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“Working faster, better, more profitably... we help our customers get there through ingenuity, experience... and really knowing their business.” John Summers Air Products European Food Business Manager Freshline solutions for food processing

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Page 1: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

“Working faster, better,more profitably...

we help our customersget there through

ingenuity, experience...and really knowing

their business.”

John SummersAir Products

European Food Business Manager

Freshline™

solutions for food processing

Page 2: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international
Page 3: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

WAir Products’ Freshline™

solutions can help you do it all… better

Whether your packaging, cooling,chilling, or freezing applications includebakery goods, fruits and vegetables,poultry, meats, ready meals, ice cream,beverages, or anything in-between,Air Products offers the high-puritygases and equipment, the internationalsupply capability, and — mostimportant — the unmatched industryexperience and technical support tohelp you succeed, just about anywherein the world.

Air Products helped pioneer the use ofliquid nitrogen for ultra-fast food freezingin 1965. Since then, we’ve been helpingfood-industry customers use the latestgas-based technologies to their utmostcompetitive advantage in all kinds of

applications — from tunnel, batch, andimmersion freezing to cryo-mechanicalrefrigeration, modified atmospherepackaging (MAP), and more. In fact,we’ve derived many of our greatestproduct innovations from problems ourcustomers asked us to solve.

As a leading supplier to the industry,we also know that food byproducts canmake wastewater treatment difficult.That’s why, in addition, we offerWastewater Solutions: a combination ofgas-based technologies and servicesdesigned to rapidly address yourcompliance issues and emergencyevents or to help you better monitor andoptimize your wastewater treatmentprocesses on a continuing basis.

With so many choices, today’s consumers are more demanding than ever.

Pleasing them means anticipating their needs as well as their desires, offering

differentiated products that say“pick me!”over the rest. At the same time, you’re

challenged to keep costs down, quality up, throughput high, safety a top priority,

and profit margins as wide as possible.

When it feels like a lot to ask, ask Air Products for help.

Page 4: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

Better food begins withcryogenic systems

Unlike mechanical systems,Air Products’ cryogenic systems usenitrogen (N2) — an inert gas thatcomposes roughly 78% of the air webreathe. When liquefied, nitrogen isextremely cold (-320˚F or -196˚C).At this temperature, freezing occurslightening fast, preserving the originaltaste, texture, and appearance of food.Cost-effective, high-purity liquid nitrogenprovides the safest, most efficient,environmentally friendly food freezingand chilling available today —

drastically reducing processing time,increasing shelf life, and keeping yourfood products as fresh as fresh.

Innovations to keep you ahead of the crowd

Air Products’ technology has representedthe cutting edge of cryogenic foodfreezing from its earliest beginnings,when we helped launch the first liquidnitrogen tunnel freezer for the fast-foodhamburger market. Over the years,we’ve invested extensively in researchand development to help our customerscontinually stay ahead of the curve.

What Air Products’ nitrogen-based Freshlinetechnologies can do for you

IN FOOD FREEZING AND CHILLING

Increase production capacity■ Rapidly freeze and chill —

up to 10 times faster thanmechanical systems

■ Require less space than mechanical methods

■ Allow greater production flexibility

Improve yields and efficiency■ Reduce dehydration and drip loss■ Prevent products from

sticking together and adhering to conveyor belts

Enhance product quality■ Improve texture, taste, and

appearance■ Promote growth of very small

ice crystals that keep food cells andtissues intact

■ Lock in moisture■ Increase shelf life of chilled foods■ Reduce weight loss in thawing

Provide a cost-effective alternativeto mechanical freezing■ Require lower capital investment

and minimal maintenance■ Lower fixed costs — variable costs

linked directly to production■ Improve freezing efficiency

IN BEVERAGE PROCESSING■ Prevent oxygen pick-up■ Yield 58% more gas volume

per weight unit than CO2

■ Minimize losses to cleaningprocesses — less than 2% solubility vs. CO2

■ Produce finely bubbled,stable foams

■ Maximize performance of caustic cleaning systems —chemically inert

■ Provide an abundant, automaticallyrecyclable resource

Page 5: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

Process optimizationmeans six-figure savingsfor Holten MeatFour years after U.S.manufacturer Holten Meat, Inc.expanded into a $10-millionfacility, the company found itselfrunning out of capacity andsearching for growth withoutinvesting additional capital.Air Products offered assistance.

