Development of an Industrial Berry Freezing Facility in the Volyn Region
A modern IQF freezing solution was implemented for a company specializing in industrial berry processing and frozen food production. The project included the installation of a Unidex TZF 2A CO₂ tunnel freezer designed for continuous shock freezing of berries while maintaining product structure, appearance, and quality during long-term storage.
The facility, located in the Volyn region of Ukraine, is capable of processing up to 3000 kg of berries per day. The total refrigeration capacity of the cooling system reaches 600 kW.
The scope of work included:
- delivery and installation of industrial refrigeration equipment;
- integration of an IQF tunnel freezing line;
- installation of a CO₂-based refrigeration system;
- automation of technological processes;
- commissioning and system testing;
- adjustment of freezing modes for different berry products.
Industrial Berry Freezing Requirements
The production facility is focused on freezing and processing:
- strawberries;
- raspberries;
- blueberries;
- blackcurrants;
- blackberries;
- other berries intended for export and long-term frozen storage.
Freezing delicate berry products requires stable and precisely controlled operating conditions. Particular attention was given to:
- rapid passage through the crystallization zone;
- minimal damage to the cellular structure of the product;
- prevention of product sticking;
- uniform freezing temperature distribution;
- consistent airflow across the freezing tunnel.
To achieve these goals, the project was based on IQF (Individual Quick Freezing) tunnel freezing technology.
Advantages of IQF Tunnel Freezing Technology
Tunnel freezing systems are among the most efficient solutions for industrial berry processing plants due to their ability to maintain high product quality while operating continuously during seasonal production peaks.
Key advantages of IQF technology include:
- high production capacity;
- continuous operation mode;
- uniform freezing of individual products;
- preservation of berry texture and shape;
- reduction of product losses;
- improved conditions for packaging and storage;
- compliance with export quality standards.
Intensive circulation of low-temperature air allows the product to pass rapidly through the critical freezing zone. This significantly reduces the formation of large ice crystals inside the berries and helps preserve their natural texture after defrosting.
Such an approach is especially important for:
- retail packaging applications;
- maintaining visual product quality;
- reducing juice loss after thawing.
Unidex TZF 2A CO₂ Tunnel Freezer
The project utilized a Unidex TZF 2A CO₂ tunnel freezer engineered for high-capacity industrial freezing lines used in the food processing industry.
The system provides:
- stable low-temperature operation;
- efficient heat transfer performance;
- reliable operation under high production loads;
- optimized energy consumption;
- continuous operation during seasonal peak periods.
The tunnel design is suitable for freezing:
- berries;
- vegetables;
- fruit products;
- semi-finished foods;
- various IQF food products.
CO₂ Refrigeration System for Industrial Freezing
One of the key engineering features of the project was the implementation of a CO₂ refrigeration system.
Using carbon dioxide as a refrigerant offers several important benefits:
- lower environmental impact;
- higher energy efficiency;
- reduced operating costs;
- stable low-temperature performance;
- compliance with modern environmental standards.
Today, CO₂ refrigeration technologies are increasingly used in modern food processing plants and industrial freezing facilities due to their efficiency and sustainability.
GEA BOCK Compressor Equipment
The refrigeration plant was equipped with GEA BOCK compressor technology widely used in industrial refrigeration and large-scale freezing systems.
GEA BOCK solutions are commonly applied in:
- industrial refrigeration systems;
- freezing complexes;
- IQF production lines;
- high-capacity cooling installations.
Main advantages include:
- high operational reliability;
- stable performance at low temperatures;
- energy-efficient operation;
- long service life;
- simplified maintenance.
Güntner & Alfa Laval Heat Exchange Equipment
Güntner heat exchange equipment was used within the refrigeration system to ensure efficient thermal performance and stable operating conditions.
The installed heat exchangers provide:
- efficient cooling performance;
- stable operating parameters;
- resistance to industrial workloads;
- optimized operation during intensive freezing cycles.
Carel & Schneider Refrigeration Automation System
Process automation was implemented using Carel control solutions designed for industrial refrigeration applications.
The automation system provides:
- temperature monitoring and control;
- capacity management;
- equipment operation monitoring;
- protection of refrigeration components;
- stable process control during operation.
Energy Efficiency of Industrial Berry Freezing
During the design and implementation stages, particular attention was given to:
- reducing energy consumption;
- maintaining stable system operation;
- improving heat exchange efficiency;
- process automation;
- reliable operation during seasonal peak loads.
For IQF berry freezing facilities, energy efficiency directly affects:
- storage costs;
- processing expenses;
- product competitiveness;
- overall production profitability.