Blast Freezer

A Blast Freezer (also known as shock freezer or flash freezer) is an advanced refrigeration system that uses high-speed, low-temperature air circulation to rapidly freeze food products. Its core purpose is to lock in freshness, prevent microbial activity, and maintain food safety standards required for both domestic and export markets.

1. Loading the Product – Food items (meat, fish, bakery, dairy, etc.) are placed on trays, racks, or trolleys.
    
2. Rapid Cooling Cycle – Cold air (–35°C to –40°C) is blown at high velocity over the product.
    
3. Fast Heat Transfer – Heat inside the food is extracted quickly, lowering the product temperature from +30°C/+25°C down to –18°C in a few hours.
    
4. Storage Transition – Once core temperature reaches –18°C, the product is shifted to a cold storage room (–18°C to –25°C) for longer-term preservation.
    

1. Cabinet Blast Freezer
    
   • Compact, upright design.
      
   • Best for restaurants, bakeries, catering businesses.
      
   • Capacity: 50–500 kg per cycle.
      

1. Tunnel Blast Freezer
    
   • Continuous freezing system (conveyor-based).
      
   • Suitable for large-scale industrial plants.
      
   • Capacity: several tons per hour.
      

1. Batch Blast Freezer (Room Type)
    
   • Walk-in chamber with racks/trolleys.
      
   • Flexible for medium/large-scale food industries.
      
   • Capacity: 500 kg to 20 tons per cycle.
      

• Temperature Range: –35°C to –40°C (air temperature).
   
• Product Core Temp after Freezing: –18°C or below.
   
• Freezing Time: 2 to 8 hours (depending on product size, thickness, and load).
   
• Air Velocity: 2 – 5 m/s (high-speed fans for quick cooling).
   
• Panel Insulation: PUF/PIR panels, 100–150 mm thick.
   
• Refrigeration System:
   
  • Compressors: Semi-hermetic/scroll/screw type.
     
  • Refrigerants: R404A, R507, R22 (eco-friendly options available).
     
• Control System: Microprocessor/PLC-based with temperature sensors & data logging.
   
• Loading System: Stainless steel trays, trolleys, or conveyors.
   

✅ High-Capacity Refrigeration: Multiple compressors for redundancy and faster pull-down.
✅ Uniform Freezing: Even airflow ensures consistent product quality.
✅ Food Safety: Rapid freezing prevents bacterial growth.
✅ Energy-Efficient Insulation: Reduces power consumption.
✅ Flexible Design: Can be customized for product type and batch size.
✅ Compliance: Meets HACCP, FSSAI, WHO, and export regulations.

• Seafood Processing Units – Prawns, shrimp, tuna, sardines, etc. (export quality freezing).
   
• Meat & Poultry Plants – Chicken, mutton, beef, pork, and value-added meat products.
   
• Bakery & Confectionery – Pastries, cakes, dough, chocolate, desserts.
   
• Dairy Industry – Ice cream bases, butter, paneer, cheese.
   
• Ready-to-Eat & Packaged Food – Frozen meals, snacks, and semi-cooked foods.
   
• Hospitality & Catering – Hotels, airlines, cruise ships for bulk food preservation.
   

Feature Blast Freezer Normal Freezer Freezing Time2–6 hrs18–24 hrs. Ice Crystal Formation Small (preserves texture)Large (damages food structure)Shelf Life6–18 months2–6 months Nutrient Preservation Very high Moderate Bacterial Growth Almost stopped (quick freeze)Slower reduction Industrial Suitability Large-scale, export grade Small-scale, domestic use  

• Extends product life by 3–5 times longer than conventional freezing.
   
• Maintains original taste, aroma, and nutrients.
   
• Essential for exporters where international standards demand –18°C core freezing.
   
• Reduces drip loss (weight loss) after thawing, ensuring better yield.
   
• Supports farm-to-fork cold chain integrity.
   

• Small Cabinet Freezers (100–500 kg): ₹3 lakh – ₹8 lakh
   
• Batch Blast Freezers (1–10 tons): ₹10 lakh – ₹50 lakh
   
• Tunnel Blast Freezers (large-scale continuous): ₹75 lakh – ₹2 crore+
   

(Prices depend on capacity, insulation thickness, compressor type, and brand.)