Mega Line brochure - WESSAMAT Eismaschinenfabrik GmbH
Mega Line brochure - WESSAMAT Eismaschinenfabrik GmbH
Mega Line brochure - WESSAMAT Eismaschinenfabrik GmbH
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<strong>Mega</strong>-<strong>Line</strong><br />
Efficient<br />
system concepts<br />
for productivity<br />
in ice making
Pure ice.<br />
Pure emotion.<br />
2<br />
Hollow<br />
ice cubes<br />
Ice cubes and crushed ice bring forth emotions. They stand for freshness<br />
and refreshment and make you want more. Crystal clear ice cubes and<br />
sparkling crushed ice guarantee optimal cooling and attractive presentations.<br />
They give cocktails their fascination, quickly bring drinks down<br />
to the right drinking temperature, give buffets that “special flair” and<br />
ensure the constant freshness of food and drinks.<br />
Due to the versatile use options and the ever-increasing demand, entirely<br />
new requirements are being made on the production of ice cubes and<br />
crushed ice. <strong>WESSAMAT</strong> has reacted to these requirements with the<br />
consistent development of the <strong>Mega</strong>-<strong>Line</strong> product range, thus setting<br />
fully new standards.<br />
Full ice cubes<br />
New standards in technology.<br />
New standards in performance.<br />
New standards in quality.<br />
Crushed ice
Modular ice making.<br />
Versatile use.<br />
3<br />
Ice cubes and crushed ice are in fashion.<br />
Whether on a plane or in a restaurant, in a cocktail<br />
bar or on the sun patio, in the cinema or in<br />
a theme park – ice cubes and crushed ice are<br />
becoming more and more popular everywhere.<br />
In the classical gastronomy and hotel business,<br />
event gastronomy and large-scale gastronomic<br />
events as well as in the party service or catering<br />
fields, a constantly increasing demand for ice<br />
cubes and crushed ice is noticeable. The trends<br />
set in the commercial field are also becoming<br />
more and more popular with private customers,<br />
which over the past years has led to a drastically<br />
increasing demand, particularly for prepacked<br />
ice cubes and crushed ice.<br />
With the <strong>Mega</strong>-<strong>Line</strong> product range, <strong>WESSAMAT</strong><br />
offers tailor-made solutions for all of these applications<br />
– from a single ice maker module on a<br />
storage bin through to process-controlled production<br />
systems with freezer, transport systems,<br />
exact weight filling and individual packaging in<br />
bags or thermal containers.<br />
The individual conception of the <strong>Mega</strong>-<strong>Line</strong> ice<br />
maker system enables the production of various<br />
types of ice:<br />
■ Hollow ice cubes, format approx. 47 mm<br />
x 34 mm, weight approx. 27 g<br />
■ Full ice cubes, format approx. 30 mm x<br />
30 mm x 22 mm, weight approx. 33 g<br />
■ Crushed ice (ice nuggets in irregular size<br />
and shape)<br />
For this, various different ice making methods<br />
are used and are combined in complex ice making<br />
systems and high-performance production<br />
lines. An ice-making capacity of 20 tons and<br />
more in 24 hours is achieved in doing so.<br />
Crystal clear ice cubes and sparkling crushed<br />
ice are extremely popular all over the<br />
world – in classical gastronomy, for largescale<br />
gastronomic events and also in the<br />
catering and flight catering fields. The<br />
increasing private consumption has also<br />
contributed to the rising demand, which<br />
has particularly made the production and<br />
marketing of pre-packed ice cubes and<br />
crushed ice a profitable business.
