Industrial freezing of fruit and vegetables

NATIONAL REPORT

SWEDEN

OCTOBER, 2013

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The Kingdom of Sweden is a Scandinavian country in Northern Europe,

bordering with Norway to the West, with Finland to the Northeast, the Baltic Sea

to the East and Denmark to the South. Sweden is connected with Denmark via the

bridge of Yoresund – the biggest bridge in Europe. With a territory of 449 940

sq.km and a population of 9 103 788 it is a country with a relatively low density

of the population, but being famous for the high standard of living, modern liberal

society and dedication to the environmental protection, the vegetation and

animals.

Sweden is a traditional exporter of iron, copper and timber, as well as of

industrial products with high added value – industrial machines for the heavy and

light industry, transport means, equipment for the energy and metallurgic sector.

Sweden is among the most developed countries in Europe. A small country, but

the homeland of many world famous trade marks, Sweden is known for names

like Scania, Volvo, Electrolux, Ericsson, Sandvik, Bacho, Frigoscandia

Equipment, Husqvarna, Alfa Laval, TetraPak. IKEA and ORIFLAME are among

the most popular products, being part of the home style and every day life of

millions of Europeans.

Due to the geographical position of Sweden and the climate conditions the

production of fruit and vegetables is limited to the varieties, which can be grown

in cool and wet climate: green peas, green beans, potatoes, carrots, sugar beet,

parsley and other herbs, forest fruit like lingo berries and similar. Sweden is not a

big producer of frozen fruit and vegetables with the exception of few big

producers, one of which is Findus.

Findus is the first company in Europe, which has started in the 60-ies of last

century to introduce in their plants the technology of individual quick frozen fruit

and vegetables with the method of fluidization. The fluidization is a method

which makes hard particles to behave like liquid, floating in the air supported by

streams of cold air. The purpose of that method is achieving of individual quick

freezing of each and every product. Findus is the biggest producer of frozen peas

in Sweden, as well as of frozen green beans, carrots, herbs. Due to the specific

climate conditions in Sweden the season for production and processing of green

peas is long / almost 60 days, compared to Bulgaria – 25 days maximum/ and this

allows the companies in Sweden to plan better the harvesting and processing of

green peas, without facing the danger of extreme temperature fluctuations and

destroying the crops.

Other big producers of frozen vegetables in Sweden are Top I Bralanda,

Procordia, Magnihill.

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In Sweden, as well as in other Scandinavian countries the production of frozen

mixes of vegetables and ready to eat frozen dishes is an important part of the

frozen food industry, as well a way and culture of living.

Due to the increased work load of the population, the increased number of

households with one or two persons and the loss of skills for cooking of home

made food, typical for the previous generations, the consumption of ready to eat

frozen dishes keep growing every year. Related to that the producers of frozen

vegetables in Sweden buy other types of frozen fruit and vegetables, not available

in Sweden, from countries in Central and Eastern Europe and use them as raw

material for the production of added value products.

Modern Technologies for Freezing Fruit and Vegetables

Sweden is the homeland of the new patented technology MicVac as well. In

co-operation with John Bean Technologies AB a technology for processing of

vegetables and production of ready-to-serve foods with added value is invented.

The product /different types of vegetables or a mix of vegetables, meat and

sauce/ will be cooked, filled, sealed and a valve will be placed on it.

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After subsequent heat treatment of the product / in industrial microwave -

linear or pasteurizer / the valve seals the product, so that, there is no danger of

entering air and of affecting the quality of the product. Ready meals based on

vegetables are being chilled or being frozen and offered on the stands for ready-

to-serve foods that take 2/3 of the storage racks of frozen food in Sweden.

The ready meal is reheated at home and with warming the valve that has

protected the product hit her to, opens and signals. This happens at the moment

when the product is heated uniformly, but not too hot. This makes it’s

consumption by children also safe and suitable.

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MicVac is a Swedish trade mark and also FloFreeze, Advantec, LVS. This

makes Sweden European market leader in innovations for industrial processing of

vegetables and fruit.

Unlike Bulgaria, where the industry for freezing fruit and vegetables

consists of many companies with small and medium capacity, scattered

throughout the country, Sweden has a high concentration of production capacity

in several large factories.

