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Ice Cream and Frozen Dairy Refrigeration
Ice Cream and Frozen Dairy Refrigeration

Meat Freezer Conversion UAE

Conversion of an existing meat chiller into a dedicated -20°C frozen meat storage facility, with upgraded low-temperature refrigeration, controls and electrical infrastructure.

-
°C
Design Temperature
×
HP
Refrigeration Systems
×
×
m
Room Size
R404A
Refrigerant

Why This Meat Freezer Conversion Required More Than a Temperature Change

The existing meat storage room was operating as a chiller but required conversion to a dedicated -20°C freezer. The conversion required refrigeration, evaporator, electrical and control-system upgrades to support reliable frozen meat storage.

06
Critical Challenges
01

Chiller-to-Freezer Conversion

The existing meat storage room required conversion to a -20°C frozen storage environment, with upgraded insulation, refrigeration capacity, and temperature control to support reliable long-term frozen product storage. The existing room structure was retained to minimize major construction changes. Refrigeration systems were upgraded to maintain consistent low temperatures under varying loads. Improved airflow ensures uniform cooling throughout the storage area. The converted space provides stable conditions for preserving meat quality and extending storage life.

Existing use: Meat chiller
Required: Dedicated -20°C freezer
Frozen dairy refrigeration
02

Low-Temperature Equipment Upgrade

Existing chiller evaporators required replacement with equipment suitable for low-temperature freezer operation. The upgraded system is designed to support dedicated frozen meat storage conditions. The new equipment provides the required cooling performance for lower operating temperatures. This upgrade improves refrigeration reliability across the storage space. It also ensures more consistent temperature control during freezer operation.

Replaced: Chiller evaporators
Installed: 2 × cubic-type freezer evaporators
Temperature fluctuations
03

Large Storage Volume

The existing room presented a large storage volume requiring coordinated refrigeration capacity across the full space. The size of the room required careful distribution of cooling throughout the storage area. Refrigeration capacity was planned to maintain consistent conditions across the entire volume. The system configuration was designed to support reliable frozen meat storage. Proper airflow and temperature distribution were considered for efficient operation. The overall design supports stable performance across the large storage environment.

Room size: 20.63 × 10.75 × 7 m
High energy refrigeration demand
04

Refrigeration Upgrade

Refrigeration equipment required comprehensive upgrading for dedicated freezer operation. The upgraded system was designed to meet the cooling demands of low-temperature frozen storage. New condensing units provide the required refrigeration capacity for the facility. The configuration supports reliable and consistent freezer operation across the storage space. Equipment selection was planned to maintain stable temperatures under varying operating conditions.

Installed: 2 × 34 HP air-cooled condensing units
Compressor type: Semi-hermetic reciprocating
Ice cream product formulation
05

Electrical & Controls

Electrical wiring and control systems required comprehensive upgrading to support the new refrigeration configuration. The electrical infrastructure was upgraded to accommodate the revised refrigeration equipment. Digital temperature controls were integrated for more accurate system monitoring. Automatic defrost controls were incorporated to support efficient freezer operation. The upgraded controls help maintain consistent operating conditions throughout the facility.

Scope: Complete electrical wiring upgrade
Scope: Digital temperature and automatic defrost controls
Frozen dairy hygiene control
06

Consistent Frozen Storage

The conversion required reliable and consistent frozen meat storage conditions across the facility. The upgraded configuration was designed to maintain stable temperatures throughout the storage room. Two independent refrigeration systems provide coordinated cooling for the large storage volume. This setup supports dependable operation and improved refrigeration continuity. The system was configured to meet the ongoing demands of frozen meat storage.

Configuration: Two independent refrigeration systems
Frozen dairy distribution

The existing meat storage room required conversion to a -20°C frozen storage environment, with upgraded insulation, refrigeration capacity, and temperature control to support reliable long-term frozen product storage. The existing room structure was retained to minimize major construction changes. Refrigeration systems were upgraded to maintain consistent low temperatures under varying loads. Improved airflow ensures uniform cooling throughout the storage area. The converted space provides stable conditions for preserving meat quality and extending storage life.

