In the global seafood processing industry, shrimp has become a darling of the consumer market due to its high protein and low fat characteristics. However, traditional shrimp processing commonly suffers from low production efficiency, unstable quality, and high labor costs. For example, if manual operation is used in the cooling stage after cooking, it is easy to cause temperature control errors, which can lead to bacterial growth; If the temperature is not precisely controlled during the freezing process, the fiber of shrimp meat may be damaged, affecting its taste and shelf life.
The CBFI shrimp cooking and quick freezing production line is an intelligent solution designed to address the pain points in these industries. This system achieves efficient control of the entire chain from raw material processing to finished product freezing through modular equipment combination and automated process design. It has shown significant advantages in refreezing technology, hygiene standards, and energy consumption optimization, becoming an efficient alternative solution for modern shrimp processing plants.
Core process flow of production line
1. Steaming and cooking process: precise temperature control and flavor preservation
The steaming and cooking of shrimp is a crucial step in determining the taste of the finished product. The CBFI production line adopts steam penetration cooking technology, which stabilizes the steam temperature within the range of 95 ℃± 2 ℃ through an intelligent temperature control system, ensuring that the shrimp meat protein is fully solidified while avoiding fiber breakage caused by excessive heating. The equipment is equipped with multi-stage adjustment function, which can adjust the cooking time according to the size of shrimp (such as South American white shrimp and bamboo shrimp), ensuring the consistency of flavor among different varieties.
2. Multi stage cooling: gradual cooling from high temperature to low temperature
If the steamed shrimp enters a low-temperature environment directly, ice crystal damage may occur due to excessive temperature difference. The CBFI system achieves mild cooling through a three-stage cooling process: this process improves efficiency by 30% compared to traditional single-stage cooling, while reducing the rate of shrimp shell detachment.
3. Quick freezing and refreezing: Quality stability under double-layer guarantee
(1) First quick freezing: Single spiral freezer quickly locks freshness
Using a single spiral tunnel freezer, the shrimp heart temperature is rapidly frozen at -35 ℃ with strong winds, and the temperature is reduced to below -18 ℃ within 5 minutes. The advantages of this device are:
• Rapid cooling: reduces the damage of ice crystal formation to cell walls, locks in freshness and nutrients;
• High space utilization: The spiral structure ensures that shrimp are evenly winded during transportation, avoiding accumulation;
• Energy consumption optimization: 15% -20% more energy-efficient than traditional flat freezing machines.
(2) Re freezing process: Tunnel type re freezing machine stabilizes quality
Re freezing is an easily overlooked step in shrimp processing. The CBFI system uses a tunnel type refreezer for secondary freezing:
• Continuously freeze in an environment of -28 ℃ for 3-4 hours to further stabilize the internal structure of the product and extend its shelf life;
• The tunnel is equipped with an airflow circulation system to prevent "cold spots" or local supercooling issues;
• The independent sealing design avoids cross contamination and complies with FDA and EU food safety standards.
4. Ice coating technology: extending shelf life and preservation performance
To reduce water loss (i.e. "dry consumption") during the freezing process, the production line integrates an ice jacket wrapping device. Uniformly cover the surface of shrimp with -1 ℃ saltwater through atomization spray, forming a 0.5-1mm thick ice film.
System advantages: automation, hygiene, and cost-effectiveness
1. Full process automation: reducing manual dependence
The production line adopts PLC programmable controllers and Internet of Things (IoT) sensors to achieve full automation control from conveyor belt speed to temperature. Workers only need to input parameters on the center console, and the equipment can operate adaptively, reducing manual intervention errors.
2. Health and safety design: Compliant with rigorous certification
• All stainless steel material: The contact surface is made of 304 stainless steel, which is corrosion-resistant and easy to clean;
• Sealing structure: Food grade silicone sealing rings are installed at the interfaces of each device to prevent dust and bacteria from infiltrating;
• CIP cleaning function: supports in-situ cleaning and meets HACCP system requirements.
3. Customization and Scalability
The CBFI production line supports modular assembly and can adjust equipment combinations according to customer needs.
