IQF process plant for Green Peas and select vegetables, customised, designed and offered -ready to set up.

1. Project code: MAZDA N-021 A
Individual Quick Freezing (IQF) Plant
For PEAS
Options: for Vegetables and fruits
Website: www.mazmach.com

2. NOTES
Technology:
The technology of IQF involves three sub sections:
· Processing Equipment
· Individual Quick Freezing Equipment
· Auxiliary Equipment
The current brief entails handling of up to 3000 kgs of frozen peas per
hour.
Scale Mazda Speciality Machine Systems,
INDIA
SHEET # 2007.N 021.001.
NTS
DSN

3. RAW MATERIAL RECEPTION AND MANUAL SORTING
IQF Processing does not change the physical characteristics of the raw products, therefore
care is taken that inferior raw products are weeded out .
IQF frozen vegetables are produced from fresh, field-selected raw materials
which are sorted, washed, pitted, peeled, cut according to requirements,
blanched and frozen in IQF flow-freezer and finally packed in poly lined
cardboard boxes after being metal detected.
Processing equipments involves Pea Podder, cross collection conveyor for peas,
waste collection conveyor, bucket elevator, Winnower, Fruit/Vegetable washer,
Inspection Conveyor, Pea blancher, After cooler
PNEUMATIC CLEANING
In this part of the process the light foreign materials form the farms like leaves, twigs land
particulate matter are separated out. This is achieved by a cluttered forced air circulation
generated by an electric fan. Air flow regulating devices and variable speed arrangements are
built in to adjust according to the weight of different products. The waste is collected in bag
separately and disposed of periodically.
HY DRAULIC WASHER AND DE-STONER
After removal of light impurities by pneumatic cleaning, the heavy foreign bodies and stones
are removed by means of hydraulic de-stoner. By creating an upward water flow and passing
the product over serrated belts the stones etc. are separated and deposited on a continuous
evacuation elevator which delivers them to a waste bin.
Combined with this unit is the washer with rinsing and flotation chambers to give the product a
through wash in order to remove soil.
INSPECTION
After cleaning and washing, the product undergoes another visual check. the product is
discharged over a non toxic plastic material belt , on both sides of which people can stand and
manually remove any visible bad product. The belt drive is fitted with a variable speed drive to
adjust the speed according to the product.

4. PREPARATION
In this section different functions are performed according to the type of product being
handled. Peeling, dehusking, taking out the seeds, trimming to size, cutting florets, de
clustering, slicing etc. operations are performed. Waste that is generated is collected at
frequent intervals to avoid contamination of the product by building up of bacteria due to
fermentation.
BLANCHING
After cleaning and cutting the raw material it is essential to inactivate the enzymatic reaction
which is initiated on cutting the product. The stopping of this reaction adds shelf life to the
product and thereby preserves it without the addition of any preservatives.
The above is achieved in the Blancher by heating the product in a definite time cycle upto a
certain temperature for a certain time. The Blancher is continuous process equipment and it
has automatic controls for adjusting temperatures, and holding time.
the process of Blanching may not be required for certain products specially in the Fruit
category. In that case the arrangement to by-pass the blancher is provided.

5. COOLING
The products out of the Blancher is at approximately 80 to 85 deg. Celsius. At such
Elevated temperatures it cannot be taken 20 degrees Celsius without causing thermal
shock to the product product. It is important therefore to cool down the product to a temperature
between 1 to 20 degree Celsius
Cooling also stops the deactivation process of the enzymes i.e. it ends the process of
Blanching. An added advantage of cooling down is that the product can be easily
handled for sorting.
The cooling of the products is achieved by means of a counter flow cooler in order to
obtain efficient cooling of the product without causing thermal shocks. The "Water -
product" movement comes about in the opposite direction so that the inlet of the hot
product corresponds to a hot water outlet whilst at the discharge of the cooled product
corresponds the inlet of cold water.
SORTING
After the blanching and cooling process, another manual inspection station is provided,
This is the final check on the product and if any impurity has escaped the earlier checks
it is detected and eliminated here. Overcooked products from the Blancher and
fermented material can also be eliminated.