Existing use: Meat chiller
Required: Dedicated -20°C freezer
Frozen meat storage

Existing chiller evaporators required replacement with equipment suitable for low-temperature freezer operation. The upgraded system is designed to support dedicated frozen meat storage conditions. The new equipment provides the required cooling performance for lower operating temperatures. This upgrade improves refrigeration reliability across the storage space. It also ensures more consistent temperature control during freezer operation.

Replaced: Chiller evaporators
Installed: 2 × cubic-type freezer evaporators
Low-temperature freezer equipment

The existing room presented a large storage volume requiring coordinated refrigeration capacity across the full space. The size of the room required careful distribution of cooling throughout the storage area. Refrigeration capacity was planned to maintain consistent conditions across the entire volume. The system configuration was designed to support reliable frozen meat storage. Proper airflow and temperature distribution were considered for efficient operation. The overall design supports stable performance across the large storage environment.

Room size: 20.63 × 10.75 × 7 m
Large frozen storage room

Refrigeration equipment required comprehensive upgrading for dedicated freezer operation. The upgraded system was designed to meet the cooling demands of low-temperature frozen storage. New condensing units provide the required refrigeration capacity for the facility. The configuration supports reliable and consistent freezer operation across the storage space. Equipment selection was planned to maintain stable temperatures under varying operating conditions.

Installed: 2 × 34 HP air-cooled condensing units
Compressor type: Semi-hermetic reciprocating
Freezer refrigeration upgrade

Electrical wiring and control systems required comprehensive upgrading to support the new refrigeration configuration. The electrical infrastructure was upgraded to accommodate the revised refrigeration equipment. Digital temperature controls were integrated for more accurate system monitoring. Automatic defrost controls were incorporated to support efficient freezer operation. The upgraded controls help maintain consistent operating conditions throughout the facility.

Scope: Complete electrical wiring upgrade
Scope: Digital temperature and automatic defrost controls
Freezer electrical and control systems

The conversion required reliable and consistent frozen meat storage conditions across the facility. The upgraded configuration was designed to maintain stable temperatures throughout the storage room. Two independent refrigeration systems provide coordinated cooling for the large storage volume. This setup supports dependable operation and improved refrigeration continuity. The system was configured to meet the ongoing demands of frozen meat storage.

Configuration: Two independent refrigeration systems
Consistent frozen meat storage

One Freezer. Multiple Critical Systems.

Converting a chilled room to -20°C operation requires coordinated refrigeration, evaporator, electrical and control upgrades.

Ice cream processing equipment

One Freezer, Multiple
Critical Systems.

Converting a chilled room to -20°C operation requires coordinated refrigeration, evaporator, electrical and control upgrades.

Chiller

Existing meat storage room, operating as a chiller prior to conversion.

Existing meat chiller
Status Existing
Upgraded

Existing chiller evaporators replaced with low-temperature evaporators suitable for freezer operation.

Low-temperature evaporator upgrade
Status Upgraded
2 × 34 HP

Two independent air-cooled freezer condensing units installed, each rated at 34 HP.

Freezer condensing units
Status Installed
Upgraded

Electrical wiring and power infrastructure upgraded to support the new refrigeration configuration.

Freezer electrical wiring
Status Upgraded
Automated

Digital temperature control and automatic defrost integrated into the system.

Digital temperature and defrost controls
Status Automated
-20°C

Dedicated -20°C frozen meat storage, commissioned and operational.

Dedicated -20°C meat freezer
Status Final

Engineered Around our Existing Storage Room

The conversion was engineered around the dimensions and requirements of the existing meat storage facility.

Selected Detail

Meat Freezer

Get Facility Load Assessment

Engineered for a Precise
-20°C Design Temperature

The freezer conversion was engineered around a dedicated -20°C storage design temperature, replacing the room's original chiller operation.

-20°C Design Temperature
Ice Crystal Growth Visualization
Before Chiller operation
After -20°C dedicated frozen storage
Existing Condition Chiller operation
Converted Condition -20°C dedicated frozen storage
Control Digital temperature control
Defrost Electric, automatic

Two Independent Refrigeration Systems

Redundant condensing units support reliable, continuous -20°C operation.

SYSTEM 01 34 HP
→
FREEZER ROOM -20°C
←
SYSTEM 02 34 HP
Redundant Configuration

2 × 34 HP

Two independent refrigeration systems, each rated at 34 HP, support continuous -20°C freezer operation.

