80,000 SF Frozen Food Manufacturing Facility
Integrated frozen food manufacturing with production-line cold environments, blast freezing, and frozen finished-goods storage. USDA-FSIS, HACCP, and SQF compliant throughout.
FIELD LOG · FROZEN FOOD MANUFACTURING · PRODUCTION + STORAGE INTEGRATED
Client details withheld at client request to protect operational confidentiality. Project specifications, technical details, and engineering work accurately described.
- Buildout80,000 SF integrated
- Production Floor30,000 SF · 38°F
- Blast Freeze Cells10,000 SF · -40°F
- Frozen Storage30,000 SF · -10°F
- Support Spaces10,000 SF
- ComplianceUSDA-FSIS · HACCP · SQF
By the Numbers
Integrated
Production-to-storage flow
<25 min
Blast freeze cycle
USDA
First-inspection approval
0
Recall events
Integrated frozen food manufacturing with production-line cold environments and blast freezing.
Frozen food manufacturing combines processing-line cold environments, blast freezing, and frozen storage into one continuous operational workflow. Engineering must address production-floor sanitation, rapid product freezing immediately after processing, and frozen finished-goods storage — all under one roof with USDA-FSIS compliance throughout.
This project required all of that with refrigerated production floor, IQF blast freeze cells operating at -40°F, frozen storage zone for finished goods, and continuous material flow from raw material receiving through finished frozen product outbound.
Production line, blast freeze, frozen storage — engineered together.
Production Floor — 30,000 SF · 38°F
Refrigerated production zone with sanitation envelope. Coved transitions, sealed concrete, slope-to-drain, and premium sanitation infrastructure.
Blast Freeze Cells — 10,000 SF · -40°F
Specialty blast freeze cells with 6-inch IMP envelope, cascade refrigeration, and engineered air-blast architecture supporting under-25-minute typical freeze cycles.
Frozen Storage — 30,000 SF · -10°F
Standard frozen storage receiving blast-frozen product. 5-inch IMP envelope with under-slab heating.
Material Flow Workflow
Continuous flow from raw material receiving through production through blast freeze through frozen storage through outbound shipping. Coordinated dock infrastructure.
Complete frozen food manufacturing facility. USDA-approved. Operational.
Sanitation + Frozen Envelope
Premium IMP specifications across production, blast freeze, and storage zones with continuous vapor barrier. Coved floor-to-wall transitions throughout production. Sealed concrete with epoxy coatings rated for USDA-FSIS washdown.
Cascade Refrigeration with Blast Capability
Cascade refrigeration architecture with ammonia primary and CO2 cascade for blast cells. Sized for production cooling load plus blast freeze peak load plus frozen storage. PSM-compliant mechanical room.
Production-to-Storage Workflow
Material flow engineering from receiving through production to blast freeze to frozen storage to outbound shipping. Coordinated dock infrastructure for raw material receiving and finished product shipping.
USDA-FSIS Compliance Throughout
Sanitation envelope engineering, drainage with slope-to-drain in all zones, inspection bay accommodation, and pre-operational FSIS approval coordinated through commissioning.
Pre-operational FSIS approval first inspection. Zero recall events since opening.
Facility reached pre-operational FSIS approval on first inspection. Production-to-blast-to-storage workflow has run at design specification through full operational cycles. Zero product recall events since opening.
Blast freeze cells have supported under-25-minute freeze cycles for typical product. Cascade refrigeration architecture has supported continuous operations through full operational hours.
USDA
First-inspection approval
<25 min
Typical blast freeze cycle
0
Recall events since opening
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