TurboRunner Blizzard KOMA Spiral systems RackCommander IBF Blizzard RackCommander TurboRunner PaterNoster SpiroStar KOMA refrigeration techniques
Introduction Modern production plants for highperformance blast freezing systems KOMA refrigeration technique we are committed to our name. Powerful refrigeration technique, the appropriate room climate for every product, state-of-the-art air flow systems according to the KOMA-TLR- Formula, variable sizes, components of leading manufacturers as well as the fact, that every system is customized, planned, projected and installed are basis for supply of best possible quality. Our optimal control and regulation of the fundamental conditions temperature, air and relative air humidity ensures well-balanced cooling and dough conditioning climates. This is the constant aim of our in-house design team. Refrigeration technique according to the high demands of the STEKstandard., controls and top-quality insulation panels are all manufactured in our own production facilities. We also keep to these principles when it comes to service, assembly and installation. KOMA employs its own field service staff who use KOMA approved spares. POWERFUL REFRIGERATION TECHNIQUE ALL COMPONENTS FROM ONE SOURCE Blast freezing / Chilling with ceiling evaporator Page 3 Industrial Blast Freezer (IBF) IVS with ceiling evaporator Industrial Blast Chiller (IBC) Blast freezing / Chilling with stand evaporator Page 4 Blizzard/ KTT Mistral Transportation system (KRC) Page 5 Automated rack transport system (RackCommander) The world nowadays is online and so are we. Let all facility be monitored. Installations can be monitored with faults being reported to the monitoring-department and processed immediately. 24 hours a day, 365 days a year. Further information can be found on the following pages. Our industrial systems provide solutions for continuous blast freezing, even in three-shift operation, just according to your demands. Linear belt freezing system, spiral freezer, shocking system for racks, optionally with automated transportation system, blast freezing of products placed on trays you will find our product range on the following pages. If there are questions and should you require further information, please contact a member of our sales team as detailed on the back of this brochure. Please contact our indoor service team under (+31) (0)475-474700. Of course, the responsible sales representative for your region is also available for an appointment on-site. We will be happy to provide you with the contact. CONTENTS Blast freezing of products on trays Page 8 KOMA PaterNoster (KPN) Spiral system Page 9 KOMA SpiroStar (KSP) KOMA refrigerating systems Page 10 Compressors Condensers Wiring (installation) Controls, TeleGuard, KRASS Page 11 Linear belt freezing system Page 6-7 KOMA TurboRunner (KTR) 2
Blast freezing Massive architecture, maximum cooling capacity, innovative evaporator constructions and intelligent air flow these are the requirements towards a capable and powerful blast freezer. All these characteristics are combined in an impressive manner in the KOMA Industrial Blast Freezer IBF. Large hourly outputs of up to 600 kg/hour are no problem. The ceiling evaporators custom made for KOMA with the tilted fan motors are spacesaving and allow for trouble-free integration to existing production systems. If required, the system can also be installed as a blast freezer. Optional also with Sensor Control System for measurement of the core temperature, as well as optical and acoustic signalling device. Optional also as Chiller for the chilling of oven-hot products such as baked bread or warm meals (Catering, canteen/large kitchens). The inside and outside of the chambers are made of stainless steel, the bottom is formed to a stainless steel tub, on demand with an integrated drain system so even in terms of hygiene there are no compromises. Optional with KOMA RackCommander, the automated rack transport system (see page page 5). IBF INDUSTRIAL BLAST FREEZER IBF (Industrial Blast Freezer) Blast freezing tunnel with licensed custom made KOMA ceiling evaporators 3
Blizzard Blast freezing system BLIZZARD MAXIMUM REFRIGERATION CAPACITY Massive architecture, maximum cooling capacity, innovative evaporator constructions and intelligent air flow these are the characteristics of the powerful blast freezer BLIZZARD. All these characteristics are combined in an impressive manner in the KOMA Blizzard. Large hourly outputs of up to 1.000 kg//hour are within the regular performance range. Due to the stand evaporator with extremely large surfaces and large fin interspaces the capacity also allows for large quantities of oven-hot products. On demand also with Sensor Control System for measurement of the core temperature, as well as optical and acoustic signalling device. Optional also available as a compressor for the chilling of ovenhot products such as baked bread or warm meals (Catering, canteen/large kitchens) in the KOMA Mistral BlastChiller version. The inside and outside of the chamber are made of stainless steel, the bottom is formed to a stainless steel tub, on demand with an integrated drain system so even in terms of hygiene there are no compromises. Optional with KOMA- Rack Commander, the automated rack transport system (see page 5). Mistral-Chilling-System for canteen/large kitchens and catering Blast freezing tunnel with stand evaporators 4
