BEEF PORK POULTRY FISH CONVENIENCE VEGETABLESFRUITS

The Evolution of Tunnel Freezing SHOCK FREEZING - COOLING -TEMPERING

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AAT-FREEZING Plants

We supply fully automated systems for shock freezing, temporary storage and/or tempering of food in cartons or boxes.

Advantages of an AAT BoxFreezer:

“Currently the biggest AAT BoxFreezer is in Venezuela; it is 33 metres long and more than 12 metres high. But we have a lot of ideas for the BoxFreezer and we want to use the synergies of the BT-Group to develop the product further”, says Martin Kink, head of sales for the BoxFreezer.

AAT BoxFreezers are among the most advanced freezing plants on the market. The products are loaded into the BoxFreezer automatically through a lock, then shock frozen and automatically unloaded when they have reached the target tem-

perature. The BoxFreezer works opti-mally with throughputs from 3 to 30 tonnes per hour.

The principle is simple, but the plant can be used in many different ways: single-zone shock freezing, our

patented multi-zone freezing mode or with complex adaptation to the industry 4.0 standard.

} Simultaneous freezing of different product types with different freezing times

} Improved, guaranteed freezing quality

} Labour-saving operation

} Saves energy costs with optimized freezing times

} Saves energy costs with multi-zone design; zones can be switched off when not needed.

} Large load capacity thanks to compact design

} Long operating periods between defrosting stops

} Automatic loading and unloading logistics with comprehensive display of monitoring parameters and freezing times

} Flexible, parameterizable loading and unloading strategy allows rapid adjustment to changing production conditions

} Timed unloading commands programmable by PC

} Database option allows production records and data to be saved and archived, on the plant control unit or PC (Ethernet).

} High availability, rapid error analysis via remote maintenance modem or Internet.

BOXFREEZER BOXFREEZERSMALL

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AAT-FREEZING – Innovative, Flexible and Powerful

AAT-FREEZING – Assures Your Product Quality

Our BoxFreezers are full of innovations. Their design is thought through in every detail: saving space and achieving excellent adaptability.

Transverse Air Stream 20% More Compact

Reorganizable

Flexible In- and Output

Accessible

Lock Capacity up to 2000 Units

Multitemp – the Innovation

The freezing blowers are arranged on the side of the BoxFreezer, so that the airstream blows directly into the

product stack. The freezing air reaches the product faster and shortens the freezing time. The total air path is shorter than

in other systems, because the air only has to cross the width of the plant. That means that if the plant is 30 metres long and 6 metres wide,

then the system only has to chill the 6 metres. The result is a better tempera-ture curve and more uniform freezing of the products.

The BoxFreezers produce the same performance in 20% less space than conventional designs.

The system allows the pallets to be reorganized flexibly, adapting loading and unloading to

different requirements.

The locks are customized to suit your existing plant layout. This keeps the transport paths as short as possible and allows you to achieve a

space-saving and more flexible line design.

Workers can enter the BoxFreezer even while it is running, because only the

product zones are refrigerated.

Up to 2000 units can be loaded and unloaded simultaneously.

Our BoxFreezers come with up to 3 freezing zones that can be program-med independently. For example, one zone can be used for shock freezing to −20°C, one for cooling and one can be switched off to save energy. Multitemp is our exclusive solution.

Meat and meat products are highly sensitive and must be treated accordingly. Our BoxFreezers ensure rapid free-zing that preserves the product optimally. The pre-sorting

system, the advanced freezing unit and the output distribution all contribute to your product quality.

BEEF PORK POULTRY FISH CONVENIENCE VEGETABLESFRUITS

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AAT-FREEZING – Designed in DetailUp to three freezing zones are available for products that need different refrigeration processes. This is just one of the innovations in our BoxFreezers.

Here the incoming products are pre-sorted.Example:• Freezing products –18°C: Zone 1 freezing +10°C to –18°C• Fresh products 0°C: Zone 2 cooling +20°C to 0°C• Convenience 0°C: Zone 3 cooling +30°C to 0°C

Here the products are sorted for shipping or for storage in an optional refrigerated warehouse.

Rejected products:• Packaging damaged• EAN code not readable

Thanks to the flexible design, the loading and unloading locks can be positioned at any point in the refrigeration cycle. It is also possible to install two loading locks and two unloading locks.

The BoxFreezer is surrounded by a completely insulated mantle.Our freezing units are located at the side relative to

the direction of travel. This ensures uniform cooling along the whole length of the line. It also means the air has an optimal flow path to the product.

The freezing shelves are designed so that the airflow passes over and under the product. This results in faster and more efficient freezing.

The elevator lifts the product into the programmed freezing level and ensures optimal filling of the BoxFreezer.

The system can be designed with multiple freezing zones and can therefore adapt flexibly to your needs.Example:• Freezing products –18°C: Zone 1 freezing +10°C to –18°C• Fresh products 0°C: Zone 2 cooling +20°C to 0°C• Convenience 0°C: Zone 3 cooling +30°C to 0°C

Pre-Sorting

Output Station

Quality Control

Locks

InsulationFreezing Units

Innovative Freezing Shelves

Elevator

Freezing Zones

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AAT-FREEZING – Optimal Refri-geration Quality for Your ProductsThe BoxFreezer is designed to ensure gentle handling of the packa-ging at the same time as maximum freezing performance.

Best Possible Freezing Quality BoxFreezer

Pre-Sorting and Output Station

A key aspect of our BoxFreezer is the outstanding freezing quality. The BoxFreezer delivers an optimal freezing curve and gentle handling of the packaging. The rapid freezing means your product spends the shortest possible time in

the BoxFreezer. The colour and surface of your products are less affected and their appearance remains more appealing.

