The bakery also wanted to upgrade from a manual blast freezing process by investing in a fully automated freezing system.
Starfrost designed, built, installed and commissioned two bespoke Helix spiral freezing systems for Gilsons, which enabled it to fully automate the lines, boost capacity and improve product quality.
The first spiral unit was designed for freezing baked bread rolls, with a capacity of 1,400kg/h. It has a 81.3cm wide stainless steel conveyor belt around a single rotating drum, with 26 spiralling tiers.
The second system is a flexible multi-temperature double-drum spiral, featuring a forced air ambient cooler and a dual-purpose freezer/chiller for baked loaves. It features two 12.5-tier drums with a 96.5cm wide stainless steel belt and has total processing capacity of 1,950kg/h.
In the double-drum system, the product is cooled using forced ambient air as it is conveyed around the first drum. The cooled loaves then enter a separate enclosure for final freezing on the second drum.
The system is designed to give Gilsons maximum flexibility, by using the second drum for product chilling or freezing.