The competition for food processing and the cold chain industry,
It's basically a "time and temperature" saw war.
In more than 20 years of customer service, the top of the roof has found that most generations of factories are facing a loss of Maori.It's all about the "hidden formation of the traditional freezer."
When traditional cold-freezing banks are no longer able to meet the stringent requirements of modern chemical plants for production capacity, probabilities and food security, the introduction of more advanced cold-freezing technologies is the only solution for breaking through the production bottle and raising Maori.
What does IQF mean? ♪ Quick freeze ♪
IQF Individual Quick Freezing means "one rapid, fast freezing."It is based on the use of very low temperatures and high-speed air currents below -35°C to allow food products (such as seafood, meat, vegetables) to stand alone through the largest ice-crystal generation belt in a few minutes. This is an effective way to prevent food blocks from stickling, locking water and reducing the defrosting rate to less than 1%.
Instead of placing large amounts of food in boxes and stacking on cars into cryogenic colds, the IQF technique is to make every shrimp, every blueberry, every piece of meat or every water plume frozen in a stand-alone state, in a very short period of time through a low-temperature wind hole, or a speed belt.
For the head of the plant and the head of the production line, there is a lot of work to be done.
IQF solves the "stuff problem" of the processing plant.
Under very low temperatures (usually -35°C to -40°C or even lower) and high-speed air currents, surface moisture is immediately solidified, and the food is completely non-obedient. This means that back-end measurements, distributions, and packages can directly lead to fully automated devices. A consumer or a B2B customer can also "take as much as you want" without having to take the whole block back.A major increase in the commercial value and accessibility of products.
Which industries need IQF technology most? I've seen a lot of scenery for you!
IQF technology is not an exclusive industry.
IQF is an excellent application for IQF, as long as your products are equipped with "high economic value", "fear of the knot" or "focus on the post-frozen taste":
- Aquaculture:
Shrimps, shrimps, dried beaks, scabs, fresh fish slices.
IQF avoids shrimp and seafood surface frosting, and maintains a bright and bright velvet after the thaw. - This is not the case.
Beans, corn grains, broccoli, blueberries, mangotine.
Freezing at extreme speed can lock down chlorophyll and phyll and avoid the thawing of vegetables. - Meat and poultry processing:
Chicken, meatballs, dice, burgers. Make sure the gravy isn't lost, keeps the meat bullety and sweet. - Food and bake:
Aqueducts, buns, frozen noodles, microwave ready-to-eat packs.
It is perfect to protect yeast activity in the pasta and prevent the growth of bacteria during the cooling process.
Dismantling fast-frozen principles: the final battle "Maximity Crystal Generation Belt"
In order to understand why IQF can successfully lock up the freshness of food, it has to be explored from a food science perspective.Speed freeze.。
The key to the technology, it's on temperature. 0°C to -5°C Area.
The physical system of the biggest crystals.
In nature, most foods fall between 60% and 90%.
When the temperature of the food dropped to 0°C, the internal water began to freeze.
But when the temperature continues to drop to -5°C, about 80% of the free water inside the food will turn into crystals. According toFood and Agriculture Organization of the United Nations (FAO) Refrigeration Technology GuideThe food science community defines this area as the "Maximity Crystal Generation Belt".
At the heart of the fast-frozen principle is:
Using a strong cooling system and currents, using the most violent cooling speed, force the food to kill in seconds.。
The deadly difference between microcrystals and big ice crystals.
The slow rate of cooling directly determines the physical shape of water molecule ice.
This is also the most important indicator of "student reduction" and "cell integrity" for product protection and development:
- Slow cooling (traditional freeze):
Water molecules have plenty of time to move and aggregate in their cells, and eventually to form large, sharp and irregular "black crystals". - Extreme cooling (IQF fast freezing):
Temperatures are so fast that water molecules can't get to one another, they can only freeze in situ in an instant, and form a "microcrystal" that is numerous but very small in size.
Water molecules and scavengers.
Plant cells are equipped with hard cell walls, and animal cells have fragile cellular membranes.
When the traditionally frozen large crystals break through and pierce these cells like blades, the eye tends to see no difference at the moment of freezing. However, once the product enters the final consumer's kitchen or restaurant and starts to defrozen, the ruptured cells are unable to lock the water, leading to a significant loss of juice, water soluble vitamins and flavors (known as "blood water" or "freeze water").
According to top-tech plant studies:
It takes 3-4 hours at the earliest to freeze the product in a conventional freezer. Using top IQF devices, for example, it takes about 20 minutes to complete an extremely fast-frozen thaw, as is often the case with a little tunic or a soup bag; even larger, packed bags of mountain twigs, it takes about 90 minutes. The IQF equipment, through a tattered copper-covered chiller and a high-pressure winder, allows the core of the product to pass in seconds - 5°C maximum crystal-generation belts, with a time efficiency difference of more than 10 times.
