Cold Rooms for Food Processing Plants
Indian processed-food sector is projected to cross ₹4 lakh crore by 2027. Food processors need a chain of temperature-controlled spaces — raw material, work-in-progress, blast chillers, finished goods — all HACCP/FSSAI compliant. HyperCold designs integrated cold chambers for QSR commissaries, bakery chains, sauce manufacturers, ready-meal plants, and confectionery units.
Raw 0–4°C • WIP 2–8°C • Cooked-cool 4°C • Frozen finished -18°C
75–90% RH
Raw 3–14 days • Finished varies
Common Use Cases
- Raw material chiller (vegetables, dairy, meat)
- Blast chiller for cooked food cooling (90°C → 4°C in <90 min, HACCP norm)
- WIP holding chambers between process steps
- Finished goods cold/frozen storage
- Dispatch staging room
- Dough proofing room +28°C (warm)
- Spice & dry ingredient ambient-controlled room
Engineering Details
HACCP blast chilling rule
Cooked food must pass through the danger zone (60°C → 5°C) within 90 minutes to prevent bacterial growth. Blast chiller capacity: 30 kg cooked food per 1 TR for the 90-minute cycle. Air velocity 3–4 m/s for fast surface cooling. Stainless trolleys with perforated trays for airflow.
Single-direction flow
Raw inputs at receiving end, finished outputs at dispatch end, no cross-traffic. Operator routes via locker → wash → uniform → entry; one-way flow from clean to clean zones. Insulated airlock at every temperature transition.
CIP-ready design
SS304 panels with continuous welded joints (not silicone-filled). Floor 1–2% slope to stainless trench drains. Wall-to-floor coving 50 mm radius — eliminates dead zones. Hose stations every 6 m linear wall. Drain trap with anti-siphon and rodent guard.
Allergen segregation
Major allergens (nuts, milk, gluten, soy, egg) need physically separate handling chambers to avoid cross-contamination. Colour-coded utensils, dedicated air handler per allergen zone, and separate dispatch staging.
Capacity Range
From 30 m² QSR commissary cold room (~₹6 lakh) to integrated 1000 m² food plant cold chain (₹2+ crore).
FAQs
Do I need separate rooms for raw and cooked?
Yes — HACCP requires physical segregation. Cross-contamination risk between raw meat/poultry and cooked-ready products is the #1 food safety failure.
What is the typical AMC cost for a food plant?
3–5% of CAPEX/year comprehensive, given high washdown frequency and hygiene-critical operation.