12,000 m³ seafood cold storage & blast freezer — Vietnam
An export-grade seafood processor needed a multi-temperature facility combining IQF tunnels, blast freezers and long-term storage to meet EU/Japan buyer requirements.
Challenge
- Existing facility could not blast-freeze shrimp fast enough for export specs.
- Energy costs rising 14% year-on-year on R22 plant nearing end-of-life.
- HACCP and BRCGS audit gaps on temperature traceability.
ColdMatch solution
- ColdMatch sourced 3 shortlisted EPCs from Korea, Italy and Vietnam.
- Selected NH₃/CO₂ cascade plant with IoT monitoring (logger + cloud).
- Phased construction allowed processing to continue during build.
“ColdMatch handled the EPC tender across three countries — the savings paid for the upgrade in under four years.”
How this project was delivered — planning to commissioning
Multi-country EPC tender, phased construction on a live site. Total programme: 19 months, concept to full production.
- 1
Planning & feasibility
Months 1–4- Throughput study across shrimp, pangasius and value-added lines, including seasonal peaks.
- Heat-load and freezing-curve modelling to size blast capacity against export specifications.
- Capex and operating-cost case built for three plant architectures before any supplier contact.
Milestone: Approved technical brief and budget envelope signed off by the board.
- 2
Permitting & approvals
Months 4–7- Provincial construction and industrial-zone approvals for the extension footprint.
- Ammonia handling permit, safety distance study and emergency response plan.
- Environmental discharge and refrigerant registration filed with the authorities.
Milestone: Construction permit and ammonia safety approval issued.
- 3
Procurement & build-out
Months 7–15- Three shortlisted EPCs from Korea, Italy and Vietnam tendered on one common specification.
- Panel envelope, NH₃/CO₂ cascade plant room and IQF tunnels installed in two phases.
- Processing kept running throughout by sequencing the works around production windows.
Milestone: Mechanical completion of both phases with the plant charged and leak-tested.
- 4
Testing & validation
Months 15–18- Pull-down and freezing-curve testing against contractual blast-cycle times.
- Temperature mapping of every chamber, loaded and unloaded, across 72-hour cycles.
- HACCP and BRCGS traceability evidence assembled from the IoT logger platform.
Milestone: Performance guarantees verified and audit pack accepted.
- 5
Commissioning & handover
Months 18–19- Operator training on plant control, alarm response and defrost strategy.
- Spares package, service contract and remote monitoring handover.
- 12-month energy benchmark baseline agreed with the operator.
Milestone: Facility handed over in full production with warranty and service plan active.
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.