AIRMASTER® IC InterCooler is the latest addition to the REICH family. It is a genuine hybrid unit and combines the functions of a universal unit (UK series) with those of an intensive cooling system (IKK series). Consequently, all thermal processes can be realised in a single system, in particular also intensive cooling processes.
It works with vertical airflow and is perfect for hanging products and is also suitable for lying products with the loading capacity adapted. IC InterCooler systems can be supplied in all desired sizes from 1 to 14 trolleys in single or double-row versions.
The possible applications of the AIRMASTER® IC InterCooler are almost unlimited. Not only are the traditional applications of warming, drying, smoking, cooking, roasting, hot-air cooking, etc. possible, so are all the cooling processes from constant rinsing and interval rinsing (with and without fine atomisation) and high quality intensive cooling. For example, the production of sausages in natural gut becomes child's play as a result, and promises a succulent and firm end product in the shortest time.
What makes the InterCooler so unique?
A downstream intensive cooling system is needed whenever a product has to be cooled to the packing temperature after cooking, and this has to be done efficiently, gently and microbiologically safely. Various possibilities are available for this:
- Separated systems, i.e. universal unit(s) (UK series) and separate intensive cooling system(s) (IKK series)
- Or semi-continuous systems comprising two zones, which are separated by a separating door and are connected by a semi-automatic transport system. The drawbacks here are the high transport costs, the lack of flexibility, workload gaps (in most cases smoking/cooking times and cooling times are not the same, which means that sections of the system are sometimes empty), along with high maintenance and repair costs for the transport systems and zone separating doors.
- Or a HYBRID system like the AIRMASTER® IC InterCooler, which combines the functions of both systems without the disadvantages of the semi-continuous systems.
REICH has taken this path very successfully with the new AIRMASTER® IC InterCooler, which is now in series production. REICH is thus offering the first range of series units on the market to have these abilities.
Many equipment options of the AIRMASTER® UK series are already included as standard in the AIRMASTER® IC series, for example the smooth controls of the ventilator motors by means of frequency inverters, the Interlock System, the cool rinse with fine atomisation ECO Boost and the automatic door opening. Naturally there is integrated, fully-automatic CIP cleaning. Other available equipment options ensure that you can configure your unit precisely according to your specific requirements.
Unit Description
The design of the AIRMASTER® IC InterCooler systems is based on a modular kit system. Components such as controls, smoke generator and cleaning system can be arranged individually according to your desires or spatial requirements.
Depending on the unit size, the chamber housing of AIRMASTER® IC InterCooler comprises one or more chamber modules. Each chamber module is very sturdy and is made of 100 % chromium-nickel steel, material no. 1.4301, and is welded to be smoke and steam-tight. Mineral full insulation (temperature-resistant up to +650°C) protects against heat losses. Importance was attached to avoiding thermal bridges in the construction of the unit.
The top section of each chamber module contains the air preparation unit with ventilator, heat battery and intensive cooling. The greatest advantage of this modular system compared to systems with a central unit is that each chamber trolley is supplied exactly the same with air, heat or cold energy and therefore absolute consistency is also ensured from trolley to trolley.
Added-value from modular design:
- Same results in all trolleys
- Tightly welded chamber modules
- Fully stainless steel 1.4301
- Mineral full insulation
- No uninsulated housing parts
- Small width and height
- Low-maintenance and reliable
- Particular stability and service life
The AIRMASTER® IC InterCooler works with the proven vertical airflow principle. The air, which has been treated in the upper section, flows around the products from bottom to top. A newly developed blowing system guarantees that the products are treated consistently and in the shortest time in all positions of the chamber trolley.
Upon request, REICH systems can be equipped with vertical airflow and alternating flaps. This FlexFlow system allows for variable airflow supply into the treatment chamber. Different flap positions generate highly turbulent airflows and move the air breakpoint over different areas of the trolley. This is an advantage for products that lie flat or for densely loaded trolleys, to achieve much more equal product treatment.
Following advantages are achieved:
- Improved uniformity
- Shortened process times
- Increased yield through reduced weight losses
- Increased trolley loadings
- Improved energy efficiency
Compared to the competition, REICH systems work with particularly strong ventilators, thereby achieving more output and efficiency. Compared to the UK series, the circulating air volume has been increased again in the IC series.
More output:
- Highest air volumes
- Short, energy-efficient processes
- Maximum yield
- Greatest possible consistency
- Best product quality
- High load capacity
Only high quality products from German brand manufacturers are used for all heavily used parts such as motors, ventilator impellers,valves, cylinders, etc. In this way we ensure that the highest quality and reliability are achieved in detail.