There are several reasons for this:

1. Due to the high level of industrialization and earlier emerging trends in

concentration of capital and production facilities, the Swedish industry for

freezing fruit and vegetables is represented by a few large producers–

Findus, Procordia, Top I Bralanda AB.

2. Due to the geographical position of Sweden and the climate conditions,

these factories are located in the Southern part of Sweden.

Refrigeration Systems Used

Employed in the sector are several thousand people working for several

large companies. Only in Findus 6000 people work year-round, in Prokordia in

the factory for frozen vegetables in Eslov - 490 people.

These factories have a high degree of mechanization and automation and

there are almost no so-called seasonal workers.

Due to the nature of the processed raw materials - green peas, carrots,

potatoes - it is almost possible to eliminate human factor in production itself.

Fully automatic lines with high capacity will be bought and a factory is going to

specialize in processing and freezing of several major products.

In Bulgaria it is the opposite: SMEs process between 15 and 30 different

types of materials in a single season, many manual operations have been used,

seasonal workers who are on average between 100 and 200 people with

permanent professional staff in the factories between 10 and 20 people have been

attracted.

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Consumption and Production of Frozen Fruit and Vegetables in Sweden

The market of frozen foods in Sweden and in Bulgaria is very different.

If we look at the market of frozen fruit and vegetables in Bulgaria and

Sweden in monetary value - in millions of Euros, the figures show the following:

Country Frozen fruit Frozen vegetables

Bulgaria 5.5 6.6

Sweden 38.5 179,9

The data are for 2010.

If we look at the data for the market of frozen fruit and vegetables in

volume – in thousands tons / million litres/, the figures show the following:

Country Frozen fruit Frozen vegetables

Bulgaria 1.5 2.5

Sweden 7.1 59.4

The data are for 2010.

The source of both tables is Quick Frozen Foods International Magazine from

month of October 2011.

Another hallmark of the Swedish industry for freezing of fruit and vegetables

is its longer history and traditions compared to the Bulgarian one.

Findus Group started producing frozen foods already in 1941, and in 1945

began its mass supply in the Swedish stores. In 1958 started the export of Findus

frozen products in Europe.

In this regard the Swedish industry for production of machines and equipment

for individually, quick freezing of fruit and vegetables follows market trends and

needs of producers and begins to design, construct and produce first fluidized

machines for individually frozen products.

Project Partner – John Bean Technologies AB / Frigoscandia Equipment/ by

request of Findus presented on the market for the first time in the world in 1962

the FloFreeze machine.

And up to now Findus is one of the partners of Frigoscandia Equipment in

creating new generation of tunnels for freezing fruit and vegetables. By this the

Swedish industry for freezing fruit and vegetables is one of the main engines for

innovations in engineering and technology for quick individually freezing.

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The largest and most famous producer of frozen vegetables in Sweden is the

Findus Group. With a staff of 6000 people and a turnover of over one billion Euro

annually, it is one of Europe's largest producers of frozen vegetables and fish. The

factory of Findus for frozen vegetables in the Swedish city Boef has dozens

fluidized bed freezers with Frigoscandia Equipment brand and one with GEA

brand. Some of the machines are from the 70s of 20th century, other from the 80s

and mid-90s of 20th century and only the machine of GEA was delivered in 2010.

Gradually replacement of the old equipment with new generation fluidized bed

freezers began. Typical of the Swedish industry unlike the Bulgarian one is that

the companies allocate resources and attention on a regular preventive

maintenance of machines and equipment. In Sweden there are machines working

more than 40 years, but due to regular maintenance, servicing and replacement of

spare parts and consumables, these machines work and produce thousands of tons

of production annually. In Bulgaria the means of inspections, maintenance and

repairs always lack or their importance is neglected. This is a common practice in

the sector and it is acted only reactive, not preventive.

Annually Findus Group freezes 30,000 tons of green peas and if this

amount of peas will be distributed as a band around the Earth, this band will tour

the Earth at the equator 20 times. Two other major manufacturer - Magnihil and

Top and Bralanda AB - produce frozen vegetables with Frigosandia Equipment -

FFMA6, FFMA8, FFS2, FFA20. Prokordia freezes potatoes and carrots on

conveyor tunnels, supplied by English Manufacturer - Fergusson, Starfrost,

Lewis.