High demand. High efficiency.<br />
The highly rising demand from both the commercial<br />
and private sectors has particularly<br />
made the production and marketing of ice<br />
cubes and crushed ice – especially as prepacked<br />
units – a lucrative business with substantial<br />
growth potential and a high degree of<br />
productivity.<br />
Taking into consideration the produced quantitiy<br />
of ice and all costs for financing, operation<br />
and maintenance, the return of investment for<br />
the purchase of a <strong>Mega</strong>-<strong>Line</strong> ice maker system<br />
can already be reached after 2 years.<br />
<strong>Mega</strong>-<strong>Line</strong> ice maker systems also convince by<br />
utmost functionality and efficiency in the production<br />
of ice cubes and crushed ice for private<br />
use due to their demand-optimised conception.<br />
4<br />
<strong>Mega</strong>-<strong>Line</strong> ice making system incl.<br />
dispenser and integrated weighing<br />
technology, production rate<br />
approx. 7,400 kg/24 h<br />
System configuration (see page 7):<br />
9 ice making modules Z 2005 W each with<br />
approx. 820 kg ice output, water-cooled with 1<br />
cooling tower KT 100. Ice making modules<br />
mounted on dispenser D 2005, PLC control<br />
with visualisation for semi-automatic filling<br />
Production rate/year *) approx. 1.780.000 kg<br />
(240 workdays x approx.<br />
7,400 kg ice output/24 h)<br />
Investment costs approx. 178.000,– E<br />
Assembly, commissioning,<br />
instruction **)<br />
approx. 20.000,– E<br />
Total investment<br />
costs<br />
approx. 198.000,– E<br />
Fixed costs/year 1)<br />
40.070,– E<br />
Variable costs/year 2) 166.500,– E<br />
Manufacturing costs/year 206.570,– E<br />
+ 8 % admin. overheads 16.525,– E<br />
+ 20 % SG&A overheads 41.314,– E<br />
+ Costs for cooling logistics 356.000,– E<br />
(Storage and transport/<br />
0.20 E/kg x 1,780,000 kg)<br />
Original costs/year 620.409,– E<br />
Sales revenue/year<br />
712.000,– E<br />
(1.780.000 kg x 0,40 E/kg)<br />
Net proceeds per year 91.591,– E<br />
(Sales revenue ./. actual costs)<br />
Theoretical ROI ***) approx. 2,2 years<br />
<strong>Mega</strong>-<strong>Line</strong> ice making<br />
and filling system,<br />
production rate approx. 20,000 kg/24 h<br />
System configuration (see page 8):<br />
24 ice making modules Z 2005 W each with<br />
approx. 820 kg ice output, water-cooled with<br />
cooling towers. Ice making modules mounted on<br />
stainless steel support structure with storage and<br />
conveying unit, PLC control with visualisation for<br />
fully automatic filling and packaging with tubular<br />
bag machine<br />
Production rate/year *) approx. 4.800.000 kg<br />
(240 workdays x approx.<br />
20,000 kg ice output/24 h)<br />
Investment costs approx. 655.000,– E<br />
Assembly, commissioning,<br />
instruction **)<br />
approx. 45.000,– E<br />
Total investment<br />
costs<br />
approx. 700.000,– E<br />
Fixed costs/year 1)<br />
159.535,– E<br />
Variable costs/year 2) 352.360,– E<br />
Manufacturing costs/year 511.895,– E<br />
+ 8 % admin. overheads 40.952,– E<br />
+ 20 % SG&A overheads 102.379,– E<br />
+ Costs for cooling logistics 960.000,– E<br />
(Storage and transport/<br />
0.20 E/kg x 4,800,000 kg)<br />
Original costs/year 1.615.226,– E<br />
Sales revenue/year 1.920.000,– E<br />
(4.800.000 kg x 0,40 E/kg)<br />
Net proceeds per year 304.774,– E<br />
(Sales revenue ./. actual costs)<br />
Theoretical ROI ***) approx. 2,3 years<br />
*) Possibly occurring thawing losses and breakage shares have not been taken into consideration<br />
**) Actual Installation costs depend on the location and conditions at the place of installation<br />
***) Return of Investment<br />
The following basic conditions and cost rates<br />
were taken as the basis for the profitability<br />
calculations:<br />
1)<br />
Calculation of the fixed costs:<br />
– 8 years average life (AFA)<br />
– Calc. interest (8 %, ½ investment volume)<br />
– Prophylactic maintenance (2 x per year)<br />
– Expenses for premises<br />
– Insurance<br />
2)<br />
Calculation of variable costs:<br />
– Electricity costs (0.12 E/kWh)<br />
– Costs for fresh water 2.20 E/m 3<br />
– Maintenance and wear<br />
– Costs for necessary service staff (full-time<br />
staff and assistants taking into consideration<br />
the amount of ice to be produced)<br />
– Costs for packaging bags (in the respectively<br />
required quantity), 2 kg content, (price per<br />
unit 0.05 E).<br />
The cost rates applied for cost calculation are<br />
based on real experience values (e. g. for service<br />
and maintenance) and on the average<br />
valid cost rates for Germany, Austria,<br />
Switzerland and the Benelux states (e.g. for<br />
electricity, water and labour).
