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  • How Does a Blast Chiller Work?

    How Does a Blast Chiller Work?

    Blast chillers are a rising player in catering services, the confectionery sector, and the food and beverage industry in general. They help retain the quality and nutritional value of food. The blast chiller market revenue is expected to cross $2 billion by 2027.

    But what exactly are blast chillers? How do they work, and how can they help your business in your efforts to Forge Forward as market trends and consumer expectations continue to evolve? Keep reading to learn more.

     

    What Does a Blast Chiller Do?

    Blast chillers are quite straightforward. These electronic appliances help lower the temperature of food quickly and are therefore also called flash freezers or blast freezers. Blast chillers work by blowing cool air over any food or beverage placed inside them.  

    In addition to the food and beverage industry, blast chillers have also proven to be in high demand within the medical industry. They are used to preserve the quality of vaccines and other medical essentials when they aren’t scheduled for use yet. 

     

    How Are Blast Chillers Different from Freezers?

    Blast chillers are used for food that requires frozen packaging or food that needs to be cooled quickly. They typically have various settings that allow them to rapidly cool down something regardless of its initial temperature — hot, warm, chilled, or cold.

    They typically come with multiple shelves that conveniently hold food pans and even sheet pans that need to be chilled or stored at extremely low temperatures.

    Commercial freezers can also keep food products frozen for an extended period. However, they fall short when it comes to rapidly freezing food.

     

    What Are the Benefits of a Blast Chiller?

    Blast chillers do more than freeze food instantly and for a prolonged period. The rapid freezing process prevents large ice crystals from forming and affecting the flavor and quality of the products. It also locks in nutrients and vitamins and reduces bacterial growth.

    Here are the key benefits of using a blast chiller:

    • Prevent bacteria and microorganisms from forming on pre-cooked food
    • Maintains the moisture content of all kinds of food products, from meats to vegetables, maintaining their integrity
    • Locks in the freshness and flavor of food
    • Retain nutrients 
    • Ensures food safety standards are met
    • Streamlines and quickens the food prep process
    • Extend the shelf life of food products

    Many chefs, particularly those specializing in desserts, invest in high-quality blast chillers that help cool down food products quickly minus the formation of ice crystals.

    How Do Blast Chillers Help Avoid Food Contamination?

    The food industry is well aware that any food product that stays within the 41°F to 135°F temperature range for too long is prone to contamination. Any food product that has spent four consecutive hours within this temperature range must be thrown away for food safety purposes and to prevent food poisoning.

    In addition, the FDA has set strict limits on how quickly heated or semi-cooked food must be cooled if they are meant to be stored or frozen. Hazardous bacteria can form on such food if the cooling process takes longer than prescribed. 

    Blast chillers solve that problem by cooling food products fast enough and lowering the temperature of pre-cooked food heading for storage, preventing bacterial contamination. 

     

    Adapt to the Evolving Needs of Consumers

    At nexAir, we ensure you have the right knowledge and equipment to take your business to the next level. Rely on our KnowHow to help you Forge Forward or contact us for more information.

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    Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.

    The Hidden Costs of Gas-Related Downtime

    When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:

    • Production rescheduling that disrupts carefully optimized sequences
    • Rush shipping fees to meet customer deadlines despite delays
    • Quality inconsistencies when processes restart after interruptions
    • Overtime costs to catch up after unplanned stoppages
    • Reputation damage when delivery commitments are missed

    For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.

    From Reactive to Proactive: The Supply Continuum

    Most facilities follow a predictable pattern in their gas management evolution:

    Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.

    Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.

    Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory. 

    Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.

    Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.

    Customizing Solutions for Maximum Uptime

    Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:

    • For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
    • For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
    • For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
    • For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.

    This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.

    Beyond Traditional Supply: Integrated Services for Total Reliability

    Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:

    Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions

    These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.

    Measuring Success: The Results That Matter

    The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:

    Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability

    These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.

    Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.

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