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At CSTHEATEXCHANGER, we design and manufacture ultra-low-temperature, high-pressure Carbon Dioxide (CO2 / R744CO2 / R744) IQF Evaporator Coils and Fluidized Bed Air Coolers engineered specifically for continuous blueberry, raspberry, strawberry, diced mango, and fruit quick-freezing tunnels and spiral freezers (refrigeration cooling capacities engineered from 30 kW to over 1,200 kW per coil block, operating at evaporating temperatures of −40∘C to −52∘C and design operating pressures rated for 60 bar to 90 bar / 1,305 psi60 bar to 90 bar / 1,305 psi). Built with heavy-wall seamless AISI 304/316L or specialized high-strength copper-iron (CuFe2P) pressure tubes mechanically bonded into heavy-gauge marine AlMg3 or pure aluminum corrugated fins, our CO2 fruit freezing coils provide exceptional inside-tube boiling heat transfer coefficients (∼2–3× higher than halocarbons). Featuring staged progressive variable fin spacing (16 mm / 20 mm inlet down to 8 mm / 6 mm discharge) and hygienic stainless steel casings, CST coils ensure rapid surface crust-freezing in under 60–120 seconds, locking in natural berry cell structure, Brix sugar levels, and zero clumping or bleed-out during post-thaw handling.
High-sugar, fragile soft fruits (blueberries, raspberries, diced peaches) demand instant sub-zero surface crusting to prevent cellular rupturing, juice bleeding, and cluster agglomeration:
CO2 (R744) FLUIDIZED BED BERRY FREEZING COIL DYNAMICS
======================= WARM FRESH BERRIES ON FLUIDIZING BELT =======================
[ High Sugar / Sensitive Fruit Cells Enter at +15°C to +20°C ]
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┌────────────────────────────────────────────────────────────────────────────┐
│ [ZONE 1: HIGH-PRESSURE CO2 (R744) SUB-ZERO EVAPORATION (-45°C TO -50°C)] │
│ • Ultra-high volumetric heat capacity & superior boiling heat transfer │
│ • High density vapor allows high mass flow velocities with minimal ΔP drop │
└───────────────────────────┬────────────────────────────────────────────────┘
│
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┌────────────────────────────────────────────────────────────────────────────┐
│ [ZONE 2: HIGH-STATIC VERTICAL AERATION AIR JET FLUIDIZATION] │
│ • Sub-zero air (-42°C) lifts and suspends individual berries in mid-air │
│ • Instant crust freezing locks fruit moisture & cell walls in < 90 seconds │
└───────────────────────────┬────────────────────────────────────────────────┘
│
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======================= 100% INDIVIDUALLY QUICK-FROZEN (IQF) BERRIES =======================
[ Zero Fruit Clumping, Perfect Spherical Shape, Natural Color & Full Brix Retention ]================================================================================
CST HIGH-PRESSURE CO2 (R744) VS. TRADITIONAL AMMONIA (NH3) & FREON IQF COILS
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Thermodynamic / Safety Parameter CST CO2 (R744) IQF Coil Ammonia (NH3 / R717) Coil Freon (R404A / R507) Coil
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Inside-Tube Heat Transfer Coeff. Extremely High (Superior) High (Good) Moderate (Lower efficiency)
Operating Pressure Rating Range 60 bar to 90 bar (High-Strength)25 bar Design Rating 25 bar Design Rating
Volumetric Refrigeration Cap. ~5x to 8x Higher than Freon High Volumetric Density Low Volumetric Density
Refrigerant Piping Diameter Ultra-Compact (Small footprint)Medium Diameter Large Diameter Pipework
Food Toxicity & Safety Rating 100% Food-Grade / Non-Toxic Toxic / Pungent Odor Risk Non-Toxic Synthetic Gas
Environmental Impact (ODP / GWP) Natural: ODP = 0, GWP = 1 Natural: ODP = 0, GWP = 0 High GWP (Global phase-down)
Evaporating Temperature Floor $-45^\circ\text{C}\text{ to }-52^\circ\text{C}$ Steady $-38^\circ\text{C}\text{ to }-42^\circ\text{C}$ Typical $-35^\circ\text{C}\text{ to }-40^\circ\text{C}$ Typical
Cell Structure & Drip Loss ImpactNear-Zero Drip Loss (<0.5%) Low Drip Loss (<0.8%) Higher Drip Loss (1.2–2.0%)
================================================================================CO2CO2 operates at high evaporating pressures even at deep sub-zero temperatures (e.g., 10 bar at −40∘C vs. near-vacuum for other refrigerants), eliminating suction-line pressure drop penalties and compressor volumetric losses. This allows CST coils to maintain rock-solid evaporating temperatures down to −50∘C, enabling continuous fluidized tunnels to crust-freeze delicate berry skins in under 90 seconds90 seconds.
