Starfrost helps FRoSTA AG boost production capacity


25 October 2023

Freezing technology solutions specialist Starfrost has helped German frozen food manufacturer FRoSTA AG to achieve a 20% increase in production capacity.

One of the largest frozen food manufacturers in Europe, FRoSTA AG specialises in a wide range of 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, FRoSTA has established itself as a household name in frozen food.

In a move to expand its product line, FRoSTA asked Starfrost to introduce a processing line for its rice and vegetable product. The investment also presented the opportunity to revolutionise its production process, with a primary focus on upgrading its freezing technology.

Starfrost designed and installed a cutting-edge Individual Quick Freeze (IQF) solution which was integrated into FRoSTA AG’s existing production line. The tunnel incorporates ground-breaking fluidised technology that enables rapid freezing without compromising on product quality.

The newly installed 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.

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The IQF tunnel installed designed to freeze delicate and sensitive food products. The freezer fully deep freezes small particles with fluidised technology that delivers no clumping or sticking. The freezing process preserves natural appearance, and maintains volume and shape resulting in a premium product with a high yield for the vegetable processor. 

Dr. Christian Paul, Plant Operations Manager at FRoSTA AG, said: "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."