System Specification

Repeated partial thawing + refreezing

Compressor type: Semi-hermetic reciprocating Configuration: Two independent circuits

Why It Matters

Two independent refrigeration systems provide redundancy for continuous frozen storage.

Condensing units: 2 × 34 HP, air-cooled, freezer duty.

Digital Control with Automatic Defrost

Temperature and defrost functions are managed through an integrated digital control system.

Automated

Defrost & Temperature Control

01 Temperature Control
→
02 Automatic Defrost
→
03 Freezer Operation
Control Specification
Control Type Digital Temperature control
Defrost Type Electric Automatic operation
Systems Controlled 2 Independent refrigeration circuits
Digital temperature and automatic defrost control were integrated as part of the freezer conversion.

Storage Temperature Matters

Temperature fluctuations above the ideal storage condition accelerate quality deterioration and shorten usable shelf life.

Complete Refrigeration Solution for the Freezer Conversion

Six main components, engineered together to convert the existing chiller into a dedicated -20°C freezer.

Continuous Ice Cream Freezers

CONDENSING UNITS

Best For Freezer refrigeration
Capacity 2 × 34 HP
Temperature -5°C to -8°C
  • Precision overrun control
  • Rapid, uniform crystallization
  • Hygienic barrel design for continuous multi-shift operation

Specifications

Scraped-surface freezing barrel with dasher-driven mix agitation, ammonia or glycol refrigerant loop, in-line overrun metering.

Best For 120–180 kWh typical draw
Investment Range Scales with L/hour capacity
Quality Outcome Consistent overrun and fine initial ice structure
View System

Complete Refrigeration Solution for the
Freezer Conversion

Six main components, engineered together to convert the existing chiller into a dedicated -20°C freezer.

Condensing Units
Best For Freezer refrigeration
Capacity 2 × 34 HP
Temperature Air-cooled, freezer duty
  • Two independent air-cooled condensing units
  • Sized for dedicated -20°C freezer duty
  • Replaced the original chiller equipment

Specifications

Two independent air-cooled condensing units, each rated at 34 HP, installed to replace the original chiller condensing equipment.

Best For 120–180 kWh typical draw
Investment Range Scales with L/hour capacity
Quality Outcome Consistent overrun and fine initial ice structure
View System
EVAPORATORS
Best For In-room air
distribution
Capacity 2 units
Temperature -25°C to -40°C
  • Two matching cubic-type evaporators
  • Electric defrost integrated
  • Sized to replace existing chiller evaporators

Specifications

Two matching cubic-type evaporators with electric defrost, installed to support consistent -20°C air distribution across the storage room.

Best For 180–300 kWh typical draw
Investment Range Electric
Quality Outcome 2 × cubic-type
View System
Electric
Best For Low-temperature
freezer duty
Capacity Semi-hermetic
Temperature -35°C to -40°C
  • Semi-hermetic reciprocating compressors
  • Integrated within the condensing units
  • Suited to low-temperature freezer operation

Specifications

Semi-hermetic reciprocating compressors integrated within each condensing unit for dedicated low-temperature freezer duty.

Best For TypeSemi-hermetic reciprocating
Investment Range Semi-hermetic reciprocating
Quality Outcome Uniform hardening across full belt width
View System
REFRIGERANT PIPING
Best For System
interconnection
Capacity Complete scope
Temperature -25°C to -35°C
  • Complete refrigerant piping installation
  • Full insulation across all lines
  • Connects condensing units and evaporators

Specifications

Refrigerant piping and insulation installed throughout the facility to connect the condensing units and evaporators.

Best For Complete piping & insulation
Investment Range RefrigerantR404A
Quality Outcome Stable product temperature and extended shelf life
View System
ELECTRICAL & CONTROLS
Best For System operation
Capacity Complete upgrade
Temperature Digital
  • Complete electrical wiring upgrade
  • Digital temperature control
  • Automatic defrost control

Specifications

Electrical wiring and control systems upgraded to support the new refrigeration configuration, including digital temperature and automatic defrost control.

Best For Complete electrical upgrade
Investment Range Control TypeDigital
Quality Outcome Consistent texture and controlled overrun
View System
DEFROST SYSTEM
Best For Ice management
Capacity Electric
Temperature Automatic
  • Electric defrost
  • Automatic operation
  • Integrated with digital temperature control

Specifications

Automatic electric defrost integrated with the digital temperature control system across both evaporators.

