Required IQF capacity (kg/h) = daily output (kg) ÷ effective production hours, plus a margin for peak season and product mix. For example, 20 tonnes over 20 production hours is 1,000 kg/h; with a 15% margin, plan for about 1,150 kg/h. The real capacity also depends on product size, infeed temperature and refrigeration, so a GLORY engineer confirms the final figure.
1. Calculate your capacity
2. How the calculation works
The calculator divides your daily output by the hours the freezer actually produces. Effective hours exclude cleaning, defrosting and shift changes: a plant running two 10-hour shifts usually has about 18 to 20 effective hours.
- Required capacity = daily output (kg) ÷ effective hours
- Planned capacity = required capacity × (1 + margin)
- Freezer type depends on the product: belt marks, product shape, packed or loose
- Line configuration depends on the glazing rate your buyers require
Read more
It then adds the margin you choose. A margin of 10 to 20% covers peak harvests, smaller sizes that freeze more slowly and short stops. GLORY lines typically run 15 to 20% above their committed capacity when refrigeration and feeding are sufficient, but planning with a margin is still good practice.
3. What changes the real capacity
| Factor | Effect |
|---|---|
| Product size and thickness | Larger pieces and thicker fillets need longer freezing time, so capacity drops |
| Infeed temperature | Warmer product carries more heat into the freezer |
| Target core temperature | A colder target means a longer freezing time |
| Packed or loose | Trays, bags and boxes slow heat transfer compared with loose product |
| Refrigeration | Capacity needs enough refrigeration at an evaporating temperature of about –45 °C |
| Belt loading | An evenly covered belt uses the full freezer; gaps waste capacity |
Capacity is always quoted for a reference product, for example peeled shrimp of 31 to 40 pieces per pound, entering at +6 to +10 °C and leaving at –18 °C. Your real figure moves with these factors:
4. Worked examples
| Plant | Daily output | Effective hours | Required | With 15% margin | Typical choice |
|---|---|---|---|---|---|
| Shrimp exporter | 20 t | 20 h | 1,000 kg/h | 1,150 kg/h | Mesh belt IQF line with glazing |
| Fish fillet plant | 8 t | 16 h | 500 kg/h | 575 kg/h | Steel belt IQF freezer |
| Vegetable processor | 60 t | 20 h | 3,000 kg/h | 3,450 kg/h | Fluidized bed IQF freezer |
| Small value-added line | 3 t | 12 h | 250 kg/h | 288 kg/h | Compact IQF freezer |
5. Frequently asked questions
Why is my real capacity different from the nameplate?
Nameplate capacity refers to a reference product and temperatures. Larger sizes, warmer infeed or packed products lower it; smaller loose products can raise it.
What margin should I use?
10 to 20% is common. Use more if your sizes vary a lot or peak harvests are short and intense.
Is it better to buy one large freezer or two smaller ones?
Two lines give redundancy and flexibility for different products; one large line costs less per kg and needs less space. GLORY engineers compare both for your plant.
What else do I need besides the freezer?
Usually an infeed conveyor, and for most seafood a glazer, hardening conveyor, re-freezer and outlet conveyor, all synchronized by Master AutoCell®.
Ready for an exact calculation?
The freezer questionnaire asks the same questions GLORY engineers use to design a line. It takes about 5 to 10 minutes.