Manual filling.<br />
Cost-effective solution.<br />
Thanks to its modular design, the variable<br />
<strong>Mega</strong>-<strong>Line</strong> concept in producing ice cubes and<br />
crushed ice guarantees maximum flexibility and<br />
efficiency. <strong>WESSAMAT</strong> plans and delivers for you<br />
exactly the system that is tailored to the individual<br />
needs, requirements and investment budget.<br />
From the low-budget solution for manual<br />
take out to complex production systems with<br />
automated conveying, filling and packaging<br />
technologies, <strong>WESSAMAT</strong> offers you innovative,<br />
technically sophisticated solutions with a high<br />
degree of reliability and productivity.<br />
Comfortable flap<br />
for manual ice cube<br />
take out<br />
Ice making module Z 2000 L/W<br />
(Output: approx. 820 kg ice cubes /24 hours<br />
or approx. 1,640 kg/24 hours with two ice<br />
making modules Z 2000 L/W)<br />
Insulated stainless steel<br />
storage bin B 750, with<br />
double base for the<br />
drainage of melting<br />
water, capacity 560 kg<br />
5<br />
1 ice making module Z 2000 L/W<br />
■ Ice-making output: approx. 820 kg in<br />
24 hours (Ice-making capacity when using<br />
a 2nd ice making module Z 2000 L/W:<br />
approx. 1,640 kg in 24 hours)<br />
■ Dimensions: H 600 mm x<br />
W 1,700 mm x D 850 mm<br />
■ Power consumption: 4.10 kW<br />
■ Mains connection: 400 V/50 Hz*)<br />
■ Weight: 245 kg<br />
■ Design: Stainless steel housing<br />
■ Cooling:<br />
Model Z 2000 W:<br />
Water cooling with fresh water, cooling<br />
tower or water chiller<br />
Model Z 2000 L:<br />
Prepared for the connection to a remote<br />
condenser<br />
*) Special voltages on request<br />
System concept 1<br />
The ice making modules type Z 2000 L/W for modular application practically represent the centrepiece<br />
of all <strong>Mega</strong>-<strong>Line</strong> ice making systems for the production of hollow ice cubes. These ice making<br />
modules can be combined with other system components (e.g. storage bin, conveying and filling<br />
units) depending on the ice cubes required and the output. The combination of an ice making module<br />
Z 2000 L/W (air cooled or water cooled version) with a storage bin for manual ice cube take out<br />
is the starter model of the <strong>Mega</strong>-<strong>Line</strong> product range. Ideally suitable for all users with an increased<br />
requirement for ice cubes (up to 820 kg in 24 hours) and for whom automatic filling and further<br />
processing of the ice cubes is out of the question for economic reasons. The required quantity of ice<br />
cubes can be taken as needed from the storage bin, which has a capacity of 560 kg. After taking<br />
out the desired amount of ice cubes, the ice cube production by the ice making module<br />
Z 2000 L/W is automatically resumed until the ice in the storage bin has reached its maximum filling<br />
height again.<br />
Apart from water cooling with fresh water, cooling tower or water chiller (model Z 2000 W), this ice<br />
making system is also available as an air cooled model (Z 2000 L) for connection to a remote<br />
condenser. In case of increasing ice cube demand, the ice cube output can be doubled to approx.<br />
1,640 kg in 24 hours by the use of a second ice making module Z 2000 L/W.<br />
B 750 Storage Bin<br />
■ Capacity: 560 kg<br />
■ Dimensions: H 1,100 mm<br />
x W 1,700 mm x D 1,005 mm<br />
■ Empty weight: 150 kg<br />
■ Design: Stainless steel<br />
■ Required floor load capacity:<br />
min. 300 kg/m 2<br />
Storage bin B 750 with 1 ice making module<br />
Z 2000 W for the production of<br />
approx. 820 kg ice cubes/24 h.
Variable output.<br />
Automated filling.<br />
Time is money – this simple formula also applies<br />
to the production of pre-packed ice cubes e.g.<br />
for catering firms, gastronomy companies or<br />
private consumers. For the portioned filling of<br />
ice cubes, the dispenser D 705, developed by<br />
<strong>WESSAMAT</strong>, provides ideal prerequisites.<br />
Dispenser D 705 with integrated<br />
conveying device and automatic,<br />
interval-controlled loosening unit,<br />
storage capacity 480 kg.<br />
Ice making module Z 2005 L/W<br />
(Output: approx. 820 kg ice cubes /24<br />
hours or approx. 1,640 kg/24 hours with<br />
two ice making modules Z 2005 L/W)<br />
Filling unit for the portioned<br />
filling of 2 kg - 5 kg<br />
ice cubes<br />
(Portion quantity is firmly<br />
set at the factory)<br />
Dispenser D 705 with 2 ice making modules<br />
Z 2005 L/W for the production of approx.<br />
1,640 kg of ice cubes in 24 hours.<br />
6<br />
1 ice making module Z 2005 L/W<br />
■ Ice-making output: approx. 820 kg in<br />
24 hours<br />
(Ice-making capacity when using a 2nd<br />
ice making module Z 2005 L/W:<br />
approx. 1,640 kg in 24 hours)<br />
■ Dimensions: H 600 mm x<br />
W 1,700 mm x D 850 mm<br />
■ Power consumption: 4.10 kW<br />
