What makes up the operating cost of an IQF freezing line?

You pay the purchase price of an IQF freezer once; you pay its operating cost every shift, for years. This article lists the main operating costs of an IQF line and what to look at when evaluating equipment.

Short answer

Operating cost of an IQF line has six parts: electricity, downtime for defrosting, start-up time, labour, water and ice for glazing, and product loss. How much of each you can cut depends on the machine design and how well the whole line is synchronized.

1. Electricity

Most power goes to refrigeration and fans. Aerodynamically designed airflow and IE3 efficiency motors keep energy per kilogram of product low. When comparing, ask for the refrigeration capacity needed at about –45 °C evaporating temperature for exactly the capacity you need.

2. Defrosting

Every defrost stops production. Thermal Jet® IQF freezers run more than 20 hours between defrosts, up to 23 hours with the latest generation, with air blowing that clears frost from the belt during production. Fewer defrosts mean more production hours and steadier temperature.

3. Start-up

The chamber pulls down from +28 °C to –36 °C in about 30 minutes from a cold start and about 15 minutes between shifts, so the crew on shift does not wait long.

4. Labour

• Infeed: GLORY's patented individual freezing technology separates shrimp by itself, so pieces need no careful spacing. With an inclined infeed conveyor, 3 to 4 people typically feed about 1,000 kg/h of individual shrimp.
• Adjustment: the Master AutoCell® control panel sets every belt speed by product, size and load, so no one has to adjust each machine.
• Packing: shrimp come out separate, so packers do not break up clusters.

5. Water and ice for glazing

The GLORY dipping & spraying glazer has a built-in chiller and needs no flake ice. Chilled water consumption is about 0.4–1.0 m³/h, and SUS 316 spray nozzles can save up to 42% of water compared with standard nozzles.

6. Product loss and yield

High-velocity impingement freezes the surface very quickly, so the product loses little moisture. At belt transfers, GLORY's own flighted incline conveyor releases every piece cleanly, so product does not cling to the belt and drop off on the return side.

Self-assessment checklist

• How many hours does the freezer run between defrosts?
• How many minutes of start-up does each shift lose?
• How many people are needed at the infeed per 1,000 kg/h?
• Does glazing need flake ice, and how much water per hour?
• Are glazing rate and belt speeds adjusted automatically or by hand?

Frequently asked questions

Is cheaper equipment always more economical?
Not necessarily. Electricity, defrosting, labour and product loss over several years usually add up to more than the difference in purchase price. Compare the operating cost per shift as well.

Can costs be reduced on an existing line?
Yes. GLORY can add an MC compact freezer, a glazer and re-freezer, or upgrade to Master AutoCell® to raise capacity and automation.

How do I estimate costs for my plant?
Fill in the freezer questionnaire or read the IQF freezer guide.