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Product cooling

JD Cooling are industry leaders in product cooling. We have developed, installed and maintained systems from cooling individual baked goods all the way up to thousands of tonnes of product in multiple stores, and everything else in between. Product cooling is simply the removal of heat from a product following a manufacturing or grading process, or removal of heat following harvest of fresh produce from the field.

The product can be a food product, fresh fruit or vegetable, a liquid, sauce or drink, or a manufactured item such as a plastic bottle or turbine blade for a jet engine. Product cooling is generally done by passing air or fluid (usually water) at low temperatures over the surface of the product. The heat energy within the product is transferred to the surrounding air or water, which is in turn cooled by a refrigeration system. Once cooled, the product is then ready for transfer to a holding store or onto its final destination.

Blast chilling / freezing

Blast chilling products is a vital part of the cold chain, especially for a range of products where bacterial growth is rapid at temperatures between 68 oC and 8 oC.  Blast chilling / freezing is the process of rapidly reducing the temperature of a product (such as fresh fruit or prepared vegetables). Many processes are subject to regulation whereby cooling times are set as a vital part of the overall integrity of the manufacture.  Others just benefit the customer and end-user by providing a greater shelf time.  We have a huge wealth of experience, with unrivalled knowledge in high humidity blast chilling.

Cooling tunnels are designed to carry out accelerated product cooling (blast chilling / freezing) within a small area whilst moving the product linearly as part of the production process.  The keys to successful rapid temperature reductions are knowledge of product (and packaging) thermal properties then applying the correct air temperatures and over-product velocities accordingly.

Individually Quick-Frozen applications provide some of the best product quality for frozen foods, as the product is passed through the freezer tunnel whilst air is blown from the underside of the belt generating a ‘Fluidized’ product. Freezing times are very short which reduces ice crystal formation and improving product quality.

Impingement methods use specially designed air distribution plates with nozzles and exhausts are used to generate high velocity air streams, which are directed at the product perpendicular to the surface. This method of cooling increases the heat transfer rate and therefore, provide effective fast processes where batch cooling is not desired.

Bespoke chambers are designed to carry out accelerated product cooling (blast chilling / freezing) often as a batch process.  The key to success with bespoke chambers is understanding production demands and limitations with knowledge of product (and packaging) thermal properties, then applying the correct air temperatures and over-product velocities accordingly.

Rapid cooling

Rapid cooling is essential for many industries, including fresh produce, manufacturing and moulding.

Post-harvest cooling for fresh produce is the most vital process, which will, to a great extent, determine the ‘whole-life’ quality of a particular crop. Upon harvest, products should be cooled to their optimum storage temperature range as quickly as possible for optimum post-harvest quality. The demands vary greatly across the produce range and the prevailing conditions at the actual time of harvest also have a deep impact on the effectiveness of the post-harvest cooling system.

Batch cooling is the process of cooling products in cycles.  The key to success with batch cooling is understanding the batch process, production requirements (such as loading rates), batch entry and exit temperatures, in addition to determining the best method of removing the heat. Knowledge of the product(s) being cooled is crucial to ensure that the cooling process is not detrimental to the quality of the product.

Our pallet cooling pods are installed within a cold store to allow the user to rapidly remove heat from a pallet of product without affecting the function of the cold store (as a chilled storage facility). The pod forms an enclosure around the pallet leaving one side exposed to the room and utilises the cooling equipment installed within the cold store rather than having its own refrigeration system. The pod is fitted with a fan, which increases the air flow over the product to remove heat faster than if the pallet was free standing within the store. The pod can be fitted with a temperature probe and illuminated beacon to signal when the product is cooled to the desired temperature. Multiple pods can be installed in one store or can be made portable.

JD Cooling have pioneered a revolution in hydrocooling, re-establishing it as the primary means of removing field heat from root crops like carrots, parsnips and new potatoes. We use much more re-circulating water than other manufacturers, with a unique coil design and improved filtration. The result is low, uniform crop temperatures and vastly enhanced quality. We also make stainless steel hydrocoolers for processed produce like peeled potatoes and carrots.

JD Cooling are specialists in the design and installation of secondary cooling (glycol) systems. Secondary cooling is the most practical way to cool potable towns (mains) water to use in process applications. The mains water is passed through a heat exchanger, which uses Food Safe Glycol on the primary side of the plate to cool the water down as low as +2°C. We use a valve arrangement and control system to maintain the water set point whilst preventing freezing of the water within the heat exchanger. Applications for this system include pasta refresh, batter mixing and post cook cooling of foods.

In field solutions

JD Cooling has a down to earth approach when looking for a solution to a customer’s problem. We understand that there may not be the space or the budget for a shiny new cooling facility on a site. We don’t mind getting our hands (or boots) dirty and can supply and install permanent or temporary cooling systems in the most remote of locations. We have recently installed a diesel generator powered blast chiller for freshly picked fruit, which is located in the corner of the field where the fruit is harvested.

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