Self-Stacking Spiral Freezer Line: High-Capacity Food Processing
Custom configuration. Commissioned 2023–2025. Reference performance data available.
Self-Stacking Spiral Freezer
Square’s self-stacking spiral freezer is a compact and hygienic freezer design. Compared to the traditional low-tension spiral freezer, the self-stacking spiral freezer eliminates the rails supporting the belt, which means up to 50% more freezing output with the same footprint.
The conveyors are almost 100% accessible for cleaning thanks to the elimination of the belt rail and drum. The freezer has combined the state-of-the-art clean-in-place (CIP) system.
This open and accessible structure improves hygiene, minimizes downtime for maintenance, and prolongs equipment lifespan by preventing waste accumulation.
Customized to client specifications
Capacity ranges from 300kg to 5000kg/hr
Efficient, Energy-Saving, Easy Cleaning
Product Features
Why Choose Square's Self-Stacking Spiral Freezer
Explore the original product feature overview, including Self-Stacking Belt, Self-contained Freezing Zone, Efficient Evaporator, and the key technical advantages behind this system.
Self-Stacking Belt
Our self-stacking spiral freezer features a self-stacking belt, chain-driven system, and vertical airflow.
The food can be frozen in a shorter time and better quality. The self-stacking spiral freezer meets the highest hygiene and energy-efficiency standards.
The self-stacking belt is driven by a chain system and operates completely on rolling balls. The resistance and noise caused by running the chain are reduced, so smaller motors can drive the system.
The belt is not in tension in the run. The belt is less likely to be stretched and deformed. Self-stacking belt stacks on the top of each other’s side links.
This self-stacking feature eliminates the rails supporting the belt.
Self-contained Freezing Zone
The unique belt design contains the product in a self-contained freezing zone, for gentle and uniform handling and superior hygiene.
The vertical airflow of high velocity touches the product through all stacks, providing an even, quick, efficient freezing result.
The special holes on the side links also introduce cold air into the product zone and create turbulence. This provides uniform product temperature across the belt and increases the heat-exchanging efficiency.
The centrifugal fans on the top of the coil suck the cold air from the coil and push the high-velocity air down through all belt tiers.
Efficient Evaporator
The design was simulated with European professional heat exchanger software.
All tubes are expanded hydraulically rather than mechanically. More uniform expansion and tighter fit between tube and fins. Improved heat exchanging performance.
Variable fin pitch is used to delay the frost formation on the fin surface. Longer frosting interval.
Easy access and cleaning
Tube material: Stainless steel, Aluminum
Fin material: Aluminum
ADF System
The ADF system blows pulses of pressurized air of high velocity repeatedly over the evaporator fins to remove the frost while the products continue to run in the freezer.
The heat transfer efficiency is significantly improved. Air Defrosting can extend production runtime by 150 to 200% by eliminating frost buildup on the evaporator.
Multiple Automatic Cleaning Systems
The design eliminates the belt-supporting rails and cages. It is hygienic and easy to clean.
The self-stacking freezer provided multiple automatic cleaning systems. They are PZC, PZE, and CIP. PZC cleans the product zone that is in direct contact with the product.
PZE cleans the product zone and coil. CIP is the full mode. It cleans product zones, coils, enclosures, and structures.
The systems have multiple cleaning programs for customers to choose from, including lathering, rinsing, disinfectant spraying, and belt drying.
The self-stacking freezer is ideal for quick freezing of fried food, ready meals, and pastries.
Insulated Enclosure
Continuous PIR panel fabrication line from German Hennecke. 50mm to 250mm thick. Limited combustibility.
A fully welded stainless steel enclosure is available as an option.
Fully Welded Floor
Modular stainless steel fully welded floor, leakproof. Sloped floor, fast drainage through four drains at the corners. Easy Access.
Intelligent Control System
PLC touch screen, friendly interface, easy operation.
Real-time display of equipment running status,
temperature of each area, and fault alarm.
Preset freezing programs tailored for different products.