Rack transport system The KOMA RackCommander provides optimisation and automation. It allows for computer-controlled automation of the complete production process. Production cycles that include fermentation, bracing and blast freezing can be automated via the rack transport system. Defined processing steps eliminate fluctuations and help to improve the quality of your final product. Ground-clear assembly (hygiene!), rack transport via jackscrew-tensionsystem, state-of-the-art sensor technology and computer controls guarantee a trouble-free production process, so there is no need for moving the racks by hand anymore. The integration of automatic sliding doors is also trouble-free and even the backhaul of the racks can be included to the automatic cycle. Automated rack transportation system RackCommander, two-rowed with automatic sliding doors KOMA RACK COMMANDER Production line consisting of: Conditioning/Fermentation Bracing Blast Freezing Packing with integrated rack transport system KOMA Post Curing Room with connection to the automated rack transport system RackCommander 5
KOMA TurboRunner The TurboRunner is a linear belt freezing system for continuous production processes. The TurboRunner is designed for large hourly outputs of 2.000 kg/hour or more. The system may be integrated into automated production lines via modern transportation technique. Despite the size and the massive construction of the KOMA TurboRunner it adapts very flexibly to changes in capacity or production structure. The modular design of 3 m sections allows for extension of the system by one or more sections. Thus, even rearrangements in production may be performed without complete disassembly. The premounted, modular design of the TurboRunner ensures a relatively costeffective and quick installation on site. So no particular recesses in the factory bottom are necessary. The linearly led belt is ideal for very sensitive products, that could be damaged in form and structure by the bend-lead of the belt in a conventional spiral system. The construction of the third generation TurboRunner is consequently based on the hygienic TURBO RUNNER BELT FREEZING TurboRunner 3rd generation TurboRunner slim version for ice cream 6
KOMA TurboRunner SYSTEM KOMA-production for TurboRunner Evaporator with hinged fan motors Hygiene station concept. The belt is led freely over the ground, so the belt as well as the bottom are freely accessible for cleaning purposes. The bottom of the cabinet is tilted downwards at the edges, so that condensate and cleaning water as well as seepage can flow out to sides of the door. Evaporator tubs, fan motors as well as the condensate tub can be tilted downwards with just a few snatches. An automated belt cleaning system ensure easy cleaning during the defrosting phase. Optional also available with a special cleaning- and sterilizing system. Compared to systems using cryogenic gases, the TurboRunner ensures very low average production costs by the use of conventional cold (incl. service-, energy- and depreciation costs), as shown in the exemplary calculation. Freely led stainless steel transportation belt 7
KPN KOMA PaterNoster arranged with their blow-out-area to cover the vertical transportation area of the trays. Just like all of our insulation rooms, our cabinets for our spiral freezers are manufactured in our own panel plant. The insulation is made of high pressure, CFC-free polyurethane-hardfoam of sandwich construction and incorporating a conical locking mechanism to ensure high insulation values. modern, half-hermetic reciprocating compressor, amply designed evaporators and condenser surfaces only. The refrigeration cycle meets the high demands of the STEK Norm in order to ensure a high degree of safety and environmental compatibility. 8 The KOMA PaterNoster state-of-theart transportation technique and powerful refrigeration technique allow for high hourly outputs of products placed on trays and run through the production process on theses trays. The modular structure of the system allows for the insertion of four trays at a time. After entrance, the transport ascends vertically upwards. At the top follows a horizontal transport to the second section, and afterwards, the trays are transported vertically downwards and forwarded to the exit. The powerful evaporators are optimally