■ Mains connection: 400 V/50 Hz*)<br />
■ Weight: 245 kg<br />
■ Design: Stainless steel housing<br />
■ Cooling:<br />
Model Z 2005 W:<br />
Water cooling with fresh water, cooling<br />
tower or water chiller<br />
Model Z 2005 L:<br />
Prepared for the connection to a remote<br />
condenser<br />
D 705 Ice Cube Dispenser<br />
■ Dispenser storage capacity: 480 kg<br />
■ Filling output dispenser: 25 - 30 kg per<br />
minute (acc. to the portion size)<br />
■ Dimensions (incl. filling unit, without ice<br />
making module Z 2005 L/W):<br />
H 2,125 mm x W 3,120 mm x D 850 mm<br />
■ Empty weight: 410 kg<br />
■ Power consumption: 1,10 kW<br />
■ Mains connection: 400 V/50 Hz*)<br />
■ Design: Housing, storage bin and filling<br />
unit made from stainless steel<br />
■ Required floor load capacity:<br />
min. 800 kg/m 2<br />
*) Special voltages on demand<br />
System concept 2<br />
The dispenser D 705 can be combined with one or two ice making modules of type Z 2005 L/W<br />
for the production, provisioning and filling of ice cubes. Hence, ice outputs of 820 kg or 1,640 kg<br />
of ice cubes in 24 hours can be realised.<br />
The ice cubes are stored in the dispenser which has an interval-controlled loosening mechanism.<br />
The ice cubes are filled in portions by means of an integrated conveying mechanism with semi-automatic<br />
filling unit. For this, the weight of the desired ice portion is firmly set at the factory (can be<br />
freely chosen between 2 kg and 5 kg). As an alternative to the portioned filling with constant<br />
weight, the output of the ice cubes can also be controlled by a foot-operated switch. This is useful<br />
for larger containers and wherever no exact weight specifications have to be met. The entire function<br />
and control of this ice making system is effected through a PLC control unit, which ensures the<br />
highest degree of dependability and functional reliability.<br />
2 ice making modules Z 2005 L/W,<br />
mounted on dispenser D 705 with<br />
an integrated conveying unit and<br />
semi-automatic filling unit for the<br />
portioned filling of ice cubes.
Getting started in ice cube production from<br />
2.5 tons and more in 24 hours begins with<br />
modular ice making systems, which are based<br />
on the high-performance ice cube dispenser<br />
D 2005. This dispenser has a capacity of 1,100 kg.<br />
The automatic, interval-controlled loosening<br />
facility prevents the ice cubes from freezing<br />
together. The ice can be filled in portions (set to<br />
a constant weight between 2 kg and 5 kg at the<br />
factory) or by means of a foot-operated switch<br />
(continuously variable).<br />
Dispenser D 2005 for the storage and semi-automatic filling of<br />
ice cubes in combination with 9 ice making modules Z 2005 L/W.<br />
Output approx. 7,380 kg ice cubes in 24 hours.<br />
Dispenser D 2005 with 6 or 9 ice making modules<br />
Z 2005 L/W for the production of approx.<br />
4,920 kg or 7,380 kg of ice cubes in 24 hours.<br />
7<br />
9 ice making modules Z 2005 L/W<br />
■ Ice-making output: approx. 7,380 kg in<br />
24 hours<br />
■ Dimensions per module: H 600 mm x<br />
W 1,700 mm x D 850 mm<br />
■ Power consumption: 4.10 kW per module<br />
■ Mains connection: 400 V/50 Hz*)<br />
■ Weight: 245 kg per module<br />
■ Design: Stainless steel housing<br />
■ Cooling:<br />
Model Z 2005 W:<br />
Water cooling with fresh water, cooling<br />
tower or water chiller<br />
Model Z 2005 L:<br />
Prepared for the connection to a remote<br />
condenser<br />
D 2005 Ice Cube Dispenser<br />
■ Dispenser capacity: 1,100 kg<br />
■ Filling output dispenser: 25 - 30 kg per<br />
minute (acc. to the portion size)<br />
■ Power consumption: 2.0 kW<br />
■ Mains connection: 400 V/50 Hz*)<br />
■ Empty weight: approx. 1,100 kg<br />
■ Dimensions with filling unit: (without ice<br />
making modules)<br />
H 2,150 mm x W 1,940 mm x D 4,070 mm<br />
■ Design: Housing, storage bin and filling<br />
unit made from stainless steel<br />
■ Required floor load capacity:<br />
min. 1,200 kg/m 2<br />
*) Special voltages on demand<br />
System concept 3<br />
Ice making modules of the type Z 2005 L/W, of<br />
which up to 9 modules can be installed on the<br />
dispenser D 2005, ensure the production of the<br />
required quantity of ice cubes. Due to the quantity<br />
of the modules to be installed (max. 3 modules<br />
can be installed on top of one another), the<br />
respective output can also be gradually adapted<br />
to the actual requirements (up to max. 7,380 kg).<br />
Furthermore, the modular construction enables<br />
the selective activation and deactivation of individual<br />
ice making modules, in order to adapt the<br />
ice output to the fluctuating ice cube demand<br />
(e.g. seasonal fluctuation). The dependable<br />
function and operational reliability of the system<br />
is guaranteed by a PLC control unit.<br />
Portioned filling of ice<br />
cubes with the<br />
dispenser D 2005.
