In the field of food production, Guangzhou Cleanroom Construction Co., Ltd., as an industry expert specializing in cleanroom construction, deeply understands the crucial role of the air conditioning and refrigeration screw machine system in food factories. From meat processing to bakery production, from dairy product manufacturing to beverage filling, a suitable refrigeration system is not only related to product quality but also affects production efficiency and food safety. This article will delve into the mysteries of the air conditioning and refrigeration screw machine system in food factories and share our unique insights and rich experience in this field.
I. Why Screw Machine Systems are the Preferred Choice for Food Factories
(1) Exceptional Stability to Ensure Product Quality
Food production has extremely high requirements for environmental temperature stability. Take meat freezing as an example; temperature fluctuations can cause repeated freezing and thawing of meat, affecting its texture and taste, and may also lead to bacterial growth, posing a threat to food safety. Thanks to the meshing design of the twin-screw rotors, the screw machine system can achieve continuous and stable refrigeration with pulsation-free exhaust, and the temperature fluctuation can be controlled within ≤±0.5°C. This means that throughout the production process, food remains in an ideal low-temperature environment, avoiding quality problems caused by temperature changes. Compared with traditional piston machines, screw machines have an overwhelming advantage in terms of stability, safeguarding food quality.
(2) Powerful Refrigeration Capacity to Meet Diverse Needs
Food factory production covers a variety of processes, each with different requirements for refrigeration temperatures. Ranging from cold storage at 0 - 10°C to freezing at -18°C or even lower, screw machine systems can easily handle these demands. Single-stage compression can reach -30°C, and two-stage compression can go as low as -40°C. Whether it's the deep freezing of seafood and meat or the fresh-keeping refrigeration of fruits and vegetables, the requirements can all be met. For instance, in the production of quick-frozen dumplings, rapidly reducing the central temperature of dumplings to below -18°C can effectively lock in moisture and nutrients, maintaining their taste. The powerful refrigeration capacity of the screw machine system plays a vital role in such scenarios.
(3) Energy-Saving Advantages to Assist in Cost Control
With the increasing energy costs, energy conservation has become a focus of attention for enterprises. The volumetric efficiency of the screw machine system exceeds 95%. Compared with other refrigeration equipment, it has a remarkable energy-saving effect, enabling power savings of up to 30%. In large food factories where the refrigeration system operates 24 hours a day, over the long term, the energy-saving advantages of the screw machine system can help enterprises save a significant amount of electricity expenses. Through technical means such as optimizing the refrigeration cycle and improving the equipment's energy efficiency ratio, the screw machine system achieves efficient energy utilization while ensuring the refrigeration effect, reducing the operating costs of enterprises.
II. Key Components and Technologies of Screw Machine Systems in Food Factories
(1) Rotors - The "Heart" of the System
Rotors are the core components of the screw machine system, and their performance directly affects the overall performance of the system. We adopt rotors with a 5:6 asymmetric tooth profile design. Compared with traditional tooth profiles, the leakage is reduced by 20%, significantly improving the efficiency of the compressor. At the same time, the surface of the rotors is hardened to a hardness of HRC58+, ensuring their durability under high-speed operation and high-pressure environments, with a service life of over 100,000 hours. This not only reduces the frequency of equipment maintenance and lowers maintenance costs but also ensures the long-term stable operation of the system, which is crucial for the continuous production requirements of food factories.
(2) Oil Separation System - The Guarantee for Efficient Operation
The oil separation system plays a crucial role in the screw machine system. Our screw machines adopt a three-stage oil separation technology, combining centrifugal, filtration, and adsorption methods, and the residual oil rate can be controlled at <3ppm. High-quality oil separation can ensure the purity of the refrigerant, improve the heat exchange efficiency, and reduce compressor wear, thereby enhancing the overall energy efficiency of the system. At the same time, it is recommended to check the differential pressure of the separator every 2,000 hours and replace it in a timely manner when the differential pressure >0.6MPa to ensure the normal operation of the oil separation system and maintain the efficient and stable working state of the system.
(3) Intelligent Control System - The "Brain" for Precise Regulation
The intelligent control system is the "brain" of the screw machine system, enabling precise regulation of the refrigeration process. Through multi-parameter PID adjustment, the system can automatically adapt to changes in storage temperature. For example, in the pork freezing process, according to the technological requirements, staged cooling control from 4°C→0°C→-18°C can be achieved, ensuring that the pork reaches the best freezing effect at each stage. In addition, the intelligent control system also has functions such as fault diagnosis and early warning, which can monitor the operating status of the system in real-time, detect potential problems in advance, and take timely measures to avoid production interruptions caused by equipment failures, ensuring the continuity and stability of food factory production.
III. Addressing the Unique Challenges of Refrigeration in Food Factories
(1) Solving the Problem of Frost Formation on the Surface of Frozen Foods
Frost formation on the surface of frozen foods is a common problem in food factories. It not only affects the appearance of the products but also causes food dehydration and nutrient loss. We optimize the design of the evaporator and reasonably adjust the fin spacing (recommended ≥8mm) to ensure uniform air circulation and reduce the occurrence of frost. At the same time, we precisely control the refrigerant charge, with an error controlled within ±5%, to ensure the normal operation of the refrigeration system and fundamentally solve the problem of frost formation. In addition, regular defrosting maintenance of the evaporator is carried out, and advanced technologies such as hot gas defrosting are used, which can not only defrost efficiently but also avoid secondary pollution to food.
(2) Avoiding Frequent Start-Stop of the Unit
Frequent start-stop of the unit will affect the service life of the equipment, increase energy consumption, and may also lead to temperature fluctuations, affecting food quality. Our screw machine system is equipped with a capacity slider, which can achieve stepless adjustment of the refrigeration capacity within the range of 25% - 100%. When the system load rate <40%, part of the compressors are automatically unloaded to avoid frequent start-stop of the unit. At the same time, through the precise prediction of the refrigeration demand by the intelligent control system, the operating state of the compressor is adjusted in advance to achieve the stable operation of the system, extend the service life of the equipment, and reduce operating costs.
IV. Professional Services and Solutions of Guangzhou Cleanroom Construction Co., Ltd.
As a professional cleanroom construction manufacturer, Guangzhou Cleanroom Construction Co., Ltd. provides comprehensive screw machine system solutions for food factories. From demand analysis and scheme design in the early stage of the project, to equipment selection, installation, and commissioning, and then to later maintenance, repair, and technical upgrades, we have a professional team to follow up throughout the process. We tailor the most suitable refrigeration solutions according to factors such as the production process, workshop layout, and production capacity requirements of food factories to ensure the efficient and stable operation of the system. In terms of after-sales service, we have established a complete response mechanism, on standby 24 hours a day, ready to solve problems encountered by customers during equipment operation, giving customers peace of mind.
The air conditioning and refrigeration screw machine system in food factories is a key infrastructure for food production. With our rich experience and professional technology in the field of cleanroom construction, Guangzhou Cleanroom Construction Co., Ltd. builds efficient, stable, and energy-saving screw machine systems for food factories, helping food enterprises improve product quality, reduce production costs, and achieve sustainable development. Choosing Guangzhou Cleanroom Construction Co., Ltd. means choosing a dual guarantee for food safety and production efficiency.