Inline freezing & defrosting sensors

Inline Freezing & Defrosting Sensors

CALLIFREEZE®

The CALLIFREEZE® is the first inline sensor to continuously monitor and optimize freezing and defrosting processes. The sensor measures the fraction of water within the product that is crystallized into ice which is expressed as the level-of-frozenness (LOF). By measuring through the product and non-metallic packaging material, the sensor provides insights about the core of the product. This information is used to provide real-time feedback to the freezing and defrosting units. The installation of our inline freezing and defrosting sensors translates into an increased production capacity and reduced energy costs while maintaining the highest quality standards. Read more about this award-winning technology in our white paper.

MICROFREEZE®

The MICROFREEZE® is used to evaluate the level-of-frozenness (LOF) of large blocks of food products (e.g. blocks of meat) or layers of products (e.g. French fries). Given the large dynamic range of the sensor, LOF measurements can be conducted on block frozen products such as meat and fish, with a block thickness of up to 90 cm. Furthermore, the MICROFREEZE® can easily handle layered products with layer thicknesses up to 50 cm. This makes our sensor ideal for monitoring bulk products such as French fries, vegetables, fruits, etc. The MICROFREEZE® can be either installed on non-metallic conveyor belts or integrated in defrosting tumblers to monitor the thawing processes in real time.

Optimized freezing parameters

The inline freezing & defrosting sensors - CALLIFREEZE® and MICROFREEZE® - were developed to continuously adjust and optimize freezing and defrosting parameters.  The main benefits of the freezing sensors are:

  • Increased production capacity
  • Reduced energy consumption
  • Minimizing product waste
  • Lowered personnel costs

The continuous process optimization translates in an increase of the production capacity up to 15% and a reduction in energy consumption of 5-15 %, while maintaining the same product quality. As an example, using the MICROFREEZE® on a 10-ton line for French fries, reduced the energy consumption with 45 000 - 60 000 Euro/year. These savings corresponds to a return of investment of 1 year. Additionally, by continuously monitoring the production process, any deviations are immediately detected. This allows to intervene very quickly and minimize product loss. On top of that, the use of our freezing sensors reduces the workload on personnel. This leads to a more efficient quality control and reduces the personnel costs.

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AI-powered sensors

Artificial Intelligence and Web Interface

The acquired sensor data are fed to our AI-algorithms which provides reliable process information about the freezing and defrosting processes. This type of intelligent sensing facilitates automatic process regulation and optimization. Depending on the application, our sensors can be combined with other sensing modalities to provide a complete image of the process.

The web interface is used to visualize the processed data and manage the device settings for different products. The software supports Modbus TCP/IP direct communication with PLC units for automatic process control.

Quality certificate

To meet the increasing demands for quality reporting and traceability of products, our system automatically generates quality reports of all processed data. The report gives an overview of the evaluated products and their respective Level Of Frozenness (LOF) values. Since the products are scanned inline, the quality of every product or batch is checked. The products which are sufficiently frozen, receive the level-of-frozenness certificate to confirm the highest quality standards. This confirmation will enhance the trust of your customers in your freezing processes.

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Applications

icon_meat_fish2

Meat & Fish

icon_frenchfries2

French Fries

icon_fruits_vegetables2

Fruits & Vegetables

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Other

Technical information

ParameterCALLIFREEZE®MICROFREEZE®
Level-of-Frozenness (LOF)70 – 100%*
* Range depends on the product
0 – 100%*
* Range depends on the product
Emitted electromagnetic power~10 dBm~10 dBm
Frequency bands61.25 GHz
Non-ionizing and non-destructive
2.4 – 2.5 GHz and 5.725 – 5.875 GHz
Non-ionizing and non-destructive
Sensor’s spot size @ product~2 cm~15 cm
Power inputAC Single Phase 100-240V~ 0.5A 50-60 HzAC Single Phase 100-240V~ 0.5A 50-60 Hz
Operational temperature range-40 °C … 40 °C-40 °C … 40 °C
HousingStainless steel AISI 304 - Hygienic designStainless steel AISI 304 - Hygienic design
IP classIP66IP66
Dimensions receiver – transmitter unit (W x H x D)177 mm x 187 mm x 178 mm177 mm x 187 mm x 178 mm
Dimensions computing unit (W x H x D)327 mm x 457 mm x 179 mm390 mm x 576 mm x 267 mm
EthernetRJ45 plugRJ45 plug
Industrial interfaceModbus TCP/IP serverModbus TCP/IP server
Web-server based user interfaceRemote interaction with the sensor via a browserRemote interaction with the sensor via a browser
DHCP clientAutomatic negotiation of IP addressAutomatic negotiation of IP address
Capacity of LOF calculations> 10 LOF values per second1 - 500 LOF values per second

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