8<br />
Ice making system with storage and conveying<br />
unit, refrigeration via a multicompressor<br />
refrigeration system, production output<br />
approx. 23,000 kg ice cubes/24 h<br />
(figure above).<br />
Process-controlled production.<br />
Highest degree of efficiency.<br />
System concept 4<br />
For the powerful, individually designed large-scale systems for the production and filling of ice cubes<br />
via storage and conveying containers, the product line name “<strong>Mega</strong>-<strong>Line</strong>” is an appropriate description.<br />
<strong>Mega</strong> powerful, mega productive and mega-economical, when it comes to the production and<br />
filling of 16,000 kg of ice cubes and more in 24 hours.<br />
The basis for this system conception is formed by the well coordinated drive, monitoring and control<br />
units. The ice making modules of type Z 2005 are installed in the required amount on stainless<br />
steel support frames and supplied with central refrigeration. If an overall refrigeration supply with<br />
brine as the refrigeration element is planned or already exists, the ice making modules can also be<br />
configured for this refrigeration type.<br />
The ice produced in the ice making modules glides into the storage and conveying unit, which has<br />
an interval-controlled loosening function. From here, the ice cubes are transported via conveyor<br />
belts and frosters (option) to a fully automatic tubular bag machine. For these systems, the weight<br />
for the various packaging units can be individually adjusted by the user at the packaging machine.<br />
Touch screen display with visualised menu<br />
guidance for user-friendly control and checking<br />
of the ice making system (figure above).<br />
Storage and conveying unit with integrated<br />
loosening function. (Figure below).
The dependable function of the system is guaranteed<br />
by a PLC control unit. The filling volume<br />
of the storage and conveying unit is monitored<br />
by light barriers. The central control and monitoring<br />
of all system components is enabled by<br />
the visualised representation of all processes at<br />
the control station.<br />
2<br />
2<br />
A plexiglass cover on the conveying unit prevents<br />
direct access and the contamination of<br />
dirt and foreign particles. This is an important<br />
aspect for operational safety and hygiene in the<br />
production and further processing of ice cubes<br />
coming under the drinking water legislation.<br />
The system concept can be planned very variably<br />
and in a customised manner with regard to<br />
the ice output and downstream conveying and<br />
packaging units. This system concept should be<br />
designed with at least 20 ice making modules<br />
of type Z 2005 L/W (for an ice output of more<br />
then 16 tons in 24 hours) for fast amortisation<br />
and high profitability. Furthermore, the extension<br />
of the system with additional ice making<br />
modules is possible. This way the required ice<br />
capacity can be successively adapted to an<br />
increasing demand. This system conception is<br />
the ideal solution for the production of large<br />
quantities of ice cubes, which are marketed in<br />
bags or other containers.<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
6<br />
3<br />
7<br />
1<br />
1<br />
4 5<br />
Stainless steel support structure<br />
Ice making modules Z 2005 W/Z/S<br />
Storage and conveying unit with interval-controlled loosening function<br />
Conveyor belt (Z shape)<br />
Control station with visualisation of the operating statuses<br />
Tubular bag packaging machine<br />
Delivery belt for end packaging (e.g. cardboard boxes, polystyrene containers or pallets)<br />
9<br />
Hollow ice cubes on conveyor belt to the packaging machine.<br />
X Ice making modules Z 2005 W/Z/S<br />
■ Ice-making output: from 16,000 kg in<br />
24 hours<br />
■ System dimensions: Depending on the<br />
system configuration<br />
■ Power consumption: Depending on the<br />
system configuration<br />
■ Mains connection: 400 V/50 Hz*)<br />
■ Weight: Depending on the system configuration<br />
■ Design: Stainless steel housing<br />
■ Cooling:<br />
Model Z 2005 W:<br />
Water cooling with fresh water, cooling<br />
tower or water chiller<br />
Model Z 2005 Z:<br />
Cooling via central refrigeration<br />
Model Z 2005 S:<br />
Cooling with brine as the cooling agent<br />
Storage and conveying unit<br />
■ Capacity: 200 kg to 1,600 kg<br />
■ Conveying capacity: 25 - 30 kg per minute<br />
■ Power consumption: 1.50 kW<br />
■ Mains connection: 400 V/50 Hz*)<br />
■ Total system dimensions: Depending on<br />
the system configuration<br />
■ Design: Housing, storage bin and filling<br />
unit made from stainless steel<br />
■ Required floor load capacity:<br />
min. 400 kg/m 2<br />
Automatic packaging station with tubular bag packaging machine and box strapping.<br />
*) Special voltages on demand
Various types of ice:<br />