Technical Specifications
Parameters
Custom dimensions, capacity, and configuration matched to your production requirements.
| Configuration | Self-stacking spiral — drumless, belt self-stacks on side rails |
|---|---|
| Tiers | 6 – 30 |
| Belt width | 600 – 1,400 mm |
| Insulated enclosure | PIR / PU, stainless steel skin both sides, optional fully welded interior |
| Infeed / Outfeed height | Low-level (~900 mm from floor) — direct conveyor integration |
| Refrigerant | NH₃ (Ammonia) / CO₂ / Freon — pump-recirculated or DX |
| Evaporator | Aluminium / Stainless steel tube, aluminium fin, variable fin pitch |
| Defrost | Water / Hot gas / ADF (Air Defrost System) |
| Freezing time | Stepless variable frequency adjustable (typically 10–45 min per product spec) |
| Cleaning | Manual / Belt washer / CIP (Cleaning-in-Place) — programmable |
| Typical lead time | 14–18 weeks (custom-engineered configuration) |
| Design life | 15+ years (structural); 8–10 years (belt, normal operation) |
Design Details
How Each Subsystem Is Engineered
Expand any section below for the engineering approach behind each critical subsystem — with links to detailed Technology pages.
Drumless Technology Advantage
The defining feature of the self-stacking spiral is the elimination of the central drum. In a conventional spiral, the belt wraps around a large rotating drum that occupies ~30% of the enclosure interior volume. By removing the drum and letting the belt stack on itself via side rails:
- 20–30% more belt length per m² of factory floor space
- Airflow is unobstructed — cold air reaches product from both sides
- Full interior access for cleaning and maintenance
- Simpler mechanical design with fewer moving parts
IQF-Optimized Airflow
The self-stacking design is inherently IQF-friendly. Without a drum blocking the center of the enclosure, cold air can be directed across the full belt width from both sides:
- Dual-direction airflow ensures every piece on the belt receives uniform cold air
- CFD-optimized baffle design minimizes air velocity variance
- Adjustable dampers compensate for product loading density
- Product dehydration kept ≤ 0.5% for IQF applications
Belt Technology & Self-Stacking Mechanism
The belt carries integrated side rails (wear strips) on both edges. As the belt completes each tier, the side rails of the new tier rest precisely on the side rails of the tier below. The entire stack is supported from the base — no drum, no central structure.
- SUS304 stainless steel belt with integrated side rails
- Self-aligning stack — belt tracking sensors ensure precise tier registration
- Friction drive at base tier provides smooth, low-tension belt movement
- Proven in 500+ installations worldwide
Defrost Strategy
Three defrost methods available, selected per your production schedule and refrigerant:
- ADF (Air Defrost System) — Pressurized air pulses clear evaporator ice while production continues
- Hot Gas Defrost — Reverses refrigerant flow; fastest cycle (8–12 min)
- Water Defrost — Warm water spray; simple and reliable
Automation & Control
Siemens PLC standard with HMI touchscreen. Real-time monitoring: zone temperatures, belt speed, fan status, evaporator performance. Recipe storage for 50+ products. Optional VPN remote diagnostics — Square engineers troubleshoot ~70% of issues without on-site visit.
Proven in These Food Applications
IQF Vegetables
IQF Fruits
IQF Seafood
Poultry Pieces
Potato Products
Frequently Asked Questions
Yes. The Air Defrost (ADF) system continuously removes frost during operation, extending run time by 150–200% compared to conventional evaporators.
Yes. Most modern Carton Freezers support integration with automatic conveyors, AGVs, and palletizers for efficient material handling.
We own CE, EAC, INF, CNAS, ISO, ASME, PED, U2, CSA, CRN certifications and 300+ patents, as well as 350+ engineers. Square vertically integrated production ensures quality control from raw materials.
Square offers customized one-stop cold chain solution that meets your requirements. We provide fully customized models with freezing capacities ranging from 300kg/h to 5000kg/h depending on your product and layout, and your demand of tailor-made designs, including belt width, number of tiers, enclosure material (PIR, PU, SS), and specific infeed/outfeed requirements.
It offers up to 50% more output in the same footprint, easier cleaning, reduced maintenance, and superior hygiene due to the open structure and no belt-support rails.
Case Studies
Self-Stacking Spiral Freezer installations in operation worldwide
Real production lines with performance data — not renderings, not claims. Each installation documented with commissioning data.
Real production lines with performance data — not renderings, not claims. Each installation documented with commissioning data.
Self-Stacking Spiral Freezer for Prepared Food Production Line
Energy-efficient configuration. Full production data available upon request.
Engineering Inquiry
Self-Stacking Spiral Freezer installations in operation worldwide
The more detail you provide, the more precise our engineering response. An engineer — not a sales representative — will review your requirements.
We typically respond within 1–2 business days. Your information is kept confidential.