The Customer

One of the largest frozen food manufacturers in Europe, FRoSTA AG specialises in a wide range of frozen products including fish, vegetables, fruits, herbs, and ready meals. With production facilities in Germany and Poland, along with sales and distribution subsidiaries in multiple European countries such as the Czech Republic, Germany, Hungary, Italy, Poland, and Romania, FRoSTA AG has established itself as a household name in frozen food.

The requirement

FRoSTA AG recently invested a substantial sum of 10,000,000€ to introduce a state-of-the-art processing line for its rice and vegetable product. This investment also presented the opportunity to revolutionise its production process, with a primary focus on upgrading its freezing technology.

The solution

Starfrost designed, manufactured, and seamlessly integrated a Turbo IQF tunnel into FRoSTA AG’s existing production line. This IQF tunnel incorporates ground-breaking fluidised technology that enables rapid freezing without compromising on product quality. The energy-efficient Turbo IQF tunnel has the capacity to freeze up to 10 tonnes per hour, together with marking a substantial improvement in overall efficiency and operating costs compared to the previous freezer used by FRoSTA AG.

Dr. Christian Paul, the Plant Operations Manager at FRoSTA AG

“We’re pleased with our bespoke solution supplied by Starfrost. The IQF freezer has not only delivered a 20% increase in production capacity, but we have also achieved a 4% improvement in product yield and reduced energy costs by 12%, with further expected improvements due to its recent installation. We have a 10,000kg/hr freezing volume combined with the lowest energy consumption compared to other freezer manufacturers. We also have the added feature of a sequential defrost on the freezer, which allows for longer operating phases without the need for frequent defrosting.”