Karro Foods Ltd

Karro Foods Ltd, nationwide producer of pork & bacon products.

The Challenge

To blast freeze up to 7600 bacon backs a day (7KG Each) from a core temperature of +4°C to -3°C within 6 hours, prior to them being moved to an equalising freezer of -8°C.

The Solution

To construct a new steel frame two-story extension, including civils, to the rear of the existing cold store to house the ground floor blast freeze chambers. Plant areas and additional storage were created on the 1st floor. Alteration to the existing structure and to up-grade the existing thermal insulation to the front and rear elevations of the existing cold store unit. Also to facilitate the installation of a new sub-station and HV supply required for the new fridge plant and ancillaries. To construct four blast freeze chambers, within the new extension, using bespoke and unique air turn chambers to maximise air flow across the product, designed by our in-house design team. New energy efficient CO2 cooling plant was used for the freezing process coupled with the bespoke turning chambers.

The Outcome

The facility we created far exceeded our client’s expectations, the efficiency of the plant had the added benefit in actually freezing the bacon in almost half the time, enabling our client to up production without having to install additional equipment. The scheme was a success all-round.