Compact Inline Tunnel CPI-1000

A tunnel freezer operates by moving products on a conveyor belt through a long, insulated tunnel where cold air is circulated to freeze the product. Key aspects include:

1. Linear design: Products move in a straight line or slight curve through the freezing zone
2. Forced air circulation: High-velocity cold air is blown over the products
3. Continuous operation: Allows for non-stop product flow
4. Temperature zones: May include multiple zones for gradual temperature reduction
5. Belt design: Can vary based on product type (e.g., mesh belts, plastic belts

While tunnel freezers have their place in food processing, they do have some limitations:

1. Space requirements: Typically require more horizontal space than spiral freezers
2. Limited capacity: May have lower throughput compared to spiral systems in the same footprint
3. Product handling: Can be less flexible with product sizes and shapes
4. Energy efficiency: May be less efficient in terms of air circulation and energy use
5. Freezing time: Limited by the length of the tunnel, which can be a constraint for some products

For factory managers considering freezing solutions, these factors should be weighed against the specific needs of their production lines and available space.

The Compact Inline Tunnel Freezer is a flexible and efficient freezing system designed by Korutek Engineering. It operates using one to three inverter-controlled conveyor belts within a single enclosure, allowing products to pass through up to three times the enclosure’s length utilising multiple belts to maximise the machine’s footprint. This design accommodates multiple product lines simultaneously or various product sizes on a single line.

Key features include:

• Easy maintenance and cleaning
• Efficient utility usage
• Vertical airflow
• Variable belt speeds
• Excellent heat transfer and defrosting capabilities
• Configurations from 2 to 9 fan systems

The Inline Tunnel Freezer is delivered as a plug-and-play solution, minimizing installation disruption. It offers advantages like a direct connection to factory systems, automatic defrosting options, and an evaporator design that prevents blockage from product debris.

The primary difference lies in their design and operational flow. A tunnel freezer uses a straight-line conveyor system, whereas a spiral freezer employs a helical belt. Spiral freezers are more compact and provide a higher freezing capacity per unit of floor space, making them ideal for factories with space constraints and high production demands. Engineering managers will appreciate the space-saving design and efficient operation of spiral freezers compared to tunnel freezers.

In food processing, cooling, chilling, and freezing are distinct temperature reduction processes, each serving specific purposes:

1. Cooling:

•  Typically reduces product temperature to around ambient levels or slightly below
•  Often used for products that don’t require refrigeration
•  Helps in safe handling and packaging of warm products

2. Chilling:

• Lowers product temperature to just above freezing (usually 10°C to -2°C)
• Preserves food quality and extends shelf life without freezing
• Crucial for fresh products like dairy, meats, and prepared foods

3. Freezing:

• Rapidly reduces temperature below 0°C (32°F), typically to -18°C (0°F) or lower
• Forms ice crystals within the product, significantly extending shelf life
• Preserves nutritional value and texture when done correctly (e.g., IQF method)

Each process requires specialized equipment tailored to the specific temperature range and product requirements. For factory managers and food processing engineers, understanding these distinctions is crucial for maintaining product quality, safety, and operational efficiency.

Korutek offers solutions for all three processes, including our Compact Spiral Series for freezing, IQF Tunnel Freezers for rapid freezing, and custom-built systems for cooling and chilling applications. Our team can help you determine the most suitable technology for your specific production needs.

Belt freezing, also known as multibelt freezing, operates on principles similar to our Compact Inline Tunnel Freezer. This efficient system uses multiple conveyor belts within a single enclosure to maximize freezing capacity and flexibility. Key features include:

1. Extended freezing time: Products can pass through up to three times the enclosure’s length, utilizing multiple belts to maximize the machine’s footprint.
2. Space efficiency: Utilizes vertical space effectively, accommodating multiple product lines or various product sizes simultaneously.
3. Flexible configuration: Allows for 2 to 9 fan systems, adapting to different production needs.
4. Temperature control: Offers precise control with inverter-controlled conveyor belts and efficient vertical airflow.
5. Gentle product handling: Ensures product integrity through carefully designed belt transfers.
6. “Plug and play” solution: Delivered as a complete unit, minimizing installation disruption and allowing for easy connection to factory systems.

This technology is particularly relevant for factory managers looking to maximize freezing capacity in limited space while maintaining product quality and operational efficiency. The Compact Inline Tunnel Freezer exemplifies these principles, offering a versatile solution for a wide range of freezing applications.

The spiral tunnel freezing method combines elements of both spiral and tunnel freezing technologies. It typically involves a spiral conveyor system enclosed within a tunnel-like structure.

This hybrid approach offers:

1. Extended freezing time
2. Efficient use of both vertical and horizontal space
3. Flexibility in product handling
4. Potential for multi-zone temperature control

This method is particularly suitable for products requiring longer freezing times or those benefiting from a gradual temperature reduction process. Factory managers dealing with complex product lines or limited floor space may find this solution especially valuable.