Each AIRMASTER® has a robust chamber floor. Packing with heavily loaded chamber trolleys is not a problem. In a special version, packing is also possible using forklifts. The floor construction is kept very flat and has a sloped entrance. The substructure of the chamber floor is reinforced in the direction of travel with strong U profiles.
All AIRMASTER® systems are fitted with one or more fully insulated, stable block doors, which are sealed against the chamber housing all the way around with a silicon seal. The door hinges are made entirely from chromium-nickel steel for the high demands of seal and long service life. The door stop can be fitted left or right as required.
For fresh air, exhaust and smoke flaps, tight-closing, metallic folding flaps or silicon rubber rotating flaps are used. These flaps have multifunctional positions for controlling the amount of the volume flows.
The systems can be fitted either with electric heating or steam heating.
Transit design
The system's rear module is designed with a door portal and a sturdy block door, corresponding with the front side, to unload the trolley in hygiene areas. A display system on both sides of the chamber informs you about the current operating status.
Interlock system
Included with the AIRMASTER® IC InterCooler.
Attached to the front module of the unit is a fully-insulated block door on solid stainless steel hinges combined with the newly-developed REICH interlock system. This system with its smart opening and locking mechanism automates numerous dehydrating and freezing processes whilst complying with international requirements for hygiene and food safety. With the transit version units, no unit can be entered from both sides at the same time. In this way, contamination of the goods can be avoided (separation of Low-Risk and High-Risk side). In addition, integrated eye-level signal lamps provide information on the current operating state of the unit.
High temperature version
An additional electric heating allows temperatures up to 200 °C.
Automatic door opening
Included with the AIRMASTER® IC InterCooler.
The chamber door is automatically opened using a pneumatic cylinder before cooling (rinsing) or after the end of the program.
Cool rinse with optional fine atomisation (ECO-Boost)
Included with the AIRMASTER® IC InterCooler.
The cooling rinse is made of high-quality chromium-nickel steel pipes and is fitted with special nozzles to cool the product consistently. Control of the shower is facilitated via a solenoid and can be run continuously or in intermittent mode. Fine atomisation of the cooling water using the ECO-Boost function reduces the cooling times by up to 30 % and reduces water consumption by 50 % at the same time.
Viewing window with chamber lighting
Each block door can be optionally equipped with the viewing window measuring 900 x 900 mm made of insulating safety glass. Optimum illumination is ensured in the chamber when the interior lighting is switched on. You can visually check your products at any time and react quickly if required.
Lifting gate
The UK unit can be provided with a pneumatically driven lifting gate as an additional option. REICH is thereby reacting to the wishes and requirements of industrial companies. The advantages of such a solution in limited spaces are obvious.
Pump unit cleaning station
Cleaning station and pressurising pump for connecting the cleaning system to an AIRMASTER® unit:
- Large cleaning container manufactured from solid chromium-nickel steel, mat. no. 1.4301
- 200 or 330 litre capacity
- Acid-resistant pressure increase pump with dry run protection
- Automatic water supply with level control
- Recommended for locally low or variable water pressure
ECOMIZER
Energy is a resource that is becoming increasingly expensive. Energy-saving and therefore environmentally friendly solutions are therefore more in demand than ever before. At REICH we have set ourselves the challenge. One result of this development is the REICH ECOMIZER. This modern fresh-air enthalpy system optimizes the drying of the product via the intake fresh air. A sensor constantly measures the climatic data of the external air and sends this to the controls. With suitable external air conditions, the cooling is only needed to temper the circulating air and no longer for drying. The REICH ECOMIZER thus provides a massive potential for saving energy.
| AIRMASTER® IC InterCooler | 2500 | 5000 | 7500 | 10000 | 12500 | 15000 | 17500 | 20000 | 22500 | 25000 | 27500 | 30000 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Number of trolleys | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 |
| Chamber length [mm] | 1200 | 2290 | 3375 | 4460 | 5545 | 6630 | 7715 | 8800 | 9885 | 10970 | 12055 | 13140 |
| Chamber width [mm] | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 |
| Chamber height [mm] | 2840 | 3000 | 3000 | 3000 | 3000 | 3000 | 3000 | 3000 | 3000 | 3000 | 3000 | 3000 |
| Minimum room height [mm] | 3300 | 3620 | 3670 | 3770 | a. Anfr. | a. Anfr. | a. Anfr. | a. Anfr. | a. Anfr. | a. Anfr. | a. Anfr. | a. Anfr. |
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