Different production methods.<br />
Various types of ice can be produced to customer<br />
requirements with <strong>Mega</strong>-<strong>Line</strong> ice making<br />
systems. To produce hollow ice cubes, full ice<br />
cubes or crushed ice, the use of different ice<br />
making methods is necessary. The concept of<br />
the respective ice making system depends on<br />
the individual demands on the quantity of the<br />
desired type of ice and the degree of automation<br />
of the ice making system for the respective<br />
application case.<br />
In order to produce the desired quantity of hollow<br />
ice cubes, full ice cubes or crushed ice, several<br />
ice making modules applying the same procedure<br />
can be combined respectively. They form<br />
the centrepiece of each <strong>Mega</strong>-<strong>Line</strong> ice making<br />
system in combination with other system components.<br />
Hollow ice cubes<br />
Format approx. 47 mm x 34 mm<br />
Weight approx. 27 g<br />
Full ice cubes<br />
Format approx. 30 mm x 30 mm x 22 mm<br />
Weight approx. 33 g<br />
Crushed-Ice<br />
(ice nuggets in irregular size and shape)<br />
10<br />
Hollow ice cubes<br />
Crystal-clear hollow ice cubes are the premium product of <strong>Mega</strong>-<strong>Line</strong> ice making systems. Compared<br />
with full ice cubes, hollow ice cubes have a larger surface and a faster and more intensive cooling<br />
effect. Furthermore, they are very popular with users and consumers due to their shape.<br />
The hollow ice cubes are produced according to the principle of centrifugal technology. For this,<br />
the water supplied for the production process is sprayed against the evaporator finger, on which<br />
the conical ice cubes are formed during the freezing phase. The ice cubes are released from the<br />
evaporator fingers when they have reached their set size and the thawing phase is initiated. Approx.<br />
820 kg of hollow ice cubes/24 h can be produced with one ice making module.<br />
In the thawing phase the hollow ice cubes detach from the evaporator fingers.<br />
Principle of the centrifugal technology:<br />
Ice making process (figure above)<br />
Thawing phase (figure below)
Full ice cubes<br />
As opposed to the hollow ice cubes, the solid<br />
full ice cubes release their cooling effect more<br />
slowly and constantly. Therefore there are also<br />
good, comprehensible arguments for the use of<br />
full ice cubes – and in various branches and<br />
regions, the typical mental image of an ice cube<br />
is the classical, square shape. Horizontal plate<br />
evaporator systems in modular construction are<br />
used in <strong>Mega</strong>-<strong>Line</strong> ice making systems for the<br />
production of these square ice cubes.<br />
Full ice cubes are sized approx. 30 x 30 x 22 mm with a weight of approx. 33 g.<br />
Horizontal type evaporator system<br />
Transport of the full ice cubes to the conveyor belt.<br />
Storage conveyor with full ice cubes.<br />
11<br />
Crushed-Ice<br />
Another very popular type of ice with increasing demand is crushed ice. Not only the global triumph<br />
of Caipirinhas, Mojitos, Caipiroskas and other cocktails and soft drinks on crushed ice basis is responsible<br />
for this. Crushed ice differs substantially with regard to appearance, consistency and cooling<br />
behaviour from flake or even scale ice, which is produced in freezing cylinders with a spiral conveyor<br />
or with rotating evaporator rollers, on the surface of which a layer of ice is formed.<br />
The original products for the production of crushed ice at <strong>WESSAMAT</strong> are always crystal-clear,<br />
hygienically perfect hollow ice cubes, which are automatically shredded after production in one of<br />
the downstream stainless steel mills. Thus, sparkling ice nuggets of firm consistency in irregular<br />
shapes and sizes are made. Due to its appearance and cooling properties, crushed ice is preferably<br />
used to make cocktails and for the attractive presentation and consistent cooling of food and drinks.<br />
Crystal-clear crushed ice is produced by the mechanical grinding of hollow ice cubes.<br />
Crusher mill
Individual refrigeration supply.<br />
Effective cooling.<br />
In order to achieve the maximum production<br />
output of ice making systems, the selection of<br />
the type of cooling and refrigeration supply is of<br />
great significance. For this, economical and ecological<br />
arguments (e.g. fresh water supply and<br />
treatment costs for fresh water) and the individual<br />
prerequisites at the application location (climate,<br />
spatial conditions, room temperature etc.)<br />
are taken into consideration. Various methods<br />
can be used for the cooling and refrigeration<br />
supply of <strong>Mega</strong>-<strong>Line</strong> ice making systems:<br />
■ Air cooling with remote condenser<br />
■ Water cooling with fresh water<br />
■ Water cooling with a cooling tower<br />
