Auto Carton Tunnel

Over the last 25 years, Realcold have developed a world leading range of mechanized tunnels for chilling and freezing cartoned product. They can vary in size from 500 to over 20,000 carton capacity.  The main advantages obtained by using a Carton Tunnel are the significant labour savings and the achievement of uniform cooling.  Auto Carton Tunnels are extensively used in both the Meat and Dairy Industries.

The Realcold tunnel consists of a portal frame structure of beams and columns.  Suspended on rails within this portal frame are two levels of pallets of multi-level shelves.  Cartons are automatically loaded and unloaded onto these shelves and mechanically moved through the tunnel.  The evaporators and fans for the refrigeration plant are positioned along one side of pallet support frame for freezing, and positioned at the end for chilling.

The evaporators are designed to remove the product heat from the circulating air flow.

Chilling Tunnels

Chilling and Freezing Tunnels are mechanically very similar.  However the very different refrigeration requirements necessitate differing general layouts.  The evaporators of a Chilling Tunnel are usually positioned at one end of the pallet stack.  This type of tunnel is typically used for chilling Dairy or Meat products.

Freezing Tunnels

Freezing Carton Tunnels generally have their fans and evaporators positioned along one side of the pallet structure.  The air blast from the fans passes through the evaporators, across the tunnel on the lower level then back through the cartons on the top level.  This allows for the greater fan and evaporator capacity required to freeze cartons.  This type of tunnel is typically used for freezing Meat, Fish or Poultry products.

Benefits of a Carton Tunnel

• Lowest overall cost automated carton freezing or chilling.
• Completely automatic.
• No operator or labour costs.
• Handles a random supply of multiple carton sizes.
• Capacities of up to 400 tonnes per day
• Carton, mould or crate operation.
• Carton presentation to achieve maximum container utilization.
• Maintains a uniform cooling regime for every carton.
• Carton handling speeds up to 25 per minute.
• Elimination of cold shortening, associated with rapid freezing of hot boned meats.
• Combining with a palletizer for fully automated unloading.
• Freezing and chilling regimes to meet international standards.
• Ensures identical flavour and colour in cheese blocks.

Carton Tunnels are custom made to an individual’s requirement. Size, length, width, height and conveyor layouts, can all be designed to suit.

Refrigerant Choices:

• Ammonia
• Carbon Dioxide
• Freon
• Glycol
• Commercial Cooling Media

Click here for our Single Retention Tunnel Brochure