Applications by Sector
Industrial Cooling for Food Industry
Sanitary chillers and cold systems for food safety and regulatory compliance
High-performance industrial cooling systems for food processing, storage and preservation. Sanitary chillers in 304/316L stainless steel with capacities from 50 to 2,000 kW, cooling from -5°C to +15°C and freezing down to -35°C. Complete solutions for cold storage, dairy, beverage industry, bakery, confectionery and general food processing. Full compliance with ANVISA RDC 275, MAPA, FSSC 22000, ISO 22000 and HACCP principles for maximum food safety and traceability.
Talk to SpecialistTechnical Specifications
Process Requirements
Rapid cooling of raw materials at reception to stop bacterial proliferation. Pre-cooling systems for fruits, vegetables and meats capable of reducing temperature by up to 70% in the first 2 hours.
Deboning, cutting and processing rooms with strict temperature and humidity control. Controlled airflow to prevent cross-contamination and maintain the cold chain throughout the process.
Slaughter and processing lines with continuous cooling. Chilled water chillers for scalding and cooling tanks, with strict bacteriological control.
Processing of milk, cheese, yogurt and derivatives. Immediate cooling of raw milk to 4°C within 2 hours after milking. Temperature control in maturation and fermentation tanks.
Controlled environment for dough fermentation, chocolate handling and confectionery production. Critical humidity control for final product quality.
Wort cooling, controlled beer fermentation, pasteurization and juice filling. Glycol systems for temperatures below 0°C in brewery processes.
Blast chilling for rapid temperature reduction of cooked products. Capacity to reduce from 70°C to 3°C in less than 90 minutes per HACCP standards.
Quick freezing (IQF) and long-term storage. Freezing tunnels with -40°C capacity for ultra-fast freezing of sensitive products.
Cold rooms for storage of finished products and raw materials. Humidity control to prevent dehydration and product weight loss.
Climate-controlled environment for primary and secondary packaging. Humidity control to prevent condensation on packaging and ensure proper sealing.
Climate-controlled area for loading refrigerated trucks. Fast doors and air curtains to minimize cold chain breaks during loading operations.
Area for washing and sanitizing equipment, utensils and PPE. Hot and cold water system with temperature control for CIP (Clean-in-Place) processes.
Technical Analysis
The Importance of Refrigeration in the Food Industry
Industrial refrigeration is the fundamental pillar of modern food safety. From the reception of raw materials to delivery to the final consumer, maintaining the cold chain is critical to ensuring the quality, safety, and shelf life of food products. FAO studies indicate that up to 40% of globally produced food is lost due to failures in the cold chain, representing a waste of natural and economic resources of alarming proportions.
Microbiology and Temperature: The Science Behind Refrigeration
Temperature control is the main tool to inhibit the growth of pathogenic and spoilage microorganisms. The microbiological danger zone, between 5°C and 60°C, is where bacteria such as Salmonella, Listeria monocytogenes, E. coli O157:H7, and Staphylococcus aureus multiply rapidly, doubling their population every 20-30 minutes under ideal conditions.
- Below 4°C: Bacterial growth practically stopped for most pathogens
- -18°C: Standard freezing point that paralyzes all microbiological activity
- -35°C to -40°C: Ultra-fast freezing (IQF) that preserves texture and nutritional quality
- Above 60°C: Pasteurization and cooking zone that eliminates pathogens
Sizing of Refrigeration Systems
The correct calculation of the thermal load is fundamental for the adequate sizing of refrigeration systems. The main factors to consider include:
| Component | Description | % of Total Load |
|---|---|---|
| Product Load | Sensible and latent heat to cool/freeze the product | 40-60% |
| Transmission | Heat gain through walls, floor, and ceiling | 15-25% |
| Infiltration | Entry of warm air through door openings | 10-20% |
| Equipment | Motors, lighting, forklifts | 5-15% |
| People | Metabolic heat of workers | 2-5% |
Refrigerants and Sustainability
The choice of refrigerant directly impacts the energy efficiency and environmental impact of the system:
- R-717 (Ammonia): Maximum efficiency, zero GWP, ideal for large-scale plants. Requires specialized design and operation.
- R-744 (CO2): Natural refrigerant with GWP=1, excellent for cascade systems with ammonia in freezing applications.
- R-134a: HFC with good performance for chilled water cooling. GWP=1430, transitioning to alternatives.
- R-513A: Low GWP (631) alternative to R-134a, compatible with existing equipment.