And the resulting microcrystals are round and small, and they preserve the cell structure perfectly.
I want to know more.👉 2nd : Breaking the "Maximity Crystal Generating Belt"! How to prevent cell damage and lock up the original frozen food?。
Common IQF equipment type: tunnel and spiral
In order to achieve the effect of "one-size-size-fits-all cooling", IQF equipment is currently available in two main mainstream types.
You can choose according to the spatial and product characteristics of the plant:
- Tunnel Freezer:
The food is flat on the net and straight through the cold tunnel.
It's for flat, light or short-term freezing.
(e.g. meat tablets, watercrackers).
The advantage is that the structure is simple, but the disadvantage is that the occupied plant is very long. - Spiral Freezer:
Take a 3D spiral to the top of the belt.
Fits to a thicker, longer frozen product.
(e.g. whole chicken, big meat, tweezers).
The greatest advantage isExtremely high plant., to exchange the smallest land-tenure for the largest continuous capacity.
I want to know more.👉 【 Title 6:Tunnel vs spiral chiller, land occupation versus property。
Compared to traditional freezing: depth analysis of five major business assessment points
In order to enable you to further evaluate the value of the investment in the equipment,
The following is a five-dimensional comparison of IQF with the traditional freezer.
| Evaluation point | Traditional freezer | IQF, speed freeze. |
| Frozen Mode and Status | Static, stacked and stored. It's a natural confrontation with cold air. The product can easily crush each other and needs to be broken. | Motivated, high-speed cold-winds are packaged in all directions through the delivery belt or fluid bed. It's clean, it's unmistakable, it's not sticky. |
| Over the crystal time. | It takes 3 to 4 hours It's easy to form big ice crystals that destroy cells. | 20 minutes at the earliestDepending on the size, the size is about 90 minutes. (Only round tiny crystals of ice). |
| Unfrozen weight loss rate | Extremely High (5% – 15%)I don't know. The cell rupture caused the loss of precious juice and weight. | Very low (usually less than 1% - 2%)I don't know. Perfectly locked water, keeping the weight and flavor of the product. |
| Power and plant. | Batch processing involves the use of a large number of spaces for stationing and manual movement. | Continuous production, direct front-to-end processor and back-end packagers, and automatic high-level automation. |
| Control of the number of food and bacteria | Slow cooling and slow-down of central temperatures increase the risk of microbial reproduction. | The immediate freezing of the fermentation activity and the growth of microbes, which is easy to meet the HACCP requirements, is immediately blocked. |
Unfrozen weight loss: Eating the "hidden form" of business profits
For meat processing or high-priced water production, the weight is revenue.
Site test:
If a aquaculture plant handles 100 tons of high-priced shrimp per month:
Using the traditional freeze, if the defrosting rate is 8%, it's equivalent to 100 tons of the product bought by the client, with only 92 tons left, and the loss of 8 tons of high-value sweet meat. This not only triggers a B2B client complaint, but it is equivalent to a potential gain of millions of dollars a month.
If the imported IQF device reduces the weightlessness rate to 1%, it is equivalent to the value of 7 tons of products recovered every month.IQF’s hardware purchases are often fully distributed within one or two years.
I want to know more.👉 10: How meat mills reduce the rate of cold weight loss。
Breaking myths: Must IQF equipment be more power-consuming?
IQF's high-pressure machine has caused a huge increase in electricity costs.
In fact, in designing the IQF system, the top technology has specifically led to "Change Wind Speed Control" and "Cyclical Flow System within Unique Wind"It is not only the cold wind that has been able to kill the ice-crystals with the same foods, but it has also increased the length of the running time and delayed frost.The energy consumption of the units is lower than that of the traditional freezer compressors, which are running at full capacity for 24 hours.
The traditional freezer, which is very slow to cool, has to be filled with compressors over a long period of time, and there is a high rate of cold energy loss due to frequent staff access.
The first IQF facility is equipped with a better wind-traffic internal flow system that can be frozen in the shortest possible time. This is the first time that the construction costs are higher.However, the long-run unit energy consumption can be reduced effectively, in line with the corporate ESG conservation and carbon reduction layout.
Food security and auto-cleaning
The temperature of the traditional freezer is slow, and the temperature of the food core is still in the "hazardous temperature zone" (7°C) ~ It's too long, it's very easy to overstate the number of bacteria and the bacterium.