KSP KOMA SpiroStar The KOMA spiral freezer state-ofthe-art transport technique and powerful refrigeration technique allow for large hourly outputs at continuous, automated production. Optionally, the belt is delivered in stainless steel or plastic version and it is equipped with an automated belt cleaning system, in order to meet the hygienic requirements (HACCP). Just like all of our insulation rooms, our cabinets for our spiral freezers are manufactured in our own panel plant. The insulation is made of high pressure, CFC-free polyurethane-hardfoam of sandwich construction and incorporating a conical locking mechanism to ensure high insulation values. KOMA uses modern, half-hermetic reciprocating compressor, amply designed evaporators and condenser surfaces only. The refrigeration cycle meets the high demands of the STEK Norm in order to ensure a high degree of safety and environmental compatibility. KOMA spiral freezers are designed for blast freezing, chilling, freezing, cooling and conditioning/fermentation and can be integrated into any automated production process. Please feel free to ask us for references. Delivery belt for spiral freezer 9
Compressors, condensers, assembly (wiring) conditions (length of lead, size of the condenser etc.). Condensers KOMA attaches great importance to an ample dimensioning of the condenser surface, so that the performance of your KOMA system is ensured even at summery temperatures! Only when compressor, evaporator surface (within the compressor) and the condenser surface are optimally harmonized, you will experience the performance required. That is why you should not only compare the HP-indications of the compressors (that actually indicate the drive power of the electric motor only), but the effective refrigeration capacity measured in KW at comparable condensation- and evaporation temperatures. NRE noise reduction enclosure Compressors The refrigeration cycles installed by KOMA are based on the strict STEK Norm. Amongst other this implies the following: All KOMA devices are specially mounted on carriages and are completely pre-wired. During assembly only the fixation of the control cables on the terminal block of the machine switch cabinet is to be carried out. Additionally, all devices are equipped with high-/ low pressure-, as well as oil pressure-sensors. The versions of the KOMA compressors with separate condenser are equipped with a compressor fan in order to ensure a heat dissipation for the device. KOMA uses capillary high pressure hoses, no copper capillary as these are vulnerable leakage. Further, oiland liquid strainer are installed. Crucial components for the safety, longevity and ease of maintenance of your KOMA compressors! The liquid tank for large refrigeration devices is always chosen large enough according to STEK-Norm, so that it can always hold the complete load of refrigerant of the cooling cycle. So we do not use a compressor offthe-shelf but adjust it to the specific KOMA Assembly standard KOMA does not use material offthe-shelf. High-grade copper tubes are laid and we are put a high effort on minimizing the amount of solder joints! An outdoor set up is also easily possible for compressors with stainless steel weather protection enclosures. KOMA manufactures these units optionally. 10
TeleGuard / KRASS TeleGuard Security online for your KOMA units. All of the KOMA units can be remotely monitored via the TeleGuard system. All of the controls in use with KOMA units are compatible with TeleGuard so that we can guarantee you maximum security. Failures are immediately reported to our monitoring department at our service headquarters. The staff is able to establish a direct connection to your refrigeration unit in order to take a real time look at all relevant data or even for editing purposes. Thus, temperatures and pressures (high pressure, low pressure, oil pressure) may be checked, icing up of the evaporator can be detected and, even an open door is recognized and KOMA immediately informs the customer. Further, our staff is always glad to assist you in adjusting your unit s programming. KRASS - Software Our software provides various possibilities for the recording and evaluation of the temperature curves. Whether it chart or table illustration, temperature recording that meets the legal requirements (HACCP obligation of documentation and storage). It also allows for control of the system via a central PC, which may be located at your Home Office or any other location. The software is easy to install on any standard PC, but we will definitely assist you with that also. Just contact us. MonoCell AT Units: Blast freezers, KTT, IBF Guaranteed quality monitoring and logical programming. Quick cooling time and duration are freely programmable. Air amounts and speeds may be adjusted in 1%-steps and thus an ideal adaptation to your quality demands is ensured. Direct intervention at failures. Permanent monitoring of all entered data. Automatic backup of all programme data due to supplementary battery supply in case of failures, power breakdowns etc. TeleGuard remote monitoring Note: Subject to technical modifications and alterations. Illustrations and charts serve for visualization/illustration purposes and may change in practice. Status 7/2009. 11
KOMA Koeltechnische Industrie B.V. Energieweg 2 NL-6045 JE Roermond Tel.: +31 (0) 475 47 47 00 Fax: +31 (0) 475 32 54 49 E-Mail: nl-info@koma.com www.koma.com KOMA subsidiaries in: Belgium, Germany, France, Great Britain, Italy, Spain, U.A.E. (Dubai) and Japan