Custom Extreme Cooling Tunnel for Meat Processing Client

Client: Meat Processing Company

Year: 2025

Expertise: PRS’ X-Stream Impingement Freezer, airflow system

Introduction

Our client, a leading meat processing company, required a high-capacity cooling solution to rapidly reduce the temperature of freshly processed meat products while maintaining food safety standards, optimising energy efficiency, and minimising product handling time.

Design Journey: From Concept to Completion

Our in-house mechanical design team began by:

Conducting site surveys to assess available floor space, flow constraints, and environmental factors
Detailed discussions with the client to understand throughput requirements, target temperatures, and compliance standards

From these insights, we developed an early concept emphasising:

Modular configuration for easy scaling
Multi-zone cooling to gradually reduce temperature and avoid thermal shock
Inline automation to connect with upstream and downstream systems

Detailed Design & 3D Modelling

Using advanced CAD tools, our team created a full-scale digital twin. Key features included:

Top-Mounted High-Performance Fans
Segmented Cooling Chambers
Integrated Conveyor System
Hygienic Design Considerations
Automated Product Entry & Exit
Testing & Validation

Results

Improved Throughput

Increased processing line speed by 25% through continuous inline cooling

Flexible Integration

Successfully connected to the client’s existing conveyor and packaging systems

Hygiene & Maintenance

Design minimises bacteria traps
Quick disassembly reduces cleaning downtime by 40%

Fully Customisable Design

Modular zones enable future expansion
Digital twin remains on file for future replication or upgrades

In-House Expertise, Delivered

This entire project was entirely developed by our in-house mechanical design team, ensuring:

Fast design iterations with minimal delays
Real-time collaboration between design and own fabricators
Tailored customisation to match client requirements precisely

Cooling Redefined

By combining cutting-edge design, hygienic engineering, and seamless integration, we delivered a high-capacity cooling tunnel that not only met but exceeded client expectations. Faster throughput, better hygiene, and future-ready scalability, all achieved through our in-house expertise and collaborative approach.