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II. Intelligent Upgrade Solution (New Production Line Launched in April 2026)
Thailand Frozen Food Processing Project
A leading frozen food manufacturer in Thailand, specializing in fried chicken products such as chicken cutlets and chicken popcorn for supermarket and foodservice markets.
Before upgrading, the customer’s production line used a traditional process of “deep frying + rack trolley cooling + manual transfer + freezing storage.” With production expansion, several issues became increasingly severe:
Low efficiency:
Maximum output was only around 200 kg/hour. After frying, products had to be manually spread on rack trolleys for natural cooling, taking 60–90 minutes. This required 2–3 dedicated workers for handling, resulting in high labor costs.
Large space occupation:
Dense placement of rack trolleys required more than 150 m² of cooling area, resulting in extremely low workshop space utilization and congestion in transfer passages, creating safety risks.
Unstable product quality:
Natural cooling was highly affected by ambient temperature and humidity, leading to uneven cooling. Issues such as partial softening, product sticking, and dull color frequently occurred, with a defect rate of approximately 3%. In addition, long exposure increased the risk of bacterial growth, posing food safety concerns.
Disconnected process flow:
After cooling, products had to be manually transported to the freezing room. During transfer, temperature would rise again, reducing freezing efficiency, increasing energy consumption, and causing loss of crisp texture.
To solve the above problems, the customer partnered with Yangguang Conveying to build a fully automated integrated frying–cooling–freezing production line, with the following key configurations:
Frying unit:
800 mm wide, 8 m long continuous frying machine, designed for chicken cutlets and chicken popcorn. It features precise temperature control (±1°C) and stable frying performance.
Cooling core:
150-meter spiral cooling tower (low-in, high-out design), with 800 mm mesh belt, made of 304 stainless steel. It is suitable for rapid pre-cooling of high-temperature fried products (85–95°C).
Freezing unit:
Spiral freezer seamlessly connected with the spiral cooling tower, enabling continuous production from cooling to freezing without manual intervention.
Automation system:
Full variable frequency speed control, automatic temperature regulation, and fully enclosed dust-proof design, compliant with food hygiene standards.
The vertical spiral structure allows a 150-meter cooling length to occupy only about 16 m² of floor space. Compared with traditional rack trolley cooling (150 m²), space usage is reduced by 70%. It perfectly fits the customer’s existing workshop layout without factory expansion.
A high-volume circulating air cooling system is adopted. Cold air flows upward following the natural rise of hot air, enabling rapid cooling of 85–95°C products to below 25°C within 15–20 minutes, improving cooling efficiency by 3 times.
The mesh belt speed is adjustable via frequency control (0.5–5 m/min), allowing precise matching with a 500 kg/h upstream frying capacity and enabling continuous, uninterrupted production—completely eliminating manual cooling bottlenecks.
The enclosed cooling environment prevents contact with external humid air, eliminating product softening and sticking issues. Crispness retention of chicken popcorn is increased to 98%, and surface color remains evenly golden.
The defect rate is reduced from 3% to below 0.3%.
The entire process is fully automated with no manual intervention required during cooling. Only one operator is needed for routine monitoring, compared with 2–3 workers in the traditional system, saving over 100,000 yuan in annual labor costs.
The enclosed design reduces heat loss and lowers cooling energy consumption by 25%. At the same time, it minimizes product loss caused by manual handling, improving overall production efficiency by 60%.
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