In high-end fruit processing export facilities (organic berries, baby food purée supply), any risk of toxic ammonia odor or synthetic refrigerant contamination is unacceptable. CO2CO2 (R744R744) is a completely non-toxic, odorless, natural refrigerant (ASHRAE A1 safety classification) that satisfies stringent organic certifications and food export standards.
CSTHEATEXCHANGER engineers CO2CO2 coils to withstand high standby and operating pressures up to 90 bar90 bar:
CST CO2 IQF EVAPORATOR STRUCTURAL ELEVATION
======================= HEAVY AISI 304 STAINLESS CASING =======================
[ High-Static Fan Cowls, Sloped Hygienic Drain Pan & Dual Hot Gas Manifolds ]
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┌────────────────────────────────────────────────────────────────────────────┐
│ CORE SUBASSEMBLY INTEGRATION │
│ ┌────────────────────────┐ ┌────────────────────────┐ ┌──────────────────┐ │
│ │ HIGH-PRESSURE CO2 CORE │ │ STAGED FIN SPACING │ │ HIGH-PRESSURE HDR│ │
│ │ 60–90 bar SS/CuFe2P │ │ 20 mm -> 12 mm -> 6 mm │ │ Sch. 80 SS316L │ │
│ │ Heavy AlMg3 fins │ │ Resists berry frost │ │ Full orbital TIG │ │
│ └────────────────────────┘ └────────────────────────┘ └──────────────────┘ │
└────────────────────────────────────────────────────────────────────────────┘ CST PROGRESSIVE VARIABLE FIN SPACING BERRY COIL MATRIX
WARM HUMID FRUIT AIR STREAM FROM INLET BELT (+15°C TO +20°C AIR)
┌─────────────────────────────────────────────────────────────────────────┐
│ [ ROW 1 - 4: 20 mm FIN PITCH ] -> Deep frost penetration; zero face bridging│
├─────────────────────────────────────────────────────────────────────────┤
│ [ ROW 5 - 12: 12 mm FIN PITCH ] -> Latent fruit vapor extraction │
├─────────────────────────────────────────────────────────────────────────┤
│ [ ROW 13 - 24+: 6 mm FIN PITCH ] -> High sensible heat crusting core │
└─────────────────────────────────────────────────────────────────────────┘
HIGH-PRESSURE VERTICAL DISCHARGE: -42°C SUB-ZERO FLUIDIZING AIR JETWe fabricate our CO2 coils with heavy-wall seamless AISI 304/316L stainless steel tubes or high-pressure CuFe2P (copper-iron) alloy tubes orbitally welded to Schedule 80 stainless steel headers. Every unit undergoes automated hydrostatic proof testing up to 135 bar and 100% helium mass spectrometer leak detection.
Fresh washed berries introduce surface water droplets into the freezing zone. Our staged progressive fin spacing (20 mm→12 mm→6 mm) ensures airborne water droplets freeze along open channels without clogging the air-entering face, extending continuous berry harvest processing runs to 16–24+ hours.
CSTHEATEXCHANGER CO2 FRUIT FREEZING CONFIGURATIONS
[1. FLUIDIZED BED INDIVIDUAL QUICK FREEZING (IQF) TUNNEL COILS]
• High-static vertical airflow array generating upward air velocity to fluidize small berries.
• Heavy 0.45 mm AlMg3 aluminum fins withstand continuous aerodynamic pulsations.
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[2. CONTINUOUS SINGLE & DOUBLE DRUM SPIRAL FREEZER COILS]
• High-capacity horizontal airflow coils for larger diced fruits, strawberries, and mangoes.
• Modular stainless steel casing with integrated sloped hygienic defrost drain pans.
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[3. MULTI-BELT FAST CRUST-FREEZING EVAPORATORS]
• Ultra-high-velocity surface crusting coils positioned immediately after the fruit infeed.(Note: The following engineering parameters represent standard manufacturing design envelopes. Operating pressure ratings, fin pitch staging, casing dimensions, and header connections are customized to specific fruit processing line requirements.)
