
For the tunnel operation, we separately:
- developed a CO₂ refrigeration system design, taking into account the tunnel’s operating mode, technological parameters, and production characteristics;
- installed a refrigeration system with a cooling capacity of 480 kW, which is sufficient for stable tunnel operation at the required capacity;
- We configured the interaction between the tunnel and the refrigeration unit to ensure optimal blast freezing modes without temperature “drops.”
The use of CO₂ as a refrigerant provided the customer with a modern solution offering good energy efficiency and compliance with current environmental requirements.
Result for the customer
As a result, the client received:
- highly productive shock freezing complex for berries with an actual capacity of up to 3.7 tons/hour;
- stable quality of frozen products thanks to controlled operating modes of the tunnel and refrigeration system;
- the ability to process and freeze significantly larger volumes of berries during peak loads;
CO₂ refrigeration system with power reserve for further production development.
Are you planning a similar project?
If you are considering launching or upgrading a blast freezing line for berries or other products, the 4 Elements team can:
- analyze your initial data and tasks;
- select a blast freezing tunnel with the required capacity;
- design and install a CO₂ refrigeration system;
- support the project from the idea stage to stable operation in industrial mode.
Leave a request and we will prepare an individual solution tailored to your production.