Russian Pancake Giant Boosts Efficiency and Safety with Square’s Self-Stacking Spiral Freezereading

A leading ready-meal manufacturer in Russia, renowned for its high-volume pancake production, faced a critical challenge. Their existing freezing process was struggling to keep pace with demand, leading to several issues:

• Production Interruptions: Frequent downtime was required for manual defrosting, creating a significant bottleneck in their production line.

• Intensive Labor: The manual cleaning and defrosting processes were labor-intensive and costly.

• Compliance Risks: Maintaining the highest standards of food safety and hygiene was a constant operational focus.

• Inconsistent Quality: Variations in the freezing process risked compromising the final texture and taste of their products.

The manufacturer needed a modern, automated freezing solution that could deliver high capacity, flawless hygiene, and unwavering reliability.

The manufacturer partnered with Square Technology Group, a leading force in China’s freezing equipment industry, to implement a state-of-the-art Congelador espiral autoapilable. The solution was engineered to directly address their challenges with advanced, automated features.

Key Solution Highlights:

1. Maximized Uptime with Automatic Air Defrosting (ADF): The freezer was equipped with Square’s innovative ADF system. This technology uses compressed air to continuously remove ice and frost from the system during operation, eliminating the need to stop production for manual defrosting.

2. Uncompromising Hygiene with an Automated Clean-in-Place (CIP) System: To guarantee food safety, the fully automated CIP system manages the entire sanitation process. With a single command from the control panel, the system executes a pre-programmed cycle of detergent foaming, warm water cleaning, and belt drying, ensuring a perfectly sanitized environment with zero water accumulation.

3. Consistent Quality & Efficiency with a Smart PLC Control Center: The freezer’s operations are managed by an advanced PLC (Programmable Logic Controller). This central nervous system provides precise control over the entire freezing environment, ensuring every pancake is frozen to the exact same standard while optimizing energy consumption to lower operational costs.

The installation of Square’s Self-Stacking Spiral Freezer delivered immediate and significant results, transforming the client’s production capabilities.

• Drastically Increased Production Output: The ADF system enabled near-continuous, 24/7 operation, shattering previous production ceilings and significantly boosting the total volume of pancakes processed daily.

• Achieved Highest Hygiene Standards: The automated CIP system guarantees a thoroughly sanitized environment, allowing the client to meet and exceed stringent international food safety regulations with ease and confidence.

• Reduced Operational Costs: By automating the defrosting and cleaning processes, the client minimized manual labor requirements and costly downtime, leading to substantial savings.

• Superior and Consistent Product Quality: Precise, consistent freezing locked in the ideal texture and taste of the pancakes, enhancing product quality and strengthening the client’s brand reputation in the market.