In this ever-evolving food processing industry, innovating technology that meets the changing consumer demands is necessary. Spiral Solutions came into picture, an innovation that transformed the freezing, cooling, and heating process. Spiral solutions resolve the space constraint issues and also offer cost and energy efficient solutions.

Learn how Neologic Engineers’ Spiral technology helps food manufacturers in saving on operational costs by utilizing less space.

What is Spiral Technology?

The Spiral technology in the food industry is key equipment that allow maximizing, mainly, the yield of the production, at the same time they optimize the space in the plant. Spiral technology addresses the challenges of freezing, cooling, and pasteurization of food products effectively. It also contributes to improved energy efficiency, enhanced product quality, and optimized production workflows.

Spiral system can be designed according to the client’s needs and can be configured depending on the process for which it needs to be applied. There are different types of Spiral system used for different products as per process requirement:

• Ambient Coolers

• Refrigerated Coolers

• Air Freezers

• Proofers

• Pasteurizers

• Water Coolers (Hydro Chillers)

Why Spiral System?

Food Products need to undergo proofing, cooling, freezing, and pasteurization; as a part of process to achieve desired product properties and shelf life. Earlier conventional systems were used for product conditioning. Two types of conventional systems used were Linear Tunnels and Blast Freezers. A typical Linear Cooling Tunnel occupies majority of the space in the Process Hall. Also, the power consumption in linear tunnels is far higher due to multiple drives than a spiral leading to higher operational and maintenance costs.

Spiral Solutions is a leading Industry standard for conditioning operations on food processing lines. Recent developments and innovations in Spiral Technology are making conditioning operations even more productive.

Uses of Spiral System

Spiral System plays a crucial role in enhancing productivity and maintaining consistency. There are different forms in which spiral solutions can be applied, as listed below:

• Freezing: Spiral freezers are widely used in ice cream and frozen foods (diced cheese, RTE products, meat and meat products) for rapidly reducing the temperature of the product up to -20degC by maintaining the surrounding temperature inside the spiral cabinet up to -40ºC.

• Cooling: The rapid cooling of food for the food industry is a key process, since it helps to avoid over cooking, cooking smell, retaining product consistency and required product properties in packed food products (hot fills). Cooling process can be carried out by air flow or by means of water, depending on the product sensitivity. Spiral coolers are ideally used for ready meals, dairy products, and bakery products.

• Pasteurization: Some products require pasteurization to eliminate pathogens in the packed products by heating the packed product at certain desired temperature and then cooling it to ambient temperature. It is used product such as packed pasta sauces, packed paneer blocks, and ready to eat items.

Types of Spiral Systems

Space is the concern for many food processing units and Spiral system which are built using stacking technique offer a solution. There are two types of Spiral systems Neologic Engineers offers the food industry:

• Spiral Water Cooler/ Spiral Water Pasteurizer (SWC/SWP)

Some processed food, such as food in Pouches, Cups, and Sachets requires cooling after packaging. Such products can be cooled using Spiral Water Coolers (SWC). SWCs are space and energy-efficient as they occupy minimum space using stacking technique with minimum power and water requirement. The water in the system is reused for maximum efficiency.

Spiral Water Pasteurization (SWPs) are used to eliminate pathogens in packaged foods. Hot water, Cooling tower water & Chilled water, is used based on the product in case of both SWP and SWC.

• Spiral Air Cooler/Spiral Air Freezers/ Spiral Air Pasteurizer (SAC/SAF/SAP)

Spiral Air Pasteurizers (SAP) and Spiral Air Coolers (SAC) work without water for products that are sensitive to water in the processing or packaging stage. SAP and SAC use ambient or temperature-controlled air (hot/cold) to heat or cool packaged and non-packaged foods. This helps optimize maintenance and labor costs in the process without affecting the final quality of the product.

Spiral Solutions are best suitable for:

• Pasta & Pasta Sauces

• Pizza & Pizza Sauces

• Tomato Ketchup, pastes, purees

• RTE/RTH/RTS

• Butter, Paneer, Cheese

• Fermented Batters

• Ice cream

• Curd

• Meat

• Bakery Products (bread loafs, cake, etc.)

Spiral Systems: Advantages and Applications

Spiral technology changed the way of freezing food items. This advanced technology is been a boon to the food manufacturers because it helps in reducing the ecosystem damage with its environment-friendly solutions. Spiral solutions use stacking technique which optimizes the available space. So, there is no extra space or special flooring needed. It consumes less water making it cost and energy efficient.

Another added advantage is that the maintenance costs are low as the components used are of high-quality. Spiral technology offers flexibility in inlet and outlet orientation and the reliability of spiral belt conveyors are also very high. The best part is there is no risk of product contamination as the belts are free from lubrication.

Area of Applications:

• Baked and Fried Products cooling.

• Hot Filled Pouches - Pulps, Puree, Baby Food, Sauces, Ketchups, Curries, Gravies, RTE items cooling.

• Batter Cooling

• Dairy products like Paneer, Cheese, Ice-cream cooling/Hardening/Freezing.

• Meat, Fish, Poultry items Cooling/ Freezing

Benefits of Spiral Systems

• Spiral Solution for Optimal Product Quality

Spiral solutions are designed to rapidly lower the temperature of food products, minimizing the formation of ice crystals within the cellular structure. With spiral technology, food manufacturers can maintain the natural appearance and taste of their products, appealing to discerning consumers who seek both convenience and quality.

• Increased Efficiency and Throughput

Efficiency is the necessity of modern food processing facilities, and spiral excel in this regard. The system features a unique conveyor system that moves products in a spiral motion, optimizing the use of space and facilitating continuous freezing. This design allows for higher production capacities within a smaller footprint, streamlining operations and reducing processing time.

• Versatility Across Diverse Applications

Spiral technology offers a remarkable adaptability across various food categories. From seafood and poultry to baked goods and prepared meals, they can accommodate a wide range of products. The customizable settings and adjustable freezing parameters cater to the specific requirements of different food items, ensuring consistent results regardless of the product being processed.

• Compliance with Stringent Regulations

Food safety and compliance with regulatory standards are non-negotiable aspects of the food industry. They are designed to meet and exceed the stringent hygiene and safety requirements set forth by food authorities. With features like easy-to-clean components, sanitary construction materials, and automated cleaning cycles, it facilitates adherence to regulations, safeguarding consumer health and brand reputation.

Adding Profitability with Spiral Solutions

In the dynamic landscape of food processing, the benefits of spiral solutions are evident and far-reaching. From preserving product quality and increasing efficiency to reducing energy consumption and ensuring compliance, these advanced freezing solutions have revolutionized the industry. As consumer preferences continue to evolve, embracing innovative technologies like spiral solutions become a strategic imperative for food manufacturers seeking to stay competitive while delivering excellence in every bite.