The food industry operates in a highly demanding environment where precision, consistency and efficiency are paramount. From frying crisps to tempering chocolate or packaging frozen snacks, every stage of production relies on maintaining the optimal temperature and humidity to ensure quality and efficiency. Commercial refrigeration and HVAC systems are instrumental in delivering the performance, functionality, and sustainability required to stay competitive in today’s market. Lets take a look at how temperature control systems aid food production, the types of equipment used and how sustainable refrigerants are redefining the industry by reducing carbon footprints while maintaining consistent operational standards.
Products:
Temperature Control Requirements in Food Production:
Temperature control is integral to every stage of snack food production. From raw material storage to packaging and distribution, each process requires precision to ensure products are consistent and indistinguishable in quality across batches. Maintaining the right temperature and humidity not only ensures food safety but also optimises productivity, reduces waste, and aligns with sustainability goals. Modern refrigeration and HVAC systems exemplify the fusion of form and function, combining high performance with environmentally conscious design.
| Area | Temperature Range | System | Key Benefits |
|---|---|---|---|
Raw Material Storage | 15–25°C (dry) | Energy-Efficient HVAC Systems, Cold Storage Rooms, Walk-in Coolers | Prevents clumping and spoilage of dry goods like flour, sugar, and nuts; stable ambient conditions for long-term use. |
| 0–4°C (perishable) | Refrigerated Storage Rooms | Maintains freshness for temperature-sensitive ingredients like butter and cheese. | |
| Refrigerated Storage Rooms | 0–4°C | Cold Rooms with CO₂ (R744), HFO blends, or Hydrocarbons (R290) | Stable refrigeration for perishable snacks, energy-efficient systems reduce carbon footprint. |
| Freezers | -18 to -25°C | Blast Freezers, Deep Freezers | Long-term preservation of frozen snacks, reducing spoilage and microbial growth. |
| Frying | 170–190°C | Ventilation Systems with Heat and Vapour Removal | Ensures safe and efficient heat management, preventing operational hazards and maintaining workplace comfort. |
| Baking | 175–250°C | Oven Exhaust Systems with Proper Air Circulation | Even heat distribution, ensuring consistent cooking results while preventing overcooking. |
Post-Production Cooling | 30–50°C | Conveyor Belt Cooling Systems, Integrated Refrigeration Units | Reduces product temperature efficiently for handling and packaging, optimising operational precision. |
Fermentation/ Proofing | 24–32°C | HVAC Systems with Humidity Control, Customised Air Conditioning | Supports yeast activity with precise temperature and 60–80% relative humidity, ensuring consistent dough rise. |
| Packaging Areas | 18–25°C | Air-Conditioned Packaging Rooms | Prevents degradation of temperature-sensitive snacks like chocolate-coated products. |
| Chilled Loading Bays | 0–4°C | Chilled Loading Bay Refrigeration Systems | Maintains cold chain integrity, reducing thermal shock during product transition. |
| Refrigerated Transport | 0–4°C (chilled) | Refrigerated Trucks, Cold Chain Systems | Keeps chilled snacks fresh during distribution, ensuring consistent quality upon delivery. |
| -18°C (frozen) | Refrigerated Trucks with Smart Temperature Controls | Ensures frozen products remain intact and indistinguishable from their original condition. | |
Freeze- Drying | -40 to -50°C | Freeze-Drying Systems with Vacuum Chambers | Preserves sensitive snacks like dried fruits by freezing and sublimation, maintaining intrinsic quality. |
| Sustainability Measures | Varies by Application | CO₂ (R744), Ammonia (R717), HFO Blends (R1234yf, R1234ze), Hydrocarbons (R290) | Energy-efficient refrigerants reduce carbon footprint, align with industry regulations, and ensure sustainable growth. |
A Guide to Sustainable Refrigerants, Reducing Carbon Footprints:
As the industry moves towards environmentally friendly practices, refrigerants with low global warming potential (GWP) have become instrumental in reducing carbon footprints. Transitioning to sustainable refrigerants is both a practical and critical step for snack food manufacturers aiming to align with global sustainability goals.
