Frequently Asked Questions

Yes, we welcome direct communication with our customers. You can reach us through the following channels:

• Phone: +44 (0)1603 672 455
• Email: info@korutek.com
• Website: korutek.com

Yes, Korutek can service a wide range of industrial freezers.

Knowing what’s best isn’t always easy.

When you’re presented with multiple options, your go-to might be to look for the cheapest solution – or maybe you look for the highest quality.

Check out our guide to help you make the right decision.

Whether it’s energy, fuel, interest rates, the price of the pound or anything else, it’s affecting businesses just like ours and yours.

Many factories use Cryogenic Spiral Freezers or IQF Tunnels which require Liquid Nitrogen to operate. Due to this being a consumable that can only be used once, it requires regular purchasing.

But the cost of Liquid Nitrogen has more than tripled in recent months, and it’s becoming a soaring expense that you could avoid…

Read more on this subject here

A legacy spanning more than two decades in designing, manufacturing, installing, servicing, and modifying industrial freezers, chillers, and ambient coolers for the worldwide food industry.

Korutek offers several types of industrial freezers and coolers:

• Compact Spiral Series (CPS 300, 450, and 600).
• IQF (Individual Quick Freezing) Tunnel Freezer and Chiller range.
• Compact Inline Tunnel Series.
• Custom and site-built options for various freezing and cooling needs.

Spiral freezers are complex pieces of machinery that are essential to keep your food manufacturing business running smoothly.

Over the years, technological advances have changed the shape of the food industry and changing tastes have come along with it.

All of that means when you’re looking for long-term reliability, ease of set-up, and the least amount of effort to maintain and run, our Compact Spiral Series is the perfect solution.

Find out more

Cold Room Blast Freezers and our Compact Spiral Series both do broadly the same job, right?

So, what’s the difference, and what should you be looking for to keep your production in the best shape?

View our complete guide here

A spiral freezer operates by continuously moving products along a spiral conveyor belt through a temperature-controlled enclosure. Cold air is circulated over the product at high velocities, rapidly extracting heat and freezing the items uniformly. This process allows for:

1. Efficient use of vertical space.
2. Continuous production flow.
3. Precise temperature control.
4. Consistent product quality.

The system’s design enables it to handle large volumes of product while maintaining a relatively small footprint, making it an essential tool for factory managers focused on maximizing production efficiency and product consistency.

Spiral freezers offer numerous advantages for large-scale food production operations:

● Space efficiency: Maximizes production capacity in a smaller footprint
● Continuous operation: Enables non-stop production for high-volume processing
● Product quality: Ensures consistent freezing, maintaining product integrity
● Flexibility: Handles various product sizes and types
● Energy efficiency: Optimizes cold air circulation for reduced energy consumption
● Hygienic design: Facilitates easy cleaning and maintenance
● Automation compatibility: Integrates seamlessly with automated production lines

While spiral freezers offer significant advantages, there are some considerations to keep in mind:

• Initial cost: Higher upfront investment compared to some traditional freezing methods
• Complexity: More intricate design may require specialized maintenance
• Height requirements: Vertical design may not suit facilities with low ceilings
• Product limitations: Some delicate or unusually shaped products may not be suitable

For maintenance managers, it’s crucial to factor in these aspects when planning for long-term operational costs. However, for many large-scale operations, the benefits often outweigh these considerations.

A Compact Spiral Freezer is a space-efficient industrial freezing solution designed for food manufacturing facilities with limited floor space. These systems offer the benefits of spiral freezing technology in a more condensed format, making them ideal for factories looking to expand production capacity without significant infrastructure changes.

Their compact size means they can travel easily on road and shipping routes which allows them to be supplied fully assembled, only needing connection to utilities to go into production when arrive on site. Installation period is negligible therefore minimal disruption on site.

They also sit on their own dedicated food safe stainless steel base frame, removing the need to build a concrete plinth with heater mat for the spiral freezer to sit on. This also makes it very easy to relocate to other parts of the factory or a complete different location. This flexibility means that there is huge demand for CPS machines in the second hand/ pre owned machinery market.

Our CPS range includes models CPS 300, CPS 450, and CPS 600, each tailored to different production volumes and space requirements. These modular systems are particularly valuable for maintenance managers and engineering teams tasked with upgrading freezing capabilities in existing facilities as they can install new CPS machines as they grow rather than having to buy an oversized machine to cater for potential future production.

A spiral freezer is an advanced industrial freezing system designed for high-volume food production environments. It utilizes a continuous spiral conveyor belt to freeze or chill products in a compact footprint efficiently. Spiral freezing is the process of rapidly reducing product temperature as it travels along this helical path, allowing for consistent, high-quality freezing of various food items.