Best For Type Electric
Investment Range Operation Automatic
Quality Outcome Maintains product temperature through final-mile delivery
View System

The Right Conditions for Frozen Meat Storage

Premium Ice Cream

Meat Freezer

Dedicated frozen meat storage, converted from the existing chiller room.

View Solutions
Application Dedicated frozen meat storage
Design Temperature -20°C
Refrigeration 2 × 34 HP
Evaporators 2 × cubic-type
Defrost Electric

What matters most for your facility?

Recommended system Continuous Ice Cream Freezers

Built for Controlled Frozen & Storage

Temperature, defrost and system controls were integrated into the upgraded freezer system.

-20°C — Design Temperature
Digital — Temperature Control
Automatic — Defrost Control
2 Systems — Independent Refrigeration
Pressure Tested — System Testing
Commissioned — Final System Commissioning

System Configuration

System 01 34 HP
Piping Insulated
-20°C Freezer Room
Evaporators 2 × Cubic-Type
System 02 34HP

Testing & Commissioning

Pressure Testing
Evacuation
Refrigerant Charging
Final System Commissioning

Upgraded Refrigeration Without Compromising Reliability

Refrigeration energy efficiency
Dedicated freezer condensing units and evaporators installed
Completed
Two independent refrigeration systems configured.
Completed
Complete electrical wiring upgrade carried out.
Completed
Digital temperature and automatic defrost controls installed.
Completed
Pressure testing and evacuation carried out.
Completed
Refrigerant charging and complete system commissioning carried out.
Completed
Commissioned
Refrigeration, electrical and control systems fully commissioned for dedicated -20°C operation.

A Meat Freezer Conversion Engineered Around the Existing Facility

Client Profile

Large food storage and distribution facility requiring the conversion of an existing meat chiller into a dedicated low-temperature meat freezer.

Challenge

Existing meat storage room operating as a chiller required conversion to a -20°C freezer, including replacement of existing chiller evaporators and comprehensive refrigeration, electrical and controls upgrades.

Solution Implemented

Dismantling of existing chiller evaporators and installation of two independent air-cooled freezer condensing units, two matching cubic-type evaporators with electric defrost, complete refrigeration piping, insulation, electrical and control systems, followed by testing and commissioning.

Project Outcome

Successful engineering conversion from chilled to -20°C frozen meat storage.

Read More
-20°C
Design Temperature
2 × 34 HP
Condensing Units
2
Independent Systems
7 m
Room Height

From Chiller to Dedicated -20°C Freezer?

-20°C Dedicated Frozen Storage
2 × 34 HP Refrigeration Configuration
2 Independent Systems
Complete Chiller-to-Freezer Conversion
Ice cream cold chain process from raw milk storage to distribution
Ice cream cold chain process from raw milk storage to distribution
Reliable Frozen Storage
Recommended configuration: Two independent refrigeration systems.
Low-Temperature Performance
Recommended configuration: Dedicated freezer condensing units and evaporators.
System Redundancy
Recommended configuration: Two independent refrigeration systems.
Automated Control
Recommended configuration: Digital temperature and automatic defrost control.

Dairy Refrigeration Questions, Answered

Conversion of an existing meat chiller into a dedicated -20°C frozen meat storage facility, including upgraded refrigeration, evaporator, electrical and control systems.

The dedicated design temperature for the converted freezer is -20°C.

The existing meat storage room measures 20.63 m × 10.75 m × 7 m.

Two independent refrigeration systems were installed for redundancy and reliable frozen storage.

Two air-cooled freezer condensing units were installed, each rated at 34 HP (2 × 34 HP total).

Semi-hermetic reciprocating compressors were used, integrated within the condensing units.

Two matching cubic-type evaporators with electric defrost were installed.

Electric defrost, operating automatically and integrated with the digital temperature control system.

R404A refrigerant was used across the upgraded refrigeration system.

Digital temperature control and automatic defrost control were installed as part of the conversion.

Pressure testing, evacuation, refrigerant charging, and configuration of the digital temperature and automatic defrost controls, followed by final system commissioning.

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