Common Sustainable Refrigerants in Food Production include:
- CO₂ (R744): A natural refrigerant with a GWP of 1, exemplifying sustainability in large-scale refrigeration.
- Ammonia (R717): Zero GWP and excellent efficiency, widely used in industrial cold storage.
- Hydrofluoroolefins (HFOs): Low-GWP synthetic refrigerants like R1234yf, ideal for commercial refrigeration.
- Hydrocarbons (e.g., Propane - R290): Environmentally friendly and efficient for smaller-scale applications.
Here’s a comprehensive table of the refrigerants used in the industry, including their “Ozone Depletion Potential” (ODP), Global Warming Potential (GWP), typical applications and other relevant details:
| Refrigerant | Type | ODP | GWP | Applications | Key Features |
|---|---|---|---|---|---|
| CO₂ (R744) | Natural | 0 | 1 | Cold storage, blast freezers, process cooling | Sustainable, high efficiency, requires high-pressure equipment |
| Ammonia (R717) | Natural | 0 | 0 | Industrial refrigeration, cold storage, large-scale cooling | Zero GWP, excellent thermodynamic properties, toxic, needs safety measures |
| Propane (R290) | Hydrocarbon | 0 | ~3 | Small-scale refrigeration, chillers | Highly efficient, low GWP, flammable |
| Isobutane (R600a) | Hydrocarbon | 0 | ~3 | Domestic refrigeration, small-scale cooling | Low GWP, efficient, flammable |
| R1234yf | HFO | 0 | <1 | Commercial refrigeration, automotive air conditioning | Ultra-low GWP, non-ozone depleting, mildly flammable |
| R1234ze | HFO | 0 | <1 | Chillers, industrial refrigeration | Ultra-low GWP, non-flammable, highly efficient |
| R32 | HFC | 0 | 675 | Split air conditioning, small commercial systems | Higher efficiency than older HFCs, mildly flammable |
| R448A | HFO/HFC Blend | 0 | 1273 | Cold rooms, supermarket refrigeration | Medium GWP, suitable as a retrofit for R404A |
| R449A | HFO/HFC Blend | 0 | 1397 | Commercial and industrial refrigeration | Medium GWP, drop-in replacement for high-GWP refrigerants like R404A |
| R410A | HFC Blend | 0 | 2088 | Air conditioning, heat pumps | High efficiency, being phased out due to high GWP |
| R404A | HFC Blend | 0 | ~3920 | Older refrigeration systems | High GWP, being replaced by lower-GWP options |
Investing in the Future of Food Production:
We have worked with the food production industry encompassing a vast array of specialised sectors, each playing an integral role in transforming raw ingredients into consumable products. At its foundation lies agriculture, including crop farming, livestock rearing and aquaculture, supplying essential raw materials like grains, meat, dairy, and seafood. These feed into processing industries such as baking, snack production, dairy, and confectionery, where advanced techniques and precision HVAC and refrigeration equipment help create packaged foods, beverages and convenience items.
For food manufacturers, investing in advanced refrigeration and HVAC systems is a logical and practical choice. These systems are critical to maintaining consistency, optimising production, and meeting sustainability targets. By integrating cutting-edge technology and environmentally friendly practices, manufacturers can future-proof their operations and remain competitive in a demanding market.
Temperature control systems are not just a support function in snack food production, they are intrinsic to achieving operational excellence. From maintaining critical conditions for fermentation to ensuring consistent cold storage, refrigeration and HVAC systems exemplify the balance of form and function.
Sustainable refrigerants, precision engineering, and energy-efficient technologies are redefining the industry, reducing carbon footprints while enhancing productivity. For manufacturers aiming to optimise production efficiency and align with sustainability goals, these systems are instrumental.
Contact us today to explore tailored refrigeration and HVAC solutions that exemplify performance, sustainability, and operational reliability. Together, we can help you achieve your production goals while reducing your environmental impact.
Contact Us:
Orion Air Conditioning And Refrigeration Limited
10 Grisedale Court
Woburn Road Industrial Estate
Kempston
Bedfordshire
MK42 7EE
United Kingdom
Sales & Spares: +44 (0)1234 841221
Fax: +44 (0)1234 852662
Email: info@orionair.co.uk
Created 26/11/24