■ Water cooling with a water chiller<br />
■ Central multicompressor refrigeration supply<br />
with refrigerating agent<br />
■ Central refrigeration supply with brine as<br />
refrigeration agent (warm brine and cold<br />
brine)<br />
By means of these alternative methods it is possible<br />
to individually plan the cooling and refrigeration<br />
supply, thus optimising water consumption.<br />
An important contribution to the reduction<br />
of operating costs and a concrete example of<br />
the high degree of flexibility and adaptability of<br />
this variable system concept.<br />
Cooling tower system consisting of 3 cooling<br />
towers, type KT 100, for the cooling of<br />
max. 27 water-cooled ice making modules<br />
Z 2005 W.<br />
12<br />
Air cooling with remote condenser<br />
A condenser is installed for each ice making unit<br />
outside the building (e.g. on the outer wall or<br />
on the roof of the building). Hence, the heating<br />
up of the rooms in the vicinity of the ice making<br />
system is prevented.<br />
Water cooling with fresh water<br />
In the case of a water cooling system without cooling<br />
tower, a relatively high requirement of cooling<br />
water arises depending on the environmental temperature<br />
and ice production. This water is expelled<br />
unused as wastewater when operated without a<br />
cooling tower, which cannot be approved in most<br />
cases for ecological and economical reasons. For<br />
this reason the cooling with fresh water function<br />
is basically only used when the ice cube production<br />
is comparatively low and cooling water is<br />
available at a low cost in adequate supply.<br />
Water cooling with a cooling tower<br />
In this version, a cooling water circulation is<br />
established between the individual ice makers<br />
and the cooling towers. The water in the cooling<br />
water system permanently circulates between<br />
the ice makers and the cooling tower,<br />
which is installed in the outdoor area of the<br />
building. When using this cooling method, only<br />
the fresh water lost by evaporation must be<br />
replaced. As several ice making units can be<br />
connected to one cooling tower, this method is an<br />
economical and environmentally friendly solution.<br />
Water cooling with a water chiller<br />
The <strong>Mega</strong>-<strong>Line</strong> ice making systems can be prepared<br />
for connection to a water chiller or can<br />
be delivered with a water chiller. By means of<br />
the water chiller – also referred to as a water<br />
cooler or process cooler – the system is continuously<br />
supplied with cooling water with a constant<br />
temperature. Therefore external temperature<br />
related fluctuation in the ice output (e.g.<br />
due to high external temperatures or large temperature<br />
differences between day and night or<br />
winter and summer) can be minimised. A high<br />
temperature accuracy is maintained even during<br />
temporary temperature peaks, thus guaranteeing<br />
a consistently high ice output. Due to<br />
the closed cooling water circuit, the system is<br />
permanently supplied with clean cooling water,<br />
independently of the water quality on site. This<br />
makes this type of cooling a very low-maintenance,<br />
user-friendly variant, which also requires<br />
very little space due to its compact construction.<br />
Central refrigeration supply with cooling<br />
agent<br />
The central refrigeration supply is the most<br />
effective solution in terms of energy for the<br />
operation of a high-performance ice making<br />
system of the <strong>Mega</strong>-<strong>Line</strong> product range. For<br />
this, a tailored refrigeration supply is designed<br />
on the basis of the individual requirements (ice<br />
cube requirement, filling quantity etc.), which<br />
offers a continuous ice output with the highest<br />
possible economic efficiency. Due to the investment<br />
costs, which arise from the installation of<br />
a central refrigeration supply, this variant of<br />
refrigeration supply can be recommended for<br />
systems with ice outputs of more than 7 tons in<br />
24 hours.<br />
Central refrigeration supply with brine as<br />
refrigeration agent (warm brine and cold<br />
brine)<br />
The ice making systems of the <strong>Mega</strong>-<strong>Line</strong> product<br />
range can be operated with liquid brine as<br />
the direct refrigeration agent. The use of brine<br />
as a refrigeration agent is particularly useful,<br />
when an entire building complex is supplied<br />
with brine for refrigeration. When planning an<br />
ice making system in which brine is used as the<br />
refrigerating agent, the temperature levels and<br />
flow rates of the brine units must be determined<br />
prior to installation in agreement with<br />
<strong>WESSAMAT</strong>, so that a continuous ice production<br />
and therefore also the full ice output can<br />
be reached.
