Frozen Fish

A Fresh Breeze For Käpt’n Iglo – Optimisation By The Experts

Frozen Fish in Bremerhaven has been producing fish products of the highest quality since 1896. In the largest deep-frozen fish factory in the world, perfect fish sticks have to be produced consistently and on an ongoing basis. The proper distribution of the batter is important. Ventilation plays a vital role in this.

The task

Matthias van Lengen,
Project Manager,
Frozen Fish International GmbH

"I was not satisfied. Our own in-house solution had significant room for improvement."

The production of fish sticks is the core competence of Frozen Fish. The famous Käpt’n Iglos are created, among others, in the company's production halls in Bremerhaven. Blowing off excess batter represents an important step in the process, because evenly distributed batter not only yields better baking results, but also the homogenous appearance that consumers expect from their favourite fish sticks.

Frozen Fish's own construction used here had its weak points, however: the three nozzles did not distribute the air evenly enough across the full width of the conveyor belt. The air flow had to be reduced manually at each nozzle individually – which was very inefficient with respect to energy use, because a part of the wind energy was simply lost.

Faced with this situation, Project Manager Matthias van Lengen consulted Elektror.

Consulting

Jörg Scharnberg,
North Germany Regional Sales Manager,
Elektror airsystems gmbh

"We knew right away: the Airknife was the solution. I packed a test unit and headed out to the customer."

Elektror reacted swiftly. The test device that Jörg Scharnberg tried on site yielded encouraging results. First, the current situation, i.e. the existing system was documented with pictures. Based on the images and the discussed requirements, Elektror examined the details with the in-house experts.

Steffen Gagg, working in Product Management at Elektror, designed and calculated a recommended solution on the basis of the general conditions: location of the blower, length and type of input feed, resistance, etc.

Finally, Elektror delivered a recommendation and an offer. Frozen Fish ordered the conversion of one of its production lines and installed the delivered components themselves.

The Solution

Steffen Gagg,
Product Management,
Elektror airsystems gmbh

"The idea was found quickly. But we optimised until the very end."

Three components operate together in the new solution: a radial blower that takes over the supply of a complete production line. Added to this is a frequency converter for an energy-saving regulation of the air supply. And finally the Airknife, which replaces the previous three nozzles and ensures an even air flow along the entire 900 mm width. Of course everything is food-safe and made of stainless steel.

Blower S-HP 290/30 - 105/3,0 - SLS

Volumetric flow rate up to 22 m3/h
Pressure up to 7250 Pa
Weight: 26 kg
Power consumption: 3 kW

The required volume flow is precisely regulated using the frequency converter. This means that effectively only the power required for the blower is consumed.

To be able to react flexibly to additional requirements in future as well, a little room for adjustment was included in the planning.

Standard maintenance of the blower bearings is only necessary after 22,000 operating hours. All other parts are maintenance-free.

Airknife AK 900/2-100

Length: 900mm
Connection: both sides
Vent width: adjustable from 1 mm to 10 mm
Max. pressure increase in the AK: 350 mbar

The Airknife 900 mm is made entirely of stainless steel and thus corresponds to the strict hygiene and cleaning regulations involved in food preparation.

The Result

Matthias van Lengen,
Project Manager,
Frozen Fish International GmbH

"Our product quality has improved and it was possible to reduce the energy costs."

The solution is in use 5 days a week in 2 to 3 shifts. There are no problems of any kind in day-to-day use.

Both sides speak of a close collaboration. In the meantime, Frozen Fish has equipped additional production lines with this solution and placed follow-up orders.