Seafood defrosting systemsAutomated process with end quality in focus

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

Seafood defrosting systemsAutomated process with end quality in focus

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

During the last fifteen years we have developed a system for industrial defrosting of seafood. The system is designed to meet the demands in the food processing industry and to contribute to a better economy using frozen raw material.

Defrosting is based on these criteria:

• Better use of the product by controlled and gentle defrosting to prevent yield loss and to achieve better quality on the end product.

• Automated process to reduce labour

• A minimum of water usage, and energy consumption.

• Hygienic design to meet the highest requirements.

• Flexible systems for a simple adjusting to defrosting programs, defrosting time, and quantities

• Simple and heavy design to keep a high level of operational reliability, and long life time cycle.

• A system that can easily be fitted into existing buildings.

• Flexible loading and unloading systems.

The system is based on the principle of defrosting by circulating a fluid around the product. The water is circulated by a pump, and a blower makes turbulens during loading and defrosting. The way of circulating the water is very important to keep the defrosting process under control, and to obtain the best result.

All our systems can be equipped with a heat exchanger that requires low water usage has an integrated heat exchangers to transfer energy from the energy supply to the defrosting tank. The system can be heated by warm water or steam, and the cold in the product will keep the temperature low.

A controlled defrosting can give you up to 5% better yield.

Water is one of the best energy carrier we have, and is also the most used fluid in our systems. Other fluids that are common are sea water and different types of brine. By using water we can defrost the product at a low temperature and still keep the defrosting time at a minimum. A normal defrosting temperature is below 5-6 deg. C, and an end temperature below 0 deg C.

The design meets the highest requirements in the food processing industry. Our system is based on hygienic design, and all parts in the system is easy to clean either between each batch or on a periodic basis. We can supply systems for filtering and cleaning the water either before, during or after defrosting.

A PLC system is controlling the temperature in the tank, and the defrosting parameters are easily programmed on the touch screen. It is possible to make 20 different defrosting programs, and store them in the PLC. The defrosting software is developed through many years, and we use the same software for all our systems. The user interface is simple and require a short period of training. However, some experience is needed to perform an accurate defrosting.

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF12-LB

Batch defrosting of single or block forzen products

Water is filled into the tank to a level that fits the amount of product to be defrosted. The operator puts the blocks over the edge manually or uses our loading systems with conveyor or swingloader.

The software must be programmed, or the operator chooses one of the preprogrammed defrosting procedures. It is possible to preprogram up to 20 different programs for different amounts, types of fish and block size.

After finished defrosting the operator lifts the bottom up until the product flows over the top edge. The product will be handled very gentle and no damage will occur.

When the product is unloaded the system can be prepared for the next batch, or the cleaning procedure can be started. The defrosting fluid can be used later in the process for storing or for defrosting the next batch.

Technical data:

Standard model: 1000kg/batch 2000kg/batch

Defrosting time: 10 minutes to 10 hours depending on block

size

Example for 1000 kg system:Product: 800 kg blockfrozen

mackerelBlock size: 400x600x120Defrosting time 2 hoursEnd temp 0 degree CDefrosting temp 6 degree CEvening temp. 1 degree C

Payback model (example from 2006)Product: Pangasius FiletsDefrosting system Stette DF12-LB 1000kgPrice € 49.500,-Pangasius fillets 2,5 Euro/kgEnergy consumption 2kW/hYield savings 60 kg / 150

Euro/batch

A producer is defrosting two tons of pangasius fillet daily.When defrosting at too high temperature the yield is 94%. DF12-LB can defrost max 1000kg pangasius fillets per cycle of 4 hoursThe yield after defrosting is 100%.With 200 production days per annum the saving is €60.000,- . Paybacktime is then 10 months.The example does not take into account savings on energy, water, labour etc.

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF12-LB 1000 kg/batch

DF12-LB 2000 kg/batch

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF01-SC

Batch defrosting of single or block frozen products

Water is filled into the tank to a level that fits the amount of product to be defrosted. The operator puts the blocks over the edge manually or uses our loading systems with conveyor or swingloader.

The software must be programmed, or the operator chooses one of the preprogrammed defrosting prosedures. It is possible to preprogram up to 20 different programs for different amounts, types of fish and block size.

After finished defrosting the operator uses the swinging carrier to lite the product up to and over the edge. The product will be handled very gentle and no damage will occur.