- R-290 (Propane): Natural hydrocarbon with excellent efficiency for small/medium-scale systems.
Monitoring and Traceability Systems
Temperature traceability is a mandatory requirement for food safety certifications. Modern systems include:
- Dataloggers with continuous recording and real-time alarms
- Wireless sensors with LoRaWAN or Wi-Fi transmission
- Integration with SCADA and ERP systems
- Automatic reports for audits and certifications
- SMS, email, and mobile app alerts
- Cloud backup with data retention for 5+ years
Energy Efficiency in Industrial Refrigeration
Refrigeration can account for up to 70% of the energy consumption of a food processing plant. Optimization strategies include:
- Compressors with frequency inverter: 20-40% savings at partial loads
- Evaporative condensers: 15-25% reduction in consumption vs. air condensation
- Heat recovery: Utilization of rejected heat for water heating
- Adequate thermal insulation: PIR panels with optimized thickness
- High-speed doors and air curtains: Minimization of infiltration
- LED lighting: Reduction of internal thermal load
- Smart defrosting: Optimized cycles based on real demand
Sector Challenges
The cold chain cannot be interrupted at any point, from reception to shipping. Any break can compromise food safety and result in significant product losses. Redundant systems and continuous monitoring are essential.
Simultaneous compliance with multiple national (ANVISA, MAPA) and international (FDA, EU, Codex) standards. Frequent audits by clients and certifiers require complete documentation and full traceability.
Agricultural harvests, holidays and promotional campaigns generate production peaks that can triple cooling demand. Systems must be sized to meet peaks without compromising efficiency at partial loads.
With cooling representing up to 70% of energy consumption, efficiency is critical for competitiveness. Each percentage point improvement in COP represents significant savings in large-scale plants.
Constant exposure to moisture, aggressive cleaning products, ammonia and saline environments (fish cold storage). Equipment must be built with corrosion-resistant materials.
Continuous temperature recording with precise timestamps to meet recall and audit requirements. Data must be stored for 3 to 7 years per regulations.
Equipment must allow complete cleaning without residue accumulation areas. Hygienic design with smooth surfaces, rounded corners and adequate drainage is mandatory.
Food processing plants frequently operate continuously. Unplanned shutdowns can result in millions in product losses and contractual penalties.
Air flows and personnel movement must be controlled to prevent contamination between areas of different hygiene levels. Differential pressurization and airlocks are frequently required.
Growing pressure from consumers and regulators for emissions reduction. Transition to natural refrigerants and high-efficiency systems is an irreversible trend.
Our Solutions
Centralized chilled water cooling for pasteurization, fermentation, product cooling and production area climate control. Capacities from 50 to 2,000 kW with COP above 4.5.
View ProductHigh capacity for large-scale plants with continuous 24/7 operation. Screw compressors offer lower vibration, longer lifespan and excellent efficiency at partial loads.
View ProductDedicated solution for specific production lines or processes requiring different temperatures. Simplified installation and independent operation.
View ProductAir handling units with stainless steel construction, rounded corners, complete drainage and high-efficiency filtration. Ideal for processing and packaging rooms.
View ProductClimate control for production, packaging, storage and shipping areas. Models with copper-aluminum or copper-copper coils for corrosive environments.
View ProductPrecise water temperature control for washing, sanitization and CIP (Clean-in-Place) processes. Proportional hot and cold water mixing with fast response.
View ProductClimate control for shipping rooms, offices, quality control laboratories and administrative areas. Simplified installation without need for mechanical room.
View ProductHumidity control in packaging areas, dry ingredient storage and chocolate and confectionery production rooms. Prevents condensation and quality issues.
View ProductProcess cooling at temperatures below 0°C, such as beer fermentation, ice cream production and product freezing. Food-grade propylene glycol solutions.
View ProductLarge-scale industrial refrigeration plants with maximum energy efficiency and zero environmental impact. Design, installation and maintenance by specialized team.
View ProductRegulations and Standards
Benefits for Your Business
Success Case
Poultry Cold Storage - Santa Catarina
Complete modernization of the refrigeration system of one of the largest poultry cold storage facilities in southern Brazil, with a slaughter capacity of 500,000 birds/day. The project included replacement of a 25-year-old obsolete ammonia system with a modern plant featuring screw compressors, high-efficiency evaporative condensers and complete automation. Four 500 TR chillers were installed for process chilled water, a glycol system for IQF freezing tunnels and 12 evaporators for storage chambers. The integrated monitoring system enables complete temperature traceability at all critical points.
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