COOLING SYSTEMS

Design and Engineering

At PTG Group, we have a long-standing experience in designing innovative, safe, energy-efficient, reliable, and cost-effective cooling systems for poultry slaughterhouses and cold storage facilities. Our team of experienced and specialized engineers possesses the expertise to develop cooling systems that fully meet your cold storage requirements.

Our work demands innovation and attention to detail, as every cooling system is unique and tailored to specific needs. Our in-house design professionals collaborate closely with clients to deliver flexible, economical, efficient, energy-saving, high-quality, and customized solutions.

Our team is committed to advancing the cooling industry through the use of cutting-edge technology, energy-efficient solutions, and innovative designs, providing our clients with exceptional service and reliable systems.

Safety is our top priority. PTG Group’s cooling systems are engineered to ensure the protection of your staff and the safety of your products, combining innovative design with rigorous safety standards for a secure and reliable operation.

Cold Storage Methods

After slaughter, poultry can be cooled using two main methods. One of the most widely used methods is water chilling.

Water-Chilled Poultry

Water chilling systems are the most commonly used and highly efficient method for poultry cooling. When combined with proper agitation, sufficient cooling, and adequate retention time, water chilling delivers the best overall results.

Advantages of Water Chilling:

Lower Initial Investment: Significantly cheaper than air chilling systems.
Reduced Operating Costs: Lower electricity and cooling expenses compared to other methods.
Space Efficiency: Requires up to eight times less space than air cooling.
Shorter Retention Time: Water chilling needs much less holding time than alternative methods.
Higher Yield & Quality: Water chilling minimizes moisture loss and, when paired with proper scalding and collection, maintains higher water content in the meat. The new Rocker chilling technology can even increase boneless, skinless breast yield.

Advantages of Air Chilling Systems

While a few air chilling systems exist in the United States, Canada and most of Europe widely prefer air chilling. Globally, air chilling is the preferred method for poultry cooling in many regions.

There are three main types of air chillers:

Traditional Downflow Dry Air Chillers
Multi-Stage Chillers with Added Humidity
Combined Air/Water Chilling Systems

Although traditional downflow dry air systems are still in use, most new installations now employ multi-stage units with humidity control, which provide significantly better performance. In specific applications, combined air/water chilling systems are increasingly used and deliver different results compared to the first two types.

Compared to traditional dry and multi-stage humid air systems, water chilling has distinct advantages and disadvantages, which should be considered when selecting the optimal cooling method for your facility.

Advantages of Air Chilling

Reduced Labor Complexity: Carcasses can be automatically re-hung, minimizing additional manual labor.
Maintained Product Identity: Birds entering the chiller first exit first (FIFO), allowing easier integration with identification and grading systems before chilling.
No Moisture Fluctuation: Ensures more precise sizing and consistent product quality.
Perceived Higher Quality: In many markets, air-chilled poultry is considered superior in quality.

Disadvantages of Air Chilling

Higher Initial & Operating Costs: Air chilling systems are significantly more expensive than water chilling.
Larger Floor Space Required: May require up to eight times more space than water chilling systems.
Longer Retention Time: May need up to twice the time to reach the same internal temperature as water chilling.
Lower Yield: Traditional dry air systems may experience up to 2.5% dehydration loss, whereas multi-stage humid air systems reduce dehydration loss to 0–0.25%.
Product Appearance Issues: Potential cuticle damage can lead to dry, dark spots after air chilling. Air-chilled products may appear drier with higher red and yellow skin values, which can be perceived negatively.
Microbiological Control Challenges: Air chilling does not inherently provide carcass washing or chemical intervention, making microbial management more difficult.

Combined Water/Air Chilling Systems

Combined water/air chilling systems have been in limited use for several years. Some facilities start with rotary water chillers and then manually hang the birds on an air chilling line. The fastest-growing and most widely used combination systems integrate scalding tanks directly into the air chilling line, eliminating the need for manual re-hanging. Most of these sequential systems are installed in the air chilling rooms located below the air conveyor line.

Advantages of Combined Systems

Classified as Air-Chilled: When operated correctly, the product can still be classified as air-chilled.
Controlled Moisture Pickup: Humidity can be controlled between 0–2%, improving yield.
Maximized Air-Chilling Floor Efficiency: Reduces the required footprint compared to standalone air chilling.
Reduced Retention Time: Faster processing compared to pure air chilling systems.
Supports Antimicrobial Applications: Provides a controlled environment if antimicrobial treatment is applied.
Improved Product Quality: Reduced brown spots and lower red/yellow skin values enhance overall product appearance.

Cold Storage

After slaughter, poultry must be cooled to 0–+4°C within 2.5–3 hours. A portion of the birds undergoes quality control before being stored in cold rooms. Some are packaged, while unpackaged birds are sent to the cutting and processing section for product diversification.

Poultry can be preserved in two ways: fresh or frozen:

Fresh Storage:
- Maintained at 0–+4°C in cold rooms
- Shelf life of approximately 2 weeks
Frozen Storage:
- Carcasses or parts are first blast frozen at –35°C
- Then stored in deep-freeze rooms at –18°C
- Preservation period ranges from 6 to 24 months