Butternut Box – spiral freezer for pet food in pouches

The Customer

Butternut Box is on a mission to “put the food back into dog food”, using freshly prepared human-quality meat and vegetables for the nation’s much loved pets. The premium pet food brand has a 5-year business growth plan to double sales year on year.

The Requirement 

A move into a recently acquired industrial unit measuring over 150,000 sq.ft enabled Butternut Box to invest in the latest technology as the business continues to grow. When it came to expanding production capacity and upgrading its entire static freezing system, Butternut Box selected Starfrost to provide a turn-key cooling solution.

The Solution

Starfrost implemented an end to end cooling solution for Butternut Box that has delivered benefits of energy efficiency and improved product quality. A Double Helix spiral freezer was designed, manufactured and installed for Butternut Box that operates using an ammonia refrigeration plant supplied by parent company Star Refrigeration.

The spiral freezer system has been designed to freeze c.4000kg per hour of vacuum packed dog food pouches, which has assisted Butternut Box in doubling its processing capacity. The automated spiral freezer provides a continuous freezing solution that has allowed Butternut Box to significantly reduce freezing times and improve the quality of its freshly prepared products.

The Double Helix spiral freezer operates with two separate temperature zones which significantly reduces the total number of kW’s of low temperature refrigeration Butternut Box require to freeze the produce. This reduces the overall operational cost of the refrigeration system and emits less carbon into the atmosphere, whilst improving quality of the packaged products.

Marco Attanasio, Head of Strategic Projects at Butternut Box:

“Our new spiral freezer and refrigeration plant has assisted the business with doubling production this year. The design specification also supports our overall growth plans allowing for future expansion. Since the installation of our new freezing equipment, we have considerably reduced our freezing times in comparison to the static freezers that were used before and the method of freezing is consistent which has greatly improved the quality of our end product.”

Butternut Box – spiral freezer for pet food in pouches
Client: Butternut Box
Sector: Food Manufacturing
Service: Plant Upgrades & Replacements
Refrigerant: Ammonia

Butternut Box – spiral freezer for pet food in pouches