It is important to emphasize that during the years as of 1962 the Swedish

fruits and vegetables freezing industry influences vastly the machinery industry

for freezing fruits and vegetables and determines next steps in the design,

construction and capacity of machines for freezing in line. Starting with the

easiest product for quickly, individually freezing - peas and getting to gentle

sensitive, delicate products such as berries or half-fried frozen potatoes with

irregular shape, requirements on the freezing technique increase gradually.

The first generation of machines is based only on the principle of

fluidization.

At the beginning of the 60s of 20th century fluidization is real revolution in

the technique of freezing. What does it mean?

• The product layer behaves as a liquid.

• Most products are individually frozen.

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• The products are individually frozen and are thawed at the end user, preserving

their good, fresh appearance and nutritional value.

The attached sketch shows the difference between the particles in normal

condition and in a state of fluidization. Fluidization brings solids into pseudo

liquid condition and the product moves like a river.

Particles in normal condition:

Particles in fluidization:

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Trends and Prognosis for the Sector Development

„Industrial Freezing of Fruit and Vegetables”

However with the development of the food freezing industry and the

increasing consumption of frozen foods, the requirements both users and

producers change. Only fluidization is not sufficient. The industry of frozen foods

in Sweden asks for INNOVATIONS and the equipment producers should meet

this demand. This leads to the next big steps in elaboration of technique and

technology for freezing fruits and vegetables:

1. Vertical movement of the products – so-called pulsation, regulated in %

- has existed since late 80's of 20th century

2. Horizontal movement of the products, regulated in steps – exists на

продуктите, регулируемо на стъпки – has existed since late 90's of

20th century

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3. Modified fluidization – patented in 2009, i.e. of the first decade of 21th

century

These three major steps in the development of the Swedish manufacturers of

equipment for freezing are also major steps in improving the quality of end

product, offered by Swedish producers of individually, quick frozen fruits and

vegetables.

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Innovations in the Freezing Methods

All producers of frozen fruits and vegetables in Sweden and 90% of those in

Western Europe use ammonia refrigeration installations. Ammonia is the only

"green" refrigerant which freely presents in nature and does not endanger the

environment, has no impact on global warming and greenhouse effect. Under the

Kyoto Agreement ammonia is the only refrigerant with 0% effect on these two

threats: global warming and greenhouse effect.

Here is a brief comparison between ammonia and freon as refrigerants and

their characteristics:

FREON AMMONIA

LOWER INTIAL INVESTEMENT

FOR REFRIGERATORY

INSTALLATION

HIGHER INTIAL INVESTMENT

HIGHER OPERATIONAL COSTS

1 kW cold capacity = 1 kW electric

capacity

LOWER

1 kW cold capacity = 0,7 kW electric

capacity

Not subject to special supervision According to current legislation in

some European countries it is

necessary to provide 24-hour service

in ammonia refrigerators, although

modern systems are equipped with

sensors, early warning systems in case

of leakage and to have technicians on

duty overtime

In some European Union countries

like Sweden and Austria it is subject to

environmental taxes because it is not

harmless for the environment. In

Bulgaria since 2020 environmental

taxes will be introduced

The only "green" refrigerant, which is

free in nature and does not affect

global warming and greenhouse

effect. It will never be banned. In

Europe 90% of the refrigerators

operate with ammonia.

Very expensive refrigerant Cheap

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It has no color and smell, can leak

completely, without being seen

Highly smelly, immediately will be

seen by leakage

Not dangerous

In high concentrations is explosive and

dangerous to the health and life of

humans, but long before it comes to

dangerous concentrations, the leak is

noticed

Worse heat exchange, it should be

worked with minus 43 С for the same

capacity of ammonia at – 40 С

temperature of evaporation

Better heat exchange

Due to the lower initial investment in Bulgaria most small and medium-

sized refrigerators for freezing fruits and vegetables work with freon. Over the

past 24 years after 1989 very few new facilities with ammonia compressors are

built. Unfortunately specialization of Bulgarian refrigeration companies for work

with freon refrigeration installations led to the loss of skilled personnel who is

acquainted with modern ammonia systems and is able to work with them.

Unfortunately new staff is also barely trained. This is a gap for the Bulgarian

industry for freezing fruits and vegetables compared to the Swedish one.

