Energy solution for ice cream brand with more than 44% market share in Vietnam: Ice cream is an extremely sensitive product to temperature fluctuations. As long as the temperature rises to -18°C for a short time, the ice cream structure will partially melt and re-freeze into spongy ice crystals, losing the smooth, fatty taste typical of Merino and Celano. The KIDO Foods ice cream warehouse project requires an extremely precise deep cooling solution and 100% safe backup.
4. Anti-Thermal Shock Technology for Merino & Celano Ice Cream Lines
High-end ice cream products are extremely sensitive to temperature: as long as the temperature fluctuates to -15°C for a few minutes, the ice crystals in the ice cream will melt and recrystallize into large crushed ice particles, completely destroying the smoothness of the ice cream. Tan Long has deployed deep cooling technology to absolutely control:
- Stable freezing chamber -28°C to -30°C continuously: Using a specialized 2-stage screw compressor assembly combined with a multi-directional circulating fan evaporator, the temperature fluctuation amplitude of the entire chamber does not exceed ± 0.4°C.
- The import-export buffer room area keeps the temperature -5°C with dehumidification: Equipped with a Rotor adsorption dehumidifier that dehumidifies the dew point at -20°C, completely eliminating the phenomenon of fog and snow on the packaging of ice cream boxes when exporting goods to refrigerated trucks.
5. Energy Efficiency & Operational Performance Assessment at KIDO
| Evaluation Criteria | Customer's Old Refrigeration System | New System Tan Long Handover | Recorded Economic Benefits |
|---|---|---|---|
| Factory cream core temperature | -22°C (easily denatured during transportation) | -28°C (solid deep frozen) | The rate of products meeting grade A quality standards increased to 99.8% |
| Monthly electricity bill | Average 285 million VND/month | Average 218 million VND/month | Save 67 million VND/month (23.5% reduction in electricity) |
| Condenser defrost time | Defrost the resistance for 60 minutes, the storage temperature soars to -18°C | Defrost Hot Gas hot gas for 18 minutes, the warehouse temperature only fluctuates slightly by 1.2°C | Does not affect the quality of cream preservation |
| Annual maintenance and repair costs | Regularly change oil and repair old compressors | Almost zero in 2 years of full warranty | Save more than 120 million VND in maintenance costs each year |
1. Rigorous Technical Requirements from KIDO Group
- Stable storage temperature -32°C to -35°C: Ensures ice cream and ice cream boxes retain their shape and absolute smoothness during 24 months of storage.
- Glycol Chiller Station -8°C quickly cools the ice cream mixing line: Lowers the temperature of the milk, butter, and flavor mixture from +65°C (after pasteurization) to +4°C in just 30 seconds to transfer to the ice cream ripening machine.
- Uninterrupted N+1 redundancy architecture: All compressor and circulating pump stations must have backup machines that automatically start when there is a problem, to prevent disruption of the ice cream production line of millions of products per day.
2. Turnkey Engineering Solutions & System Architecture Deployed by Tan Long
- Bitzer Ecoline 2-stage compressor system (Germany): Using a specialized 2-stage screw compressor assembly for deep sound, COP efficiency is 25% higher than a 1-stage compressor, integrated with a liquid gas supercooler (Subcooler).
- 150mm thick PU panel warehouse covered with 304 stainless steel on both sides: All walls and ceilings use 150mm thick PU panel density 42 kg/m³ cast with double yin and yang Camlock lock, luxurious Hairline scratched 304 stainless steel surface, no grease, easy to clean according to ISO standards 22000.
- Automatic sliding cold storage doors with radar sensor: 08 sets T-Light airtight sliding doors large size equipped with an inverter electric motor that automatically opens when a forklift loading an ice cream pallet approaches and closes automatically after 8 seconds, combined with a cold air curtain to prevent outside temperatures from entering.
- Stainless steel 304 evaporative condenser saves water: Cluster 02 Stainless steel 304 evaporative condenser cools with a capacity of 800 kW, operating smoothly in the Northwest Cu Chi Industrial Park.
3. Real-World Operational Results & Economic ROI Delivered
After more than 4 years of stable operation, KIDO Foods technical management board evaluates:
- The ice cream warehouse temperature remains stable and accurate at -33.5°C ± 0.5°C all year round, even during the peak hot months of the South.
- The percentage of ice cream products that are soft or have sensory impairment is 0%.
- The automatic inverter control system helps the factory save more than 50,000 kWh of electricity/month (equivalent to more than 800 million VND in electricity bills per year).
Technical FAQs on the Project KIDO Foods
1. Why does ice cream storage necessitate -35°C deep freeze rather than standard -18°C?
Ice cream containing large amounts of sucrose, milk and saturated fat has a very low eutectic freezing point. At -18°C, a portion of the sugar solution remains in a microfluid state, causing the ice cream structure to collapse and form gritty ice crystals over time. At -35°C, the entire ice cream structure is completely frozen, retaining its soft, creamy texture when enjoyed.