Air Products’ specialists spentseveral days with Holten,interviewing staff and evaluatingthe efficiency of freezingequipment andprocesses.After athoroughinvestigation,Air Productspresented acomprehensiveplan thatincluded ideasfor maximizingcapacity,loweringcosts, andimproving managementprocedures.

In the first eight months ofimplementation, Holten increasedproductivity by 15% and loweredliquid nitrogen consumption asmuch as 13%, resulting in a six-figure overall savings.

“Air Products has brought us a new focus, new energy… We have a barometer now to

measure performance and tools tobe even more successful.”

Our history of innovation includesnumerous pioneering efforts and food-industry breakthroughs, such as…

■ Zero adhesion molding technologyfor high-definition three-dimensional shapes in premiumice-cream novelties

■ Individually Quick Frozen (IQF) coatingtechnology for uniform coating ofsauces on frozen products like pastasand specialty vegetable dishes

■ Cryogenic pelletizing technology fortransforming liquid and semi-liquidproducts like eggs, cream, and saucesinto frozen granules

■ Liquid immersion technology forinstantaneous crust-freezing offruits, marinated products, and otherfoods that are difficult to individuallyquick freeze

■ And our latest development, theFreshline™ Z tunnel freezer — theindustry’s first indirect cryogenicimpingement freezer, combining theadvantages of both cryogenic andmechanical freezing with a host ofadditional benefits, such as increasedcapacity and better control overoperating costs.

Scott Hudspeth

Scott Hudspeth, CEOHolten Meat, U.S.A.

Page 6: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

The right equipment from the right supplier

Sure, the use of liquid nitrogen candramatically improve your foodprocessing, but it requires the rightequipment to work optimally for yourapplication. That’s where Air Productscan really help. We offer one of thelargest selections of food freezingequipment in the business with anexceptional service record. More than90% of the freezers first designed and

commissioned by Air Products are stillin operation more than 35 years later.

All of our Freshline freezing systems aredesigned specifically to minimizenitrogen consumption. The modulardesign enables us to match freezer sizeto your precise productionrequirements. This, along with a list ofspecial features like variable speedexhaust fans and programmable logiccontrols, helps make them the mostefficient, cost-effective systems around.With liquid nitrogen representing up to

90% of cryogenic freezing costs,Freshline freezers can save you a lot.

If unmatched durability, reliability, safety,and easy operation hold a place on yourlist of equipment priorities, Freshlinefreezing systems are the obviouschoice. Let our expert team help youfind the best equipment to suit yourspecific needs.

North Northern Southern Eastern America Europe Europe Europe Asia

GasesOn-site generation • • • • •Bulk • • • • •Cylinder (standard) • • • •Cylinder (special) • • • •

EquipmentTunnel Freezing and Chilling

Freshline Z tunnel freezer • • • • •Freshline GW tunnel freezer • • • •Freshline QF tunnel freezer • • • •Freshline CQ tunnel freezer • •Freshline CF tunnel freezer • • •

Batch Freezing and ChillingFreshline batch freezer • • • • •

IQF by ImmersionFreshline immersion freezer • • • •Freshline RH immersion freezer • •Freshline CD immersion freezer • •

IQF Coating by RotationFreshline rotary freezer • • • •Freshline tumbler • • • • •

Pelletizing of LiquidsFreshline pelletizer • • • • •

BeveragesFreshline nitrogen dispenser • • • •Gases for fermentation • •

Packaging SolutionsFreshline MAP packaging • • • •

ServicesFreshline process evaluations & optimization • • • • •Freshline equipment services • • • • •Freshline online services • • • •Freshline maintenance services • • • • •Freshline safety, health, environmental consulting • • • •Freshline analytical services • • • •Freshline training services • • • • •Wastewater Solutions • • • • •

Note: All of the above services are provided as a comprehensive offering to customers renting or leasing a freezer from Air Products.

Page 7: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

“The things we value about Air Products are the company’sgreat flexibility, its readiness to

serve the customer, its good service,and its special know-how in the

field of freezing, and this has onceagain paid off...”

A source of supply you can always rely on

Once you’ve selected your cryogenicequipment, you shouldn’t have to worryabout getting the nitrogen you need.With Air Products, you won’t. As one ofthe largest industrial gas companies inthe business, we customize supplymodes to meet your requirements.