In many variants ‚out of the box‘. AAT has a long and successful history of creating special designs for special solutions. Our experts will analyse your requirements exactly, so that you get a BoxFreezer that is perfectly

configured for the way you need to use it. We put efficiency and cost savings on top of the list. That means optimum utilization, product safety and quality for our customers.

We supply the complete pre-sorting system including the conveyor technology and control mechanisms to make sure your product workflow is as good as it can be. The same applies to the output station. We can

also supply the subsequent steps such as manual or robotic packaging or transport to a high-bay warehouse. We can supply any special variants of these processes you desire.

Conveying system and sorting by product. Identifica-tion by EAN code to ensure only the same products are loaded together.

The pre-sorted products are moved into the BoxFree-zer pallet by means of a friction-free V-belt conveyor and passed into the freezing process.

The freezing pallet is transported into the program-med cooling zone by the elevator. Simultaneously, a pallet is unloaded from the freezing cycle and passed to the output station.

The products come out of the BoxFreezer accurately sorted by product and are ready for the next hand-ling steps (shipping or storage).

Pre-Sorting Input Station

Transport to ZoneOutput Station

AAT-FREEZING – BoxFreezer Systems for All Your NeedsDon’t settle for poorly designed systems. We are sure to have the right solution for you.

AAT-FREEZING – Services Freezing Workflow

• 24/7 hotline• Preventive maintenance• Service Level Agreements• On-site service• IT services

• Conveyor technology• Electric monorail conveyors• Automated guided vehicles

• Freezer Management Systems• Freezer Control Systems• PLC• Visualization

CONTROL MOVE CARE

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Comparison AAT BoxFreezer vs common systems

Airflow distance is muchshorter at transversal flow –approx. 10 metres.This results in consistentair speed on all boxes.

Longitudinal airflow has to pass a much longer distance. This causes a loss of air speed and the air gets warmer.

Transverse airflow passes through a much larger area.

Longitudinal airflow affects a small frontal surface.

AAT BoxFreezer | Transverse Airflow Common systems | Longitudinal Airflow

Airflow is guided by shelf. Airflow is not guided

in any way.

Multitemp solution is possible

Airflow is guided by shelf

Input and Output are flexible

Smooth rolling transport of cartons and boxes.

The mechanical system is able to move the carrier in both directions.Rearranging according delivery program is possible.

Air flow distance is only 10 or 12m (from air cooler back to ventilator). Cold air remains cold more consistently. The delta T is minimal. The freezing results in the entire storage area are very uniform.

Access to Freezer box is possible while air is flowing. Air flows only in the product storage area.

Multitemp is not possible

Airflow is not guided

Input and output only on the front and on the back side

Pushing of cartons or boxes can cause damage to cartons or produce dust and dirt.

Carriers (platforms) can only be moved into one direction.Rearranging the carriers is not possible.

Airflow distance is much longer. 20 or 30m for example. The delta T is bigger. Compared to AAT, the products show non-uniform results.

Access not possible during ventilation because air flows through the entire area.

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One of our Top-Innovations:

The “Airflow Shelf“

The ingenious design of our “airflow shelf“ bundles the cold air like a magnifying glass concentrates sunlight. Your product will be frozen faster and more gently. This sa-ves YOUR money and YOUR time. The arrangement of the cooling units allows a complete flow of cold air throughout the shelves and thus a direct contact to each carton or crate.

Freezing TestProduct: pork feetCarton with cover: 600x400x120mmAir temp: ~-35°CFreezing time: from 7°C to -18°C = 10.5 hours

BOXFREEZERSMALL

BEEF PORK POULTRY FISH CONVENIENCE VEGETABLESFRUITS

Freezing for all small packed productsAn economic, automatic cooling or freezing system for small packed products or small production. Working in FIFO mode.

Freezing performance: 1 – 6 tonnes/h

Capacity: up to 20 tonnes

Conveying performance: up to 1200 cartons/h

Dimensions: max. l=18m x w=7m x h=5m

Dwell time: for packed products that need 1 – 5 hours for cooling or freezing

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BoxFreezer – an AAT ProductAAT manufactures complete conveying systems for mid-sized and large piece goods.

AAT – the Specialist for Conveyor Systems, Plant Engineering and Automation

With over 40 years of experience in plant engineering, AAT is the partner to turn to for automation. AAT created the first BoxFreezer line in 1983. Since then, the design has been continuously developed and improved. The cu-stomized automation of material flows and production processes gives AAT clients high added value and com-

petitive advantages. All conveyor systems are designed and fabricated in-house according to client requirements and are installed and commissioned at the client’s site. Besides the specialized conveying systems, we can also supply complete production lines.

AAT is EN1090 and ISO9001 certified.

www.cartonfreezer.com

MultiTemp Cartonfreezer for 12 Tons/hour Freezing or 20 Tons/hour Cooling Carton capacity: 7200

Insulation box complete: L x W x H = 19,94 x 12,5 x 13,5 m

Concept Phase• Specification of requirements• Material flow and process diagram• Suggested solutions • Reference visits

Project Development• Concept development• Tendering• Cost budgeting

Project Realization• Planning submissions• Project coordination and milestone monitoring• Coordination of subcontractors

Construction and Installation• Health and Safety (SCC-certified)• On-going quality assurance• Construction site management

Commissioning• Overall commissioning• Operator training• Ramp-up phase

Customer Service• Remote maintenance• Maintenance contracts• Preventive services

a member of

AAT-FREEZING a division of AAT GmbH

Phone: +43 2622 75 224-0E-mail: aat@aat.at

Scheiterlege 232493 Lichtenwoerth, Austria

www.aat-freezing.at

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