Frozen produce encompasses a large selection of food products. Just walk down the freezer aisle in any supermarket to see the scale on offer. The UK’s frozen food industry is worth over £7 billion, demonstrating its value.
It is no surprise that many manufacturers are in the business of frozen produce. With commercial rewards to be gained and demand to be met, you need to ensure you are offering high quality in the sector and exceeding customer expectations.
Providing consistent quality means overcoming challenges and understanding the requirements of frozen food. It also means investing in the right equipment and creating optimal production conditions.
Our guide explores how to optimise your frozen food production line for maximum results.
- What are the challenges when processing frozen food?
- Creating the right environment for frozen food
- Other tips for frozen food processing
- Yamato’s solutions
What are the challenges when processing frozen food?
You need to consider many challenges when working with frozen produce if you want to maintain suitable integrity and maximise productivity. We have listed the most prominent below.
Coping with cold temperatures
Frozen food requires you to work in cold temperatures. It means setting up a precise environment in your plant that enables the product to stay frozen (preventing spoilage).
You need equipment that performs in cold temperatures and maintains product integrity throughout production.
Preventing sticking
Frozen food often leads to condensation. As this builds up through the process, it may lead to reduced product flow which impacts productivity.
You need equipment tailored to your products’ needs, allowing for good product flow. This will keep production lines moving and prevent lost time having to free up items along the line.
Avoiding damage
Some frozen food is delicate, such as fruit and vegetables. This means they are susceptible to damage and bruising, which reduces their quality and appeal to your customers.
If this is the case, you must ensure your production line handles them appropriately through careful handling that minimises potential damage.
Handling high volumes
Frozen products often come in packs. You need to handle high loads at once and effectively sort them for maximum productivity.
This should not come at the cost of quality. Find systems that have a high capacity yet maintain appropriate handling, accuracy and speed while giving you the chance to uncover flawed materials.
Portion control
Abiding by pre-agreed portion limits is crucial to managing costs and reducing waste in your plant. Most frozen food products have pre-set weight limits which you must follow to ensure labelling is accurate and output is consistent
Your ability to control portions will rest on your machinery. Ideally, you want systems that allow you to input your parameters in advance and accurately sort products accordingly.
Hygiene requirements
Every food manufacturer must abide by hygiene requirements. Frozen produce often results in residue and condensation, making hygienic measures even more crucial.
You need the correct processes in place to minimise cross-contamination or other issues. It also means having machinery that is easy to clean for faster turnaround times while complying with standards.
Creating the right environment for frozen food
The foundation for any successful frozen food production line is the right environment. It is underpinned by having efficient and suitable equipment.
First, you must build a line that is effective in cold temperatures. Seek machinery that will operate fully in such climates while offering accuracy and quality. Heat reduction will be a vital feature of any machine you install as it minimises the risk of product thawing.
Systems should also be compatible with your product types. Features like anti-static coating on surfaces or rounded bucket corners are important for frozen produce as it reduces the risk of sticking.
Minimal drops and delicate handling features will also be needed, especially if you have products prone to damage.
There may be other features you need to consider, dependent on the requirements of your output. Spend time familiarising yourself with your goals and the unique characteristics of your raw materials. You will then be able to implement a project suitable to your products for optimal results.
Other tips for frozen food processing
Creating a perfect environment is the first step in a productive frozen food processing line. However, there are other aspects you must consider to improve results.
Check machinery capacity
Most frozen food manufacturers will need to handle high loads. You need machines with increased capacities to match.
Most machines will have a maximum load, which the provider should disclose. In the case of multihead weighers, it’s also worth checking how many buckets are available, as this will maximise the amount that can be processed at once.
Remember that the ability to handle high loads should not come at the cost of quality. Check that any machine you purchase still suits your product integrity, offers accuracy and allows you to create output that meets standards.
Maintain accuracy
Accuracy across your production lines is crucial. It enables you to adhere to your pre-agreed specifications, minimise waste, make the most of your supplies and manage costs.
Accuracy boils down to your equipment. You need systems that are reliable and intelligent.
Seek solutions that offer high accuracy with minimal margins of error. You will need the option to pre-set programmes enabling you to input specifications ahead of time and allowing your production line to meet them routinely.
Having a maintenance plan in place which regularly service your production line (or outsource it via a contract) is paramount to keeping it in good working conditions while preventing any flaws that could lead to inaccuracies.
Ensure speed
Speed is of the essence to meet production timeframes. It is especially crucial when working with high volumes.
Check the speed of any machine before you purchase. The higher the WPM (weighs per minute), the better. However, remember not to compromise on accuracy or quality to speed things up – you need to find systems that offer a perfect balance.
Have quality control practices
Frozen product is susceptible to contamination, just like any other food type. To meet standards and maximise quality, you need effective production inspection processes.
Most quality control procedures will revolve around an inspection system. The system you choose will depend on your product and the contamination (or other issues) it is exposed to. In the frozen sector, metal detection and x-ray are the obvious choices.
Avoiding complaints while offering the utmost quality and experiencing the benefits is what every plant strives for. By installing such systems in your production line, you will identify faults in advance, giving you time to rectify them before they reach the hands of your customers.
Have robust cleaning procedures
Hygiene is integral. You need good cleaning processes across your plant that minimise any risk to product quality while allowing you to abide by industry standards.
First, you need to ensure your machinery suits your cleaning protocols. In most cases, they will need a high IP rating that protects against water, while features like rounded corners, stainless steel and easy-to-remove parts will make the process faster.
You will need a cleaning plan that should address cleaning between batches and at the end of the working day.
Remember that cleaning should be the cornerstone of your hygiene culture, in which your staff do their part through regular handwashing, the appropriate wearing of PPE and the organisation of resources.
Yamato’s solutions
Yamato has worked with countless food manufacturers, covering multiple sectors – including frozen products. We create optimised production lines that meet product requirements and optimise results.
We offer many solutions to support the frozen food sector, including:
- The Omega Series multihead weigher – a state-of-the-art weigher boasting increased productivity, IP67 compliance and up to 32 weigh heads
- The Epsilon Series multihead weigher – providing excellent performance, IP66 compliance, accuracy and speed at an affordable price
- The metal detection combi system – for identifying and eradicating the issue of metal contamination
- The YX20 x-ray – offering the highest level of inspection and safeguarding your products from contamination
- Static scales – a final compliance check at the end-of-line or as part of your packing station
If you want to introduce a frozen food project into your plant or simply wish to optimise your existing lines, Yamato is here to assist. We will help you to plan and commission your line with world class machinery that meets your goals.
Alongside our world-leading solutions, we offer ongoing support through training, maintenance contracts and spare parts provision.
Get in touch with the team today to find out how we can help you.
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