When the product is unloaded the system can be prepared for the next batch, or the cleaning procedure can be started. The defrosting fluid can be used later in the process for storing or for defrosting the next batch.

Technical data:

Standard model: 500 kg Capasity

Defrosting time: 10 minutes to 10 hours depending on the raw material

Example for 500 kg systemProduct: 300 kg IQF frozen

pangasius filletBlock size: N/ADefrosting time 1 hourEnd temp 0 degree CDefrosting temp 6 degree CEvening temp. 1 degree C

Payback model (example from 2006)Product: Pangasius FiletsDefrosting system DF12-SC 500kgPrice € 30.000,-Pangasius fillets 2,5 Euro/kgEnergy consumption 1kW/hYield savings 36 kg / 90 Euro/batch

A producer is defrosting 600kg of pangasius fillet daily.When defrosting at too high temperature the yield is 94%. In this example DF01-SC is defrosting 300kg pangasius fillets per cycle of 1 hour.The yield after defrosting is 100%With 200 production days per annum the saving is €18.000,- . Paybacktime is then 20 months.The example does not take into account savings on energy, water, labour etc. Even with small batches, and relatively small quantities the payback time is acceptable.

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF01-SC 500 kg/batch

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF530-R

Batch defrosting of single or block forzen products

Water is filled into the tank to the top level. The defrosting fluid is usually fresh water or sea water. Next step is to program the software with the right parameters on the touch screen, or to choose one of the pre programmed receipts. It is possible to load up to 20 receipts in advance. The programme is set in auto and the first phase of the defrosting starts.

The operator uses the loading system to transport the blocks into the tank, and the top conveyor divides the fish even into the defrosting system. The loading system has a capasity up 40 ton/hour if the operator manage to fill the loader fast enough. The loader can also be fed by a forklift from a pallet or a tub if the blocks are unwrapped in advance.A simpler solution is to use a ramp to load the blocks. This is used for the smaller systems.

The defrosting will start to add energy to keep the temperature in the tank at a predefined level. The energy can be added by an internal heat exchanger, or by adding water with a higher temperature. A normal temperature for defrosting is between 4-6 deg C. If the temperature during defrosting phase is too high the yeild will drop, and the quality of the product will be poor.

The next phase of the defrosting is the evening. The temperature will drop to a level about one degree above the end temperature. End temperature is below zero deg C for a brine or seawater, and just above zero deg C for fresh water. It is important to end the defrosting at a temperature as low as possible.

Unloading the DB530-R is done by a conveyor. We use the best quality of stainless steel belt for high strength and hygiene. The system can feed directly to a processing line, but we prefer to use a hopper as a buffer. With a large hopper it is also possible to empty the defrosting system and start loading the next batch. The cold water from the defrosting system is used in the hopper for keeping the stored fish cool.

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF530-R 30 ton/batch

Technical data:

Capasity: 5-30 ton per batch

Defrosting time: 1 hour to 12 hours depending on the raw material

Example for 30 ton systemProduct: 30 ton block frozen codfishBlock size: 600x1200x150Defrosting time 12 hoursDefrosting temp 4 degree CEvening temp. 1 degree CEnd temp 0 degree C

Payback model (example from 2006)Product: CodfishDefrosting system DF530-R 30 tonPrice 240.000,- EuroCodfish 3,4 Euro/kgEnergy consumtion Seawater (no heatex changer)Yield savings 900 kg / 3060,- Euro/batch

A producer is defrosting 30 tons of block frozen codfish dailyWhen defrosting the traditional way the yield is 94%. In this example DF530-R is defrosting 30 ton codfish during night for production the next day.By using the defrosting system it is possible to increase the yield by 3 %With 200 production days per annum the saving is €75.000,- . The labour is redused by two operators, and the logistics around the defrosting process is reduced dramatic. Together this will be savings of app 60.000 Eurp per annum. The normal way of defrosting this amount is in tubs. The savings on tubs will be app. 36.000,- Euro. The total savings will be 171.000,- Euro per annum. Paybacktime is then 16 months. For some producers in Norway we have seen a paybacktime less than a year.The best defrosting will also give heigher quality on the end product, and a heigher grad of superior products.

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF530-C

Batch defrosting of single or block forzen products

Water is filled into the tank to the top level. The defrosting fluid is usually fresh water or sea water. Next step is to program the software with the right parameters on the touch screen, or to choose one of the pre programmed receipts. It is possible to load up to 20 receipts in advance. The programme is set in auto and the first phase of the defrosting starts.