This technology is particularly relevant for factory managers and food processing engineers seeking to optimize production efficiency and product quality in large-scale operations. If you’re involved in small-scale or home food production, a spiral freezer may not be suitable for your needs.

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.

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.

A spiral cooler functions by moving products along a continuous spiral conveyor through a temperature-controlled environment. The system circulates cool air over the products as they travel along the helical path.

Key features include:

• Vertical space utilization for efficient cooling
• Controlled airflow for uniform temperature reduction
• Adjustable dwell times to suit different product requirements
• Integration with existing production lines for seamless operation

A spiral cooler is an industrial cooling system that uses a similar design principle to spiral freezers but operates at higher temperatures. It’s designed to efficiently reduce product temperature without freezing, making it ideal for processes like proofing, setting, or bringing products to safe handling temperatures.

This technology is particularly relevant for factory managers in bakeries, confectionery plants, and ready-meal production facilities where controlled cooling is critical for product quality and food safety.

IQF freezing can be more energy-intensive and may require a higher initial investment compared to traditional freezing methods. However, the benefits of product quality and operational efficiency make it a valuable asset for factory and maintenance managers committed to high standards. Also, the cost per product frozen will reduce as there will be less waste, less labour requirements and due to efficient production less energy used per product frozen.

IQF stands for Individual Quick Freezing. An IQF freezer is a specialized system designed to freeze individual pieces of food separately, preventing them from clumping together. This technology is crucial for maintaining the quality and ease of use of frozen products like fruits, vegetables, seafood, and diced meats.

Factory managers in the food processing industry, particularly those dealing with fruits, vegetables, or portioned proteins, should be familiar with IQF technology as it significantly impacts product quality and marketability.

The principle of an IQF freezer is based on the rapid freezing of individual food items. Key aspects include:

• Product separation: Items are kept separate during freezing
• High-velocity cold air: Rapid heat removal from each piece
• Fluidization: Products are often kept in motion during freezing
• Short freezing time: Minimizes ice crystal formation within the product

This process results in superior product quality and allowing for better portion control for the end consumer making it a critical consideration for engineering managers in food processing plants aiming to produce high-quality and consumer demand orientated frozen products.

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.

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.

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.

Indeed, leasing our systems can offer potential tax advantages. As a monthly operational expense, lease payments are typically recognized as costs and can be deducted against revenue. This may lower your taxable profit, potentially reducing your corporation tax liability. However, tax implications can vary based on specific circumstances and jurisdictions. We strongly recommend consulting with your financial advisors or accountants to fully understand the tax benefits in your particular situation.

We offer flexible machinery leasing options to suit your business needs. Leasing allows you to access our advanced systems without large upfront costs, spread payments over time, and easily upgrade as needed.

1. Choose your equipment. (We can help you with this).
2. Contact us about applying for a lease
3. Complete the documentation
4. Delivery – You can expect your machinery within a month.
5. Payments

Yes, available on various contract hire and lease-to-buy options or an outright purchase.

• Meet peak demand without a big upfront expense.
• Our freezers can be installed for the summer season and off-hired when no longer needed. This flexibility enables you to meet seasonal demands without requiring excessive capital.
• Offset the costs of operating the machines against any profit, reducing tax liabilities.
• Get the benefits of these assets without the outlay.

At Korutek, we understand that every business has unique financial needs. We offer a range of flexible financing solutions to suit various requirements:

• Traditional leasing
• Lease-to-buy agreements
• Hire purchase options
• Outright purchase

Our team is committed to working with you to find the most suitable financing solution for your business objectives.

At Korutek, we understand that every business has unique financial needs. We offer a range of flexible financing solutions to suit various requirements:

• Traditional leasing
• Lease-to-buy agreements
• Hire purchase options
• Outright purchase

Our team is committed to working with you to find the most suitable financing solution for your business objectives.

Yes, Korutek can service a wide range of industrial freezers.

Cleaning must be carried out once the machine has been defrosted and before it’s put back into production. The spiral freezer is cleaned either by automated methods (Full CIP) or manual cleaning procedures:

Automatic Cleaning System:

1. Ensure all doors are locked and no personnel are inside the machine.
2. Check that external conveyors are clear of personnel.
3. Start the belt drive.
4. Ensure all water and air supply valves are open.
5. Select and start the cleaning program.
6. Ensure water is draining properly.

Manual Cleaning:

1. Stop the spiral belt.
2. Remove or lower external conveyor hoods and trays to clean debris.
3. Enter the machine and remove/open/lower conveyor hoods, trays, or belt covers to clean debris.
4. Check for and manually clean any large pieces of product or debris buildup on floor levels.
5. Refit all hoods, trays and belt covers to their original positions.
6. Clean any debris from floors on both levels of the machine.

