Objective
Design a custom IQF spiral freezer solution that could integrate within the existing salmon processing facility footprint, utilize available vertical space above the blast freezer, deliver a controlled temperature drop from 2°C to -18°C in a single pass, meet a throughput target of 750 kg/hr, and avoid any major structural or layout modifications to an active processing plant.
Havmek's Approach
Vertical Integration
The dual-drum IQF spiral freezer was engineered to occupy vertical space above the existing blast freezer — a space that had previously been unused. By building upward rather than outward, the system expanded freezing capacity by 750 kg/hr without requiring any increase in the facility's floor footprint or structural modifications to walls, ceilings, or load-bearing elements.
Double Spiral Configuration
A dual-drum IQF spiral freezer configuration was selected to handle the increased product load from Atlantic salmon throughput peaks. The dual-drum design distributes product across two synchronized spiral paths, maintaining controlled freezing conditions — airflow, dwell time, and belt tension — across both drums simultaneously, ensuring consistent core temperature from 2°C to -18°C without batch variance.
Custom Layout Engineering
Instead of adapting the facility, the system was designed around existing constraints, ensuring seamless integration without structural changes.
Thermal Performance Optimization
The IQF spiral freezer was configured to achieve a consistent core temperature reduction from 2°C to -18°C in a single pass — meeting EU export food safety requirements for frozen salmon. Optimised airflow distribution across both spiral drums ensures uniform cooling regardless of seasonal product weight variation or intake volume fluctuation.
System Integration
The solution was integrated into the existing processing line with minimal disruption and aligned commissioning timelines.
Performance Snapshot
Key system parameters reflecting capacity, efficiency, and operational fit.
Capacity Delivered
Sustained throughput across the dual-drum line.
Temperature Reduction
From 2°C to –18°C in a single pass.
Installation Footprint
Compact floor area for plant-level integration.
Configuration
Spiral system engineered for continuous flow.
The Outcome
Havmek delivered a custom dual-drum IQF spiral freezer that expanded salmon processing capacity to 750 kg/hr within the client's existing facility footprint — with an installed footprint of 4.16 m². The system utilized previously unused vertical space above the blast freezer, achieved a consistent temperature reduction from 2°C to -18°C in a single pass, and maintained product quality across high-throughput seasonal salmon intake peaks.The solution was commissioned without structural modifications or disruption to the active processing line. It eliminated the need for external freezing capacity or facility expansion for delivering a measurable improvement in throughput, energy efficiency, and operational control within a space-constrained Northern European seafood processing environment. Key performance parameters achieved: 750 kg/hr sustained throughput | 20°C temperature reduction in a single pass | 4.16 m² installation footprint | Dual-drum continuous flow configuration.
Impact Snapshot
Cost Advantage vs Local Market
Relocation Savings
Product Application