Innovative technology.<br />
First-class quality.<br />
The decision for an ice making system from the<br />
<strong>Mega</strong>-<strong>Line</strong> product range is a decision for a highquality<br />
product “Made in Germany”. The symbiosis<br />
of innovative technology, high-quality materials<br />
and long-standing experience guarantee<br />
top quality and the highest possible degree of<br />
performance and reliability. For this, the individual<br />
requirements of the customers are taken into<br />
consideration from planning through to aftersales<br />
service, and quality is produced through<br />
to the smallest detail. Powerful machinery and<br />
first-class technicians ensure excellence in development,<br />
construction, production and service.<br />
The prerequisite for this is the use of hygienically<br />
perfect drinking water, whose total hardness<br />
should not exceed 8°dH (German hardness levels).<br />
For drinking water with a higher degree of<br />
hardness, the use of pre-treated (softened)<br />
drinking water is required to ensure continuous<br />
operation and production of crystal-clear ice<br />
cubes and sparkling crushed ice.<br />
When it comes to production, use and marketing<br />
of ice cubes, people often forget that this<br />
foodproduct must meet the highest requirements<br />
and hygiene regulations. Therefore the<br />
compliance to hygienic standards must be<br />
ensured for production, storage and filling.<br />
The machines and systems developed by<br />
<strong>WESSAMAT</strong> as well as the automatic control and<br />
monitoring units in conjunction with regular<br />
maintenance and hygienic cleaning ensure that<br />
the quality of ice cubes and crushed ice is as it<br />
should be.<br />
Before final assembly, the output of the<br />
ice making system is checked and<br />
documented in the test field.<br />
(Figure above)<br />
Before delivery, all functions of the<br />
system components are checked within<br />
the framework of the quality control.<br />
(Figure below)<br />
13<br />
Competent advice.<br />
Customised solutions.<br />
The concept of a customer-oriented <strong>Mega</strong>-<strong>Line</strong><br />
ice making system begins with the competent<br />
consultation and a detailed requirement analysis.<br />
For this, the individual requirements of the<br />
customer and the specific conditions at the<br />
place of installation are taken into consideration.<br />
The effective combination of the various<br />
system components for ice making, cooling,<br />
refrigeration supply, storage, filling and packaging<br />
requires extensive know-how and practiceoriented<br />
experience in the planning, conception,<br />
production and installation of high-performance<br />
ice making systems.<br />
If you are interested in a powerful ice making<br />
system for private use or for the marketing of ice<br />
cubes and crushed ice, <strong>WESSAMAT</strong> is guaranteed<br />
to be your competent partner. Together<br />
with you, we plan a tailor-made solution for<br />
your project, which exactly matches your<br />
requirements. For your inquiry and an initial<br />
basic price quotation, please use the requirement<br />
analysis “<strong>Mega</strong>-<strong>Line</strong>” (available as an<br />
Internet download at www.wessamat.de) or let<br />
one of our application specialists advise you.<br />
In cooperation with internationally active planning,<br />
refrigeration and refrigeration logistics<br />
companies, <strong>WESSAMAT</strong> has realised numerous<br />
large-scale projects for bulk consumers, ice factories<br />
and renowned airlines and airline catering<br />
companies (e.g. LSG Sky Chefs, Gate<br />
Gourmet, Emirates Flight Catering in Dubai and<br />
Air Algérie in Alger) with ice outputs of up to a<br />
total of 80 tons in 24 hours. Not everyone can<br />
do that – but we can do it anywhere! In<br />
Germany. In Europe. World-wide.<br />
The high-performance and complex ice making<br />
systems of the <strong>Mega</strong>-<strong>Line</strong> product range are<br />
planned in agreement with the customer.<br />
(Figure above)<br />
The entire system is designed and the<br />
construction drawings compiled on the basis of<br />
a detailed requirement profile. (Figure below)
<strong>WESSAMAT</strong> <strong>Eismaschinenfabrik</strong> <strong>GmbH</strong><br />
Kaiserslautern factory<br />
12/2008<br />
www.wessamat.de<br />
<strong>WESSAMAT</strong><br />
EISMASCHINENFABRIK GMBH<br />
Marie-Curie-Str. 1 · 67661 Kaiserslautern/Germany<br />
Phone: +49 63 01-79 10 0 · Fax: +49 63 01-79 10 20<br />
e-Mail: perfect-ice@wessamat.de