The operator use the loading system to transport the blocks into the tank, and the blower system makes turbulens to spread the blocks in the tank . The loading system has a capasity up 40 ton/hour if the operator manage to fill the loader fast enough. The loader can also be fed by a forklift from a pallet or a tub if the blocks are unwrapped in advance.A simpler solution is to use a ramp to load the blocks. This is used for the smaller systems.

The defrosting will start to add energy to keep the temperature in the tank at a predefined level. The energy can be added by an internal heat exchanger, or by adding water with a higher temperature. A normal temperature for defrosting is between 4-6 deg C. If the temperature during defrosting phase is too high the yeild will drop, and the quality of the product will be poor.

The next phase of the defrosting is the evening. The temperature will drop to a level about one degree above the end temperature. End temperature is below zero deg C for a brine or seawater, and just above zero deg C for fresh water. It is important to end the defrosting at a temperature as low as possible.

Unloading the DB530-C is done by the fish pumping system. We have developed a vacuumpump to transport the fish from the defrosting system to the production. It is beneficial to use this system if the defrosting and the production is far apart. We can pump the fish up 100m with no damage. Inside the pipe (300mm) it is a mix of fish and water that will help to keep the product cool during transport. The cool water will be returned to the tank with a pump. We recommend this system where the cold store is far away from the production. In this way the expences related to internal transport of frozen blocks can almost be eliminated.

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

DF530-C 30 ton/batch

Technical data:

Capasity: 5-30 ton per batch

Defrosting time: 1 hour to 12 hoursdepending on the raw material

Example for 30 ton systemProduct: 30 ton block frozen codfishBlock size: 600x1200x150Defrosting time 12 hoursDefrosting temp 4 degree CEvening temp. 1 degree CEnd temp 0 degree C

Payback model (example from 2006)Product: CodfishDefrosting system DF530-C 30 ton Price 240.000,- EuroCodfish 3,4 Euro/kgEnergy consumtion Seawater (no heat

exchanger)Yield savings 900 kg / 3060,- Euro/batch

A producer is defrosting 30 tons of block frozen codfish daily.When defrosting the traditional way the yield is 94%. In this example DF530-C is defrosting 30 ton codfish during night for production the next day.By using the Stette defrosting system it is possible tp increase the yield by 3 %With 200 production days per annum the saving is €75.000,- . The labour is redused by two operators, and the logistics around the defrosting process is reduced dramatic. Together this will be savings of app 60.000 Eurp per annum. The normal way of defrosting this amount is in tubs. The savings on tubs will be app. 36.000,- Euro. The total savings will be 171.000,- Euro per annum. Paybacktime is then 16 months. For some producers in Norway we have seen a paybacktime less than a year.The best defrosting will also give heigher quality on the end product, and a heigher grad of superior products.

First Process AS • P.O.Box 111• N 6249 Ørskog NorwayTel.: +47 702 73 200 Fax.: +47 702 73 201

Email: post@firstprocess.no Web: www.firstprocess.no

Reference list

Company Capasity Type

Marine Harvest Brugge 2000 kg DF12-LBAker Seafood AS 20 ton DF530-R Nergaard AS 30 ton DF530-RMøre Codfish Comp. Bud AS 30 ton DF530-RBrødrene Sperre AS 40 ton DF530-RWNils Sperre AS avd Torsken 20 ton DF530-RPLofotcompaniet AS 10 ton DF530-RGustav Stokke AS 40 ton DF530-RWDayseaday 1000 kg DF12-LBMarine Harvest Brugge 1000 kg DF12-LBAndreas Bjørge AS 50 ton DF530-RWJacob Bjørge AS 40 ton DF530-RWKarsen Flem AS 30 ton DF530-RWGrytestranda Fiskeindustri AS 40 ton DF530-RWIngolf Engeseth AS 20 ton DF530-RGryllefjord Fryseri AS 30 ton DF530-RSigurd Folland AS 20 ton DF530-RHjønnevåg Brødrene AS1000 kg DF12-LBSjømat AS 1500 kg DF12-LBOskar Hoff AS 30 ton DF530-CBulandet Fiskeindustri Software N/AMathias Bjørge AS 20 ton DF530-CBrødrene Roald AS 3x12 ton DF530-C

Seafood defrosting systems