Professional IQF equipment not only freezes microbiological activity for an instant, but also uses SUS304 for steel, and selects a CIP (Clean-in-Place) self-cleaning system to make sure that it is clean and that the plant is comfortable. ISO 222000 Food Safety Management System or HACCPWe'll wait for strict internal and external food security standards.
Frequent problem (FAQ): 6 major details required to guide the device
Although IQF's advantage has been understood, it has come down to the construction and production line.
There are still the following recurring questions, and I will explain them once:
Q:How much budget would it take to get an IQF?
A: IQF equipment is a highly customised industrial-grade facility, the budget is estimated on the basis of capacity, but most of the mills are available 1.5 to 2 years to fully recover construction costs。
The actual price depends on the target capacity (e.g. 500 kg or 2 tons) per hour, the type of equipment (swipe or tunnel) and the selection of the CIP automatic cleansing module. Although the initial cost was higher than the traditional freezer, it was significantly reduced. 5%~15% defrozen weight lossAnd it saves manual transport and creates a very high long-term ROI.
I want to know more.👉 Shopping guide for commercial/industrial fast freezers。
Q:Should my food be "packed before IQF" or "frozen before packaged"?
A: Strongly recommends the use of "naked" (freezing first and then packaged) in order to achieve a real rapid freezing effect.
Unpacked foods are directly exposed to extremely low-temperature high-speed air currents, with the highest cooling efficiency, which enables the surface to be shelled in an instant and to maintain a clear and unscathed feed, without sewing to a fully automatic package. When packaged and frozen, packaged material prevents heat transmission and prolongs the passage of the "Maximity Crystal Generation Belt", leading to a decrease in the food mass and quality.
Q:My food processing plant has very limited space. Can IQF equipment?
A:Absolutely.A limited number of factories have preferred the smallest 3D spiral chiller.
It’s a pain in the ash of a Taiwan processing plant.Top technology.The team designed a spiral structure for a limited space, using a vertical extension of the network to cover the height of the space, with a very large frozen yield at the lowest level. The equipment can also be produced by existing plant operators, and it is recommended that the engineering team conduct a high-level evaluation of the site's impact and the plant's cleanness.
Q:IQF, do you need a high-speed defrost? Will it interrupt my continuity?
A: No frequency.Modernized IQF equipment is usually running continuously 12 to 24 hoursIt's only once.
Here.Top technology.The solution is, for example, to have an improved wind-regulating cycling system and a large-range rim copper tube, which can significantly slow the speed of the heat exchanger. This fits perfectly with the double- or triple-shift production schedule of the food-for-works plant, and simply arranges for the automatic removal of frost in the off-duty space, without interrupting the daytime capacity.
Q:What's the "cooler" with the IQF device? Are there any security or environmental concerns?
A: IQF vibrator-based fluorine, ammonia or carbon dioxide cooling systems, andFull compliance with the highest level of security and ESG environmental laws.。
Mainstream choice includes fluorine refrigerants (R404A, R507), or adaptsUnited Nations Environment Programme (UNEP) refrigeration reduction protocolNew types of low GWP environmentally friendly refrigerants; large-scale factories can choose natural refrigerants (NH3/CO2). The wiring and gas-detection ventilation system, which combines specialized teams, ensures safe and secure transit.
Q:Each product has different characteristics. Can I test my food for IQF?
A: Yeah.The first step in reducing the risk of investment is to test for the freezing of real food before a million-grade equipment purchase.
Top technology.It also provides a complete "food-based test-freezing service" because of the different reactions to the low-temperature wind speeds of water skins, seashells and plant meat. You can take your own food, verify the time of the freeze, your body is not sticky and your level of return, and make a decision when you have accurate data.
In conclusion, the IQF is rapidly freezing up, making top technology your strong. Is that a shield?
If you are in the process of expansion, or if the effectiveness of the traditional freezer has been severely compromised, from the traditional process to the IQF, it will be a key decision for you to get rid of the competition and get rid of the international order.
Whatever position you take in the business, it's important that you take the decision.
IQF technology offers a solution to the pain:
- Boss and Finance: In exchange for a very low weightlessness rate for the highest MMR, break the initial construction cost myths and create a long-lived ROI.
- Research and security: The original mass of the product is restored through microcrystal technology, and the number of bacteria is strictly controlled.
- Chief of plant and work: I'm going to say goodbye to the frequent manual move of the traditional freezer. It is important to make sure that the production line is well sequenced and that the unit's time production is extremely large.
For many years, we have been selling not only equipment, but also a full-fledged service, from the "Standing Space Program", the "Producer Frozen" and the "Roi Benefit Assessment" to the "Sustained CIP Maintenance".If your line of production is facing an increase in bottle necks and a high rate of weight loss, welcome to the top technology, and make an appointment for a special consultation!
