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Design of carcass chilling facilities - with optimal meat quality output

Laurits Beck Nielsen

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Design of carcass chilling facilities - with optimal meat quality output

When constructing new chilling facilities or upgrading existing ones, it is important to ensure proper equipment sizing and design that provide correct process parameters.This requires solid experience of how to optimally extract heat from hot carcasses and knowhow that can prevent critical design flaws and reduce overall project spending while ensuring the optimal carcass chilling process for your needs.

Bringing DMRI onboard your project will ensure exactly this, and we will provide you with technical process specifications that are tried and tested in the field by our engineers themselves. We will also assist you in contractor/supplier selection and ensure that their scope of supply lives up to the process specifications.

By the end of the project, DMRI conducts a performance test to establish any corrections needed by the contractors.

In short, we will assist you from start to finish.

DMRI designs ensure:

  • Higher meat quality
  • Low chill loss (evaporative loss during chilling)
  • Low drip loss (meat juice in packaging)
  • Reduced operating costs
  • Sufficient chilling capacity
  • Correct final product temperature
  • Low condensation level in building (no dripping)
  • Structural longevity

Value of chill loss:

The water that evaporates from the skin and meat of the carcasses poses a significant loss in yields. Analysis of sales numbers from various pork slaughter facilities determined the average value of 1% of chill loss to be approx. 1.3 EUR per carcass.

In one case, one of our customers running 700 pigs/hour in a two shift operation was able to increase yearly sales of approx. 3,500,000 EUR by reducing their chill loss with 1% by refurbishing their chilling process using DMRI’s specifications.

Based on your average sized carcass, DMRI can produce:

1. Process specifications that define:

  • Thermal process simulation
  • Evaporator design
  • Heat transferring area [m2]
  • Air flow [m3/h]
  • Process time (and thus required footprint)
  • Air temperature
  • Refrigeration valves design and operation
  • Defrost timmings
  • Fan programming
  • Refrigeration plant sizing
  • Insulation sizing and requirements
  • Air separation systems for cold/warm areas

2. Building specifications that define:

  • Insulated and heated floor structure
  • Vapour barrier requirements
  • Wall penetrations for pipes and cables
  • Equipment support columns ensuring thermal break
  • Insulated panel interface with concrete sub floor ensuring intact vapour barrier
  • Correct interface with adjacent buildings

3. Layout drawings and evaporator placement

4. 3D drawings of facility

5. Continued consultancy and interaction with local contractors on behalf of the facility owners

6. Site supervision during construction and installation

7. Performance test

 

RECENT CHILLING DESIGN PROJECTS FOR HOT CARCASSES

CustomerCountryTaskYear
Esfosa SpainDesign of new blastchiller and equalizing areas2017/2018

Kekén

 MexicoGreenfield design of blastchiller and equalizing areas2018/2019
Proan MexicoGreenfield design of blastchiller and equalizing areas2017/2018
Daejeon Chungnam KoreaGreenfield design of blastchiller and equalizing areas2017/2019
TICAN DenmarkRefurbishment of existing blastchiller and equalizing areas2013/2014
Danish Crown Blans DenmarkRefurbishment of existing blastchiller and equalizing areas2008/2009
Danish Crown Horsens DenmarkGreenfield design of blastchiller and equalizing areas2001/2004