Water up to 60°C may be used, and a strong detergent with a neutral pH or mild alkaline that doesn’t damage stainless steel and aluminium surfaces should be used.

(CAUTION: Do not use high-pressure water hoses directly onto enclosure joints. Do not stand on the belt).

Maintenance work should be carried out when the machine is above 0˚C and when all moving parts have been stopped. It should only be carried out by personnel who are deemed competent to do so i.e. site maintenance engineers.

Daily checks:

• Check belt for wear or damage
• Verify the function of belt take-up and limit switches
• Check the operation of all belt fault switches
• Inspect the function of covers and baffles
• Check overdrive
• Inspect drum, rail, and belt guide plastics

Monthly checks:

• Examine auxiliary drive sprockets for wear
• Check auxiliary drive and drive motor oil levels
• Inspect drive motor bearings for noise
• Ensure rollers, sprockets, and bearings are securely attached
• Check the header tank and gearboxes for water in the oil
• Grease the seal at the top of the main drive gearbox

Other maintenance tasks:

• Check and clean spray nozzles (for machines with water defrosting)
• Inspect fan balance, bearings, and housing
• Examine electrical equipment for moisture damage
• Check lights and wiring
• Inspect junction boxes for leaks
• Verify control panel filter pads are clear
• Test operation of emergency sensors and stops

Lubrication:

• Regular lubrication of various components like gearboxes and bearings according to the provided schedule.
• Check gearbox oil levels every month.
  -To drain oil, remove the lowest drain plug and filler plug. Drain oil and flush with oil of a similar grade. Drain and flush as above. Replace the drain plug and ensure the top of the gearbox is vented, refill directly to the top of the gearbox or through the expansion tank. With the gearbox full to the top, replace the vent plug and fill the expansion tank to 75%. Replace the fill plug in the expansion tank.

(NOTE: All charging must be done with the gearbox at room temperature).

Air balancing:

• Adjust airflow and pressure zones within the enclosure to minimize air loss and prevent warm air ingress.

It is important to follow these procedures to maintain the machine’s performance and fulfil warranty conditions.

(NOTE: All charging must be done with the gearbox at room temperature).

The operating temperature of a spiral belt freezer can vary depending on the specific application and product requirements. Typically, spiral freezers operate in the range of -30°C to -40°C (-22°F to -40°F). However, some systems may operate at higher temperatures for specialized applications such as chilling.

Key points to consider:

1. Temperature zoning: Many spiral freezers offer multiple temperature zones for optimal product treatment
2. Product-specific settings: Temperatures are often tailored to specific product requirements
3. Adjustability: Modern systems allow for precise temperature control and adjustment
4. Air flow control: Air is baffled and sheeted to direct the cold air from the evaporator coil ensuring efficient and optimal air circulation, contacting all product’s surface area to remove the heat and back.
5. Monitoring: Continuous temperature monitoring ensures consistent product quality

Understanding and maintaining the correct operating temperatures is crucial for product quality and system efficiency. Korutek Engineering’s systems offer advanced temperature control features to meet diverse production needs.

Proper cleaning of a spiral freezer is crucial for maintaining food safety and system efficiency. The process typically involves:

1. Defrosting: Allowing the system to fully defrost before cleaning
2. Disassembly: Removing accessible components for thorough cleaning
3. High-pressure washing: Using food-grade detergents and sanitizers
4. Belt cleaning: Utilizing specialized belt washing systems
5. Sanitization: Applying approved sanitizing agents
6. Drying: Ensuring all components are thoroughly dried before reassembly
7. Inspection: Checking for any wear or damage during the cleaning process

Korutek Engineering’s systems are designed with hygienic principles in mind, facilitating easier and more effective cleaning processes.

The majority of our parts come with 1 year manufacturer’s warranty. We can discuss extended warranties if wanted.

Yes, we install the parts nationally or internationally.

Yes, we deliver nationally or internationally.

For Eurotek machines, you will only have to provide us with the machine serial number for us to be able to identify the technical specifications of the required part/s.

At Korutek, we prioritize swift and efficient support for our customers globally. Delivery costs and lead times for spare parts can vary depending on the specific component required and your geographical location. We maintain a comprehensive inventory of original equipment manufacturer (OEM) parts to ensure quick availability. When parts are not immediately in stock, our well-established network allows us to source and expedite them rapidly, often exceeding industry standards. For a precise quote on delivery costs and lead times, please contact our customer support team with your specific requirements and location.

We offer a full machine inspection which will find the cause, recommend solutions and identify any other potential critical issues early on so any unplanned downtime and breakdowns are avoided.