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CSTHEATEXCHANGER CO2 IQF EVAPORATOR COIL (CST-CO2-BERRY SERIES)
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Engineering Parameter Standard Manufacturing & Design Range
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Refrigeration Capacity Range 30 kW to 1,200+ kW per coil block (Scalable)
Air Circulation Flow Rates 12,000 m³/h to 250,000+ m³/h (7,000 to 147,000+ CFM)
Operating Evaporating Temp. -40°C to -52°C (-40°F to -61.6°F) Deep IQF Crusting
Design Operating Pressure 60 bar (870 psi) or 90 bar (1,305 psi) High-Pressure Rating
Factory Hydrostatic Test Press. Up to 135 bar (1,958 psi) Structural Integrity Test
Refrigerant Feed Mechanism Direct Expansion (DX) or Pump-Circulated Liquid Overfeed
Compatible Refrigerants Natural Carbon Dioxide (CO2 / R744 Subcritical / Transcritical)
Tube Metallurgy Options Seamless AISI 304, AISI 316L Stainless Steel, CuFe2P Alloy
Tube Outside Diameter (OD) 3/8" (9.52 mm), 1/2" (12.7 mm), or 5/8" (15.88 mm) Heavy Wall
Fin Material Options Marine-Grade AlMg3 Aluminum Alloy, Pure Al 1050, AISI 304 SS
Fin Thickness Range 0.35 mm to 0.50 mm (Heavy gauge for high-static fluidization)
Progressive Fin Pitch Staging Inlet: 16–25 mm -> Intermediate: 10–14 mm -> Discharge: 6–8 mm
Tube-Fin Mechanical Bonding Precision High-Pressure Mechanical Ball Expansion (100% Fit)
Casing & Structural Frame Continuous TIG-Welded AISI 304 or AISI 316L Stainless Steel
Drain Pan Configuration Double-Wall Insulated Stainless Steel Pan with 3° Slope
Defrosting Methods Hot Gas Defrost (CO2 Loop), Hot Water Spray, Electric Rods
Pressure Vessel Certification ASME Section VIII Div. 1, CE / PED 2014/68/EU Module H/H1
Quality & Leak Testing 100% Helium Mass Spectrometer Vacuum Testing (Zero Leak Standard)
================================================================================CO2CO2 exhibits exceptionally high boiling heat transfer coefficients and maintains high suction gas densities at deep evaporating temperatures down to −45∘C to −52∘C. This enables continuous fluidized tunnels to achieve instant surface crust-freezing in under 90 seconds, locking in berry moisture and eliminating post-thaw juice bleed-out. Furthermore, CO2 is a 100% natural, non-toxic, food-safe refrigerant (ODP=0,GWP=1).
When a low-temperature freezing line is stopped for cleaning or maintenance, liquid refrigerant trapped in the evaporator warms to ambient temperatures, causing internal pressure to rise. CSTHEATEXCHANGER's 60 to 90 bar design pressure rating allows the coil to safely withstand ambient standstill conditions without requiring automatic refrigerant venting or auxiliary condensing units.
Freshly washed berries introduce high surface water into the fluidizing air stream. By utilizing wide 16–20 mm fin spacing at the air inlet, frost deposits evenly along the fin depth without blocking the air face. The fin spacing then tapers to 6–8 mm at the discharge, extending continuous harvest freezing runs to 16–24+ hours between defrosts.
Achieve instant individual crust freezing, eliminate fruit drip loss, and meet complete global food safety standards with CSTHEATEXCHANGER:
Custom High-Pressure CO2 (R744R744) IQF Evaporator Coils (30 kW to 1,200 kW+)
60 Bar / 90 Bar Rated Seamless Stainless Steel or CuFe2P Tube Bundles
Progressive Variable Fin Pitch (20 mm→12 mm→6 mm) for 24h Harvest Uptime
Fluidized Bed IQF Tunnel & Continuous Spiral Freezer Hygienic Stainless Assemblies
Full ASME / CE PED Module H Certification, 100% Helium Leak Tested & Factory-Direct Supply
Contact our specialized fruit and vegetable refrigeration engineering team today with your berry processing capacity (kg/h), tunnel dimensions, design operating pressure, and evaporating temperature for custom CAD engineering proposals and factory-direct quotations.
Website: https://www.cstheatexchanger.com/
Technical Inquiries: info@cstheatexchanger.com