One of the purposes of the present comparative analysis and other measures

within the project "Transfer of innovative practices in implementation of EU

requirements and standards for industrial freezing of fruits and vegetables"

is through experts of the project partner to fill in this gap in the training of

Bulgarian refrigeration specialists and company leaders for freezing fruits and

vegetables.

Three factors are of highest importance in the freezing of fruits and

vegetables:

1. Machine that freezes the product – i.e. where the product passes from fresh

to frozen state

2. Refrigeration system that produces cold energy for machine to freeze

3. Cold store for storage of frozen production

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Sweden has a rich history in the three main factors. Sweden is the home of the

largest and up to date leading producer in technological and technical aspect of

fluidized tunnels for individually quick freezing of fruits and vegetables.

Today modern industry uses freezers for individually quick freezing of fruits and

vegetables in line, which are integrated into the production line and a refrigerator

installation is added in, which is subject to the production requirements and needs

to optimize the overall process of freezing. Main criteria are:

а. Product quality

б. Possibility for one machine to cover wide range of products – with

different shape, size, content of water, soft, hard, juicy, sticky, fragile particles

and all these should be frozen individually without being hurt.

в. Hygiene in the machine and of the product itself

г. Minimal production losses

д. Easy and accessible service of the machines

Sweden is the home of many inventions, including dynamite, the zipper,

boiled bed metal in the mining. One of the most important inventions is the

fluidized bed freezing of fruits and vegetables. As it is evident from the above

mentioned, the Swedish producers of frozen vegetables and fruits are old, they

have 45-50 years history and all use the method of fluidization for vegetables and

fruits freezing. As regards refrigeratory installations of the machines for freezing,

the Swedish industry use completely ammonia refrigeratory systems. Ammonia

refrigeratory systems, which are used in Sweden, are pumping or with gravity

feed, or with the patented system LVS - a system with a small volume. In

refrigeration installations with a pump recirculation which historically seen are

the first built in fridges in Sweden and across Europe, the following happens:

The liquid refrigerant is pumped from receiver with low pressure (LPR) to

the evaporator of the refrigerator tunnel through the pump. In the evaporator the

liquid evaporates and the mixture of vapor and liquid refrigerant returns to

receiver. A mixture of gas and liquid returns to the receiver / LPR /. The liquid is

separated, and the vapor continues to the compressor. Compressor operation

controls pressure in the receiver and temperature of evaporation is proportional to

this pressure.

Disadvantages of pumping systems are as follows:

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- Liquid refrigerant - ammonia - returns back to the separator - the longer the

path, the greater the losses.

- Loss is expressed as a pressure drop, which increases the temperature of the

evaporation and reduces the efficiency and capacity of the freezing tunnel.

- Pressure drops are usually volatile and cyclical and cause differences in the

quality of the frozen product, especially in tunnels with a short time for freezing.

- Too small or too large flow lowers the efficiency of the evaporator.

Refrigeration installations, which are with a gravity feed, are considered for

a more modern version and are later historically developed like the pumping

installations, do not change the pressure drop, respectively, energy losses,

because rising vertically causes a drop in pressure similar to that of pumping

system. The liquid pillar increases static pressure and evaporation point - just like

a pump. Addressing problems and being a pioneer in the industry for frozen

foods, particularly fruit and vegetables, Sweden is also the home of another

innovation, aimed at reducing the losses in refrigerator installations, increase of

their energy efficiency and improvement of refrigerator installations performance.

The system Low Volume System (LVS) of Frigoscandia Equipment is based on

the use of a special type LVS - evaporators combined with specially designed

LVS vessels. This system utilizes for the recirculation of the refrigerant the

principles of gravity with an increased flow / or thermo syphon / in combination

with an effective, dynamic separation of liquid from vapor. The liquid refrigerant

is fed directly from the receiver under high pressure to the upper part of the vessel

LVS. Liquid is separated inside the vessel LVS and the vapor goes to the

compressor.