Does your demand warrant on-sitesupply? No problem. We pioneered theconcept of on-site gas generation forour customers. We offer a range of on-site solutions — including cryogenicair separation, pressure swingadsorption, and membrane productiontechnologies. We install liquid storagetanks and can help you develop acomplete system for distribution to yourpoints of use. Whether we operate afacility on your site or deliver your gasesthrough our expansive production and

distribution network — by pipeline, bytank truck, or in cylinders (for ourcustomers in Europe and Asia) — wecan provide a reliable, cost-effectivesupply that’s appropriate for you.

Detlef Jagolski, Production ManagerHussmann & Hahn, Germany

Equipment modificationleads to product innovationat Hussmann & HahnWhen German processorHussmann & Hahn wanted toturn fresh fish into premiumready-made convenience meals,they faced a challenge: how toproperly freeze semi-finishedproducts for further processingwith items like marinade or sidedishes. Liquid nitrogen freezerswere unsuitable for this purposeand ammonia-operated platefreezing offered inadequatespeed to achieve the desiredproduct quality. The solution? Air Products worked withHussmann & Hahn to re-commission an existingammonia plate freezer, replacingits compressors with liquidnitrogen in a heatexchanger.Thismodificationallowed theammonia to be cooled to -65˚C, a full30˚C lower,and thus,enabled therespected fishcompany toguarantee high product qualitywhile increasing freezingvolume — without the cost of installing an expensive new freezer.

Page 8: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

Faster, better, less costly — Air Products can help youachieve all three

What keeps you awake at night?Manufacturing issues? Cost pressures?Maybe you are simply searching for thebest production method for your newproduct idea.

Occasionally solutions come from newequipment and dependable supply alone.More often, they come from know-how,from decision-making, from teamwork.At Air Products, we bring the greatestvalue to our customers when they inviteus to work with them side by side tosolve their problems and address their

individualized needs. We make it our jobto understand your business from everypossible perspective. For more than threedecades, our dedicated food-industryteam has been collaborating withcustomers worldwide to help themaccomplish their profit, productivity,quality, and performance objectives.Some call it partnering. We call itFreshlineSM service, and it’s something webelieve no customer should do without.

Our Freshline Z tunneloffers the solution in acrunch at VanreuselAs one of Belgium’s leadingmanufacturers of meat snacks,Vanreusel developed a newminced chicken and pork productcovered with a crunchy goldenpastry. With a successful launchbehind them, they faced the nexthurdle. The pre-baked snacks —still warm when packed forfreezing — were stickingtogether when frozen. To preventthis, Vanreusel attempted to keepthe products apart in the boxesbefore placing them into the

shock freezer.This methodsoon provedhighly laborintensive.Given thecompany’srapid growth,spacelimitations,and thespecialhandlingrequired for

these products, a better approachwas in order.

After meeting with a number ofcryogenic equipment suppliers,Vanreusel found the solution fromAir Products: The Freshline Ztunnel freezer. Air Productsworked with Vanreusel toconfigure the new freezer to fitthe limited 8-meter productionspace available. Thanks to Air Products and the Freshline Ztunnel, which applies coldindirectly, Vanreusel gained bettercontrol of the freezing process,increased efficiency, andenhanced product quality with nomore sticking problems.

“The pastry we use is very light.With the speed of the freezingprocess the crust becomes crunchierand the color very yellow. It alsotastes better.”Max Vanreusel, OwnerVanreusel, Belgium

Max Vanreusel

Page 9: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

Air Products’ FreshlineSM

service supports you at every step

Process EvaluationsAn evaluation can range from analyzingpressure losses along a pipeline toconducting a complex audit of your entireprocess and procedures. Ask our food-industry experts to review your existing orproposed systems.

Process OptimizationUsing the results of our evaluations, wehelp you make the changes necessary toachieve your objectives, includinginstallation of new systems or modificationof existing equipment.

Equipment SelectionWe can recommend an appropriatesystem or build a customized solution tosuit your needs.

R&D and Analytical SupportIn addition to our global food R&D center,we operate advanced customer trial anddemonstration facilities worldwide,including our largest food laboratory inthe U.S. We can develop completefreezing profiles based on actual trials runin the lab, determine feasibility,

validate freezingparameters, analyzecost benefits, andmore. Air Productsis also affiliated withsome of the topresearch institutesin the world,including theGeorgia Tech FoodResearch Center in the U.S. and the Campden and ChorleywoodFood ResearchAssociation in the U.K.

