Integrated meat processing & cold storage — Brazil
Beef exporter expanding capacity for halal and EU markets needed an integrated chilling, blast freezing and frozen storage line.
Challenge
- Throughput target: 280 t/day chilled, 120 t/day blast.
- Power constraints required peak-shaving via thermal storage.
- Halal segregation and EU traceability in one facility.
ColdMatch solution
- NH₃ central plant with ice-bank thermal storage.
- Conveyorised blast tunnels with automated retraction.
- ColdMatch-managed tender across 5 international EPCs.
How this project was delivered — planning to commissioning
Integrated process + refrigeration EPC with staged energisation. Total programme: 24 months, concept to export throughput.
- 1
Planning & feasibility
Months 1–5- Throughput modelling for 280 t/day chilled and 120 t/day blast capacity.
- Grid capacity study and thermal-storage peak-shaving strategy.
- Halal and EU segregation designed into the product flow and hygiene zoning.
Milestone: Process flow and refrigeration concept frozen for tender.
- 2
Permitting & approvals
Months 5–10- Federal inspection service and EU establishment approval requirements mapped.
- State environmental licence covering effluent, refrigerant and noise.
- Utility connection agreement negotiated with the local distributor.
Milestone: Environmental licence and export establishment pathway confirmed.
- 3
Procurement & build-out
Months 10–20- Chill halls, two blast tunnels and frozen storage built in a single civil programme.
- Central ammonia plant with thermal storage installed and staged for partial energisation.
- Hygiene-critical finishes, drainage and dock equipment installed under supervision.
Milestone: First chill hall energised while the freezer package continues.
- 4
Testing & validation
Months 20–23- Chilling and blast curves verified against contractual throughput per shift.
- Peak-demand testing to confirm thermal storage holds the site inside its grid limit.
- Traceability and segregation audit rehearsals for EU and halal certification.
Milestone: Throughput and demand guarantees demonstrated over sustained runs.
- 5
Commissioning & handover
Months 23–24- Shift-team training on plant operation, defrost and emergency shutdown.
- Maintenance regime, spares and refrigerant management plan handed over.
- Ramp-up plan to full export volume agreed with the operator.
Milestone: Plant released to production and certification audits scheduled.
This project sits under the Develop a Food Processing Cold Chain objective. Start from the objective hub to scope capacity, permitting and budget before engaging suppliers.