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Dry suction from the machine for freezing to the engine room means:

• Lower pressure drop than conventional pump system *

• Greater flexibility in planning the location of the engine room

• Greater flexibility in the pipes

• Allows operation at low temperatures: -57 ° F/-50 ° C

• Uniform distribution of the refrigerant to all refrigeration tunnels, in case that

the LVS feeds more than one freezer

• Improved control of the air temperature for sensitive products

• Pressure drop equivalent to 1 ° C reduces the capacity of the refrigeration

installation with 5% and reduces the energy efficiency of the system

LVS GUARANTEES MINIMUM PRESSURE DROP EQUAL 0.5 TO 1 C

UNLIKE REFRIGERATION INSTALLATIONS WITH PUMP

RECIRCULATION OR GRAVITY FEED, WHERE PRESSURE DROP IS

EQUAL TO 4 C, AND VERY OFTEN 5 TO 6 C.

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Regarding the third factor - the cold stores for frozen fruits and vegetables -

the tradition in Sweden begins immediately after the end of Second World War.

In fact the founder of Frigoscandia - today John Bean Technologies AB - built

the first cold store in Sweden at the port of the city of Helsingborg in 1948. Then

began the development of Helsingborgs Frishus today named BRING

FRIGOSCANDIA - part of the big chain BRING worldwide.

Even today BRING FRIGOSCANDIA in Helsingborg is the largest cold

store in Sweden. It is part of the Swedish concept of so-called food town - city of

foodstuffs. The idea is to build a central low temperature cold store with

temperature of storage minus 30 C. Around this warehouse land is rented or sold

to producers of frozen foods. They build their factories on the land surrounding

the warehouse, but use one storage surface. Trucks for distribution / also with low

temperature regime - minus 25 ° C / can simultaneously load different frozen

products and deliver them in the supply chain. The observed low temperature

regime ensures that reaching the storage of the commercial chain or the shop

window, the product will not be compromised with quality and there is no risk of

crystallization and re - crystallization, typical for warehouses with volatile and

fluctuating storage temperatures. Particularly harmful is the fluctuation of the

temperature during prolonged storage.

Today BRING Frigoscandia has branches and warehouses in Finland,

Norway, UK, Germany, Italy, Canada and the U.S. and is part of the group of

Norwegian Postal Service. The annual turnover of BRING Frigoscandia is 70

million Euro. There are 19 low temperature warehouses with a total surface of

1.15 million m3 and 332,000 pallet places. BRING Frigoscandia is not only a

place to store frozen foods, but also logistics center, which deals with distribution

of trade marks such as Findus, IKEA, ARLA, SCAN, ATRIA, Danish Crown,

Tulip, ICA, Flodins, Valotrade, Coop and many others.

Other big refrigeratory warehouses in Sweden are Terminal 18 AB in

Helsingborg, Goeteborgs Fryshus in Goeteborg, and the warehouses of the major

producers like Findus, ProCordia I Topp I Bralanda AB as well.

Conclusion

As already mentioned several times, the industry for freezing fruit and

vegetables in Sweden is limited to a few crops suitable for growing in a humid

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and cold climate, but has a high concentration of production facilities and a high

level of technological and technical training in several large manufacturers.

In technological terms, however, Sweden is among the countries with the

largest contribution to the development of the industrial equipment for

individually quick freezing of fruits and vegetables.

Freezing equipment in Sweden because of the long history of the industry

is not always new, but is very strict serviced and maintained.

Manufacturers gradually renew existing equipment – e.g. every year Findus

purchases one new tunnel for fluidized freezing and discharges some of its oldest

equipment, but also 30 years old machines work flawlessly and look good due to

the regular maintenance, service and spare parts replacement. The dominant

brand equipment for quick individually freezing in the Swedish industry for

processing of fruit and vegetables is Frigoscandia Equipment / John Bean

Technologies, but there are single copies of GEA, Lewis and Fergusson.

The refrigeration compressors - fully working with ammonia - are brands

Sabroe, Gram, Grasso and the evaporative condensers are BAC or Evapco.

Safety work standards are strictly followed, early warning systems for

leakage of ammonia are in full working order and that is why ammonia is the

preferred refrigerant in Sweden. The advantages of ammonia have been

highlighted in the present analysis and they provide serious reason for reflection

for the Bulgarian industry for freezing fruit and vegetables.

Sweden is the first country in the world, that began offering and selling

equipment for this industry and until today is a leading country-manufacturer of

facilities for this branch.

"This document has been produced with the financial assistance of the European Social Fund. Union of

Bulgarian fruits and vegetables processors solely responsible for the content of this document and

under no circumstances can be considered as the official position of the European Union or the

Ministry of Labour and Social Policy."