Project Overview

• Location: Orsk, Russia

• Product: Traditional Russian Dumplings (Pelmeni)

• Capacity: 1,000 kg/h (1 Ton per hour)

• Key Equipment: Double Spiral Freezer, Evaporative Condenser, Automatic Multi-head Weigher Packaging Machine, and Bitzer Compressor Unit.

Introduction

In the competitive frozen food industry, maintaining the "handmade" quality of dumplings while scaling production is a significant challenge. Recently, CBFI (Icesource Group) successfully implemented a comprehensive quick-freezing solution for a leading food manufacturer in Orsk, Russia. This project features a high-efficiency Spiral Freezer designed to process 1 ton of dumplings per hour, ensuring premium texture and long-term freshness.

The Challenge: High Capacity in Limited Space

The client in Orsk needed to upgrade their production to 1,000kg/h to meet regional demand. The main challenges included:

1. Space Constraints: The workshop had height but limited floor area.

2. Product Integrity: Russian Pelmeni are delicate; slow freezing leads to dough cracking and moisture loss.

3. Automation Integration: The need to bridge the gap between manual dumpling folding and automated bulk packaging.

The Solution: CBFI’s Integrated Spiral Freezing System

1. High-Efficiency Double Spiral Freezer

The core of this line is the CBFI Double Spiral Freezer. This equipment was chosen for several key reasons:

• Vertical Space Utilization: By using a dual-drum spiral design, the conveyor belt travels upwards and then downwards, providing a massive freezing surface area within a compact footprint.

• Uniform Airflow: Equipped with powerful fans, the internal chamber maintains a consistent 3D airflow, ensuring that every dumpling achieves the required deep-frozen state rapidly and uniformly.

• Hygienic Design: Constructed entirely from SUS304 stainless steel with an easy-to-clean design, it meets the highest food safety requirements.

2. Robust Refrigeration with Bitzer Technology

To provide the necessary cooling capacity for a high-output production line:

• Bitzer Compressor Unit: The system is powered by high-performance Bitzer compressors. Their stable operation provides powerful and reliable support for the entire project's direct cooling system, even under continuous heavy loads.

• Evaporative Condenser: Installed externally to ensure efficient heat dissipation, significantly reducing overall energy consumption.

3. Optimized Production Workflow

The production process is now a seamless blend of craftsmanship and automation:

• Feeding: Prepared dumplings are placed on the mesh belt via an organized inlet system.

• Freezing: The Spiral Freezer locks in freshness by quickly passing the product through the "maximum ice crystal formation zone."

• Packaging: Frozen dumplings exit the discharge port and are immediately routed to a Multi-head Weigher, which automatically fills and seals the bags.

Results and Benefits

• Increased Throughput: The 1 ton/hour capacity has significantly boosted the client's market share in the Orsk region.

• Perfect Texture: Rapid freezing ensures the dough remains elastic and the meat juicy after defrosting, with no visible cracking.

• Lower Operating Costs: The energy-efficient Bitzer refrigeration system and optimized spiral design have reduced the energy cost per unit of product.

• Operational Stability: The system operates reliably despite the extreme external temperature fluctuations common in the Russian climate.

Conclusion

This project in Orsk demonstrates CBFI’s expertise in providing turnkey freezing solutions tailored to specific food types and factory layouts. Our Spiral Freezer technology continues to be the preferred choice for frozen food manufacturers looking for efficiency and premium quality.

Looking to upgrade your frozen food production? Contact CBFI Experts Today for a customized spiral freezer solution.