Online Services For the first time in the food industry,customers can accurately track the liquidnitrogen usage patterns of individualfreezers at single or multi-line facilitiesusing Air Products’ FreshlineSM onlinenitrogen monitoring. Take advantage ofour convenient telemetry service, too,and we can help you virtually eliminatethe risk of product runout.

MaintenanceWhether you own or lease our equipment,we offer expert routine maintenance andsystem repair by our own team of speciallytrained engineers.

Emergency ResponseAir Products offers 24-hour technicalservice and rapid response, internationally,for both customer-owned and Air Products-owned gas-related equipment.

Safety, Health, and Environmental ConsultingAir Products is an internationallyrecognized safety leader. Whenever weinstall new equipment at a customer site,

we perform a comprehensive safety auditand provide safety training at start-up asour standard practice. Consult with ourfood-industry specialists about youroverall safety, health, and environmentalconcerns. They can assist you inanalyzing your liabilities and preparing forHAZOPs and other compliance audits.

Operator TrainingWe provide comprehensive trainingprograms to help your operators use ourequipment safely and optimally.

Wastewater SolutionsWe offer a range of gas-related servicesand technologies to help you addresscompliance issues, upgrade yourbiological treatment processes, andincrease your treatment capacity by asmuch as 300%!

Page 10: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

Ask a lot of Air Products

Whether you need help solving yourtoughest production problems or simplyfine tuning your new productintroduction, ask Air Products… andexpect more. Our history of innovation,our unrivalled experience, and most ofall, our expert people have made us aworld leader in the food industry. We canhelp you improve your productivity, loweryour costs, maximize your returns, andas a result, help make you morecompetitive in a very competitive market.

“We are pleased with the solutionoffered by Air Products... It hasenabled us to increase productionand worker productivity by at least30% and improve the quality ofour frozen products by reducingtotal bacteria count.”

Complementary technologyearns high praise at Khom FoodsAn aging, inefficient spiralfreezer sent Indonesian seafoodprocessor Khom Foods searchingfor ways to de-bottleneckproduction and boost productivityat a minimum capital cost. Theyturned to Air Products for help.

After a comprehensive analysisof the company’s mechanicalfreezing operation, Air Products’food engineers proposed ahybrid solution: They fittedKhom’s old mechanical spiralfreezer with a new liquidnitrogen freezing system.The combined “cryo-mechanical”system enabled this player in the

Japanesefood marketto cut freezingtime in half,improvefreezingcapacity by 30%,maintainconsistentfrozen foodtemperatures,boostproductivity,

improve the quality of its IQFbreaded shrimp products, and atthe same time lower the overallcost of freezing operations!

Yoshinori Fujikawa, Production DirectorKhom Foods, Indonesia

Page 11: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international
Page 12: Freshline - Air Products & Chemicals · poultry, meats, ready meals, ice cream, beverages, or anything in-between, Air Products offers the high-purity gases and equipment, the international

© Air Products and Chemicals, Inc., 2004 Printed in USA 332-03-010-GLB

For more information

tell me morewww.airproducts.com/food

To learn more about our Freshline solutions for the food industry —including information on specific equipment, applications, or services — orto tell us about your needs, please contact the office nearest you or visit ourwebsite at www.airproducts.com/food. While you’re there, be sure to exploreour food industry Solutions Finder — a unique online tool we think you’llfind especially useful.

AmericasAir Products and Chemicals, Inc.7201 Hamilton BoulevardAllentown, PA 18195-1501Tel 800-654-4567Fax 800-272-4449E-mail [email protected]

EuropeAir Products PLCHersham PlaceMolesey RoadWalton-on-ThamesSurrey KT12 4RZUKTel 0800-389-0202Fax +44 (0)1932-258502E-mail [email protected]

AsiaAir Products Asia, Inc.Suite 6505-7Central Plaza18 Harbor RoadWanchai, Hong KongTel +852-2527-1922Fax +852-2527-1827

Air Products Singapore Pte. Ltd.9 Temasek Boulevard#08-02 Suntec Tower 2Singapore 038989Tel +65-332-1610Fax +65-332-1600

Air Products Japan, Inc.3-18-19 Toranomon, Minato-KuTokyo 105, JapanTel +81-3-3432-7031Fax +81-3-3432-7052