Badafi faced a 40-minute deadline: Okra harvested by 8 AM had to be cleaned, blanched, cut, and individually quick-frozen (IQF) before quality degradation. With peak-season demand surging, their existing system couldn’t scale without compromising the “field-to-plate-in-a-day” promise.

We engineered a custom IQF spiral freezer integrating three patented technologies:

1. Two-Stage Crust-Freeze™ System
   • Stage 1: High-velocity air (-40°C) instantly forms an ice crust on each okra piece within 90 seconds, preventing clumping and nutrient loss.
   • Stage 2: Gentle belt-conveyed freezing solidifies interiors without mechanical damage.
2. Zero-Downtime AirJet Defrost
   Compressed air pulses clear evaporator ice buildup every 30 minutes, enabling 24/7 production runs — critical during 18-hour harvest windows.
3. Hygienic Quick-Clean Architecture
   NSF-certified stainless steel construction with tool-free hatch access reduced daily sanitation from 1.5 hrs to 25 minutes.

• 20% Higher Throughput: Scaled to 3.2 tons/hour of IQF okra during peak season.
• Near-Zero Waste: 99.7% individual particle separation prevented $12K/month in clumped product losses.
• Extended Freshness Signature: Lab tests showed 15% higher vitamin retention versus competitors’ tunnel freezers.