6. INDIVIDUAL QUICK FREEZING (IQF)
The final deep freezing is done in the IQF tunnel. A stainless steel spreader shaker
uniformly loads and distributes products across the IQF belt. A vibrator beneath the belt
initiates the fluidization on products and assures 100% separation without excessive
agitation. Uniform air distribution through the product method of fluidization can safely
handle delicate and difficult products with minimum losses by elimination of abrasion of
the products.
By this method of freezing each individual part of the fruit or vegetable is frozen
separately so that even after attaining a temperature of -18 to -21 deg. Celsius the
pieces remain separated and do not form a block.
GRADING
Grading, after freezing is required in some for the products to sort them according to
there physical dimensions as the market demand and prices for various sizes are
different.
Two different types of grading equipment I are considered:
To grade Granular products such as peas, beans a vibrating type of a grader is used
which has an oscillating bed composed of various screens with different size as
required. A drum grader is used for grading florets of different vegetables like
Cauliflower or Broccoli.
PACKAGING
Automatic weighting and packing is done for the 400/500 gm., 1 Kg., 2.5 Kg., and 5 Kg.
bags.
For all bags above 5 Kg. manual weighing filling and closing is done.
Packaging is in variety of styles.

8. NOTES
Beans/ peas:
Mango bits
Scale Mazda Speciality Machine Systems,
INDIA
SHEET # 2007.N 021.002.
NTS
DSN

9. ALL FRUITS AND VEGETABLES NOTES
IQF – PROCESSING DELICATE FRUITS
Appearance - color
The quick freezing result in natural color of the frozen product.
Appearence - shape
Product is frozen on an upward air stream and the natural shape of
the product is maintained.
Yield
y Extremely q quick g
freezing of the surface on first bed reduces de-
hydration to a minimum. Low or zero lumps keep yield to a maximim.
Scale Mazda Speciality Machine Systems,
INDIA
SHEET # 2007.N 021.003.
NTS
DSN

10. NOTES
Handling of delicate products
With the unique air control damages on delicate
products are reduced to a minimum.
Scale Mazda Speciality Machine Systems,
INDIA
SHEET # 2007.N 021.004.
NTS
DSN

11. NOTES
Scale Mazda Speciality Machine Systems,
INDIA
SHEET # 2007.N 021.005.
NTS
DSN

12. The Plant
IQF- Individual Quick Freeze System
1000 sq Cold store
Floor Space: mtrs
Electric Power: 250 KW
Water: 5000 ltrs/hour
Scale Mazda Speciality Machine Systems, INDIA
SHEET # 2007.N 021.006.
NTS
DSN

13. An IQF unit in operation
Scale Mazda Speciality Machine Systems, INDIA
SHEET # 2007.N 021.007.
NTS
DSN

19. Y
S UE BREAK EVEN $
POINT
PROFIT
AREA
B
OST AND REVEN
LOSS
FIXED COST LINE
CO
BREAK
EVEN
VOLUME
AREA
0 P X
ANNUAL PRODUCTION (Units) Scale Mazda Systems Speciality Machine Systems, INDIA
SHEET # 2007.N 021. COM.
NTS
DSN

20. Financial Involvements NOTES
Land and Building To be provided as required
Plant Equipment USD 500,000 .- 600,000.-
-depending on inclusions.
Processing of PEAS, fresh vegetables and fruits to produce
IQF products packed for the super markets becomes a
profitable venture beyond a Break Even Volume of 1000 kgs
per hour and economically profitable at around 1500 kgs
per hour. Plant Capacity: 2.5 to 3.0 tonnes per hour
Construction of cold storage is not included in cost
Pay back period under normal conditions: 24 months
Scale Mazda Speciality Machine Systems,
INDIA
SHEET # 2007.N 021.008.
NTS
DSN