Client
ASF Food Manufacturing Company
Industry
Seafood & Frozen Foods Processing
Challenge
Excess moisture after washing and sanitizing caused product contamination risks, longer drying times, and packaging inefficiencies.
Background
A leading seafood and frozen food processing company faced recurring production inefficiencies due to prolonged drying times in their post-wash and pre-packaging stages. The company handled a wide range of seafood products fish fillets, prawns, and shellfish that required rapid and hygienic drying after washing and sanitization to maintain product quality and meet export hygiene standards.
Despite using conventional air blowers, the results were inconsistent; residual moisture on trays, crates, and packaging surfaces led to bacterial risks, compromised sealing quality, and delays in packaging throughput.
To resolve these challenges, they partnered with Nexgen Machines to integrate its advanced Air Knife Drying System, a fully automated, high-velocity air drying solution designed for precision drying in hygienic food processing environments.
Challenges
Inefficient Drying
Traditional blowers left water droplets on trays and seafood surfaces, leading to poor product presentation and sealing failures during packaging.
High Downtime
Extended drying cycles slowed overall production flow, reducing packaging line efficiency.
Contamination Risks
Residual moisture in crates and on packaging materials created conditions for microbial growth, threatening product safety and shelf life.
High Energy & Labor Costs
Manual intervention and repeated drying cycles increased operational expenses and reduced output consistency.
Solution: Nexgen Air Knife Drying System
Nexgen Hygiene Systems deployed a custom-engineered Air Knife Drying System tailored for seafood processing. The system was designed to ensure efficient moisture removal from washed seafood products, trays, and packaging surfaces before moving to the sealing and freezing zones.
Key Features:
High-Velocity Air Jets
Direct, uniform air flow across all surfaces for instant moisture removal without damaging delicate seafood.
Adjustable Airflow Control
Optimized drying intensity for different products like prawns, fillets, and packaged seafood.
Stainless-Steel Hygienic Design
Constructed with food-grade stainless steel, ensuring full compliance with hygiene and food safety standards.
Energy-Efficient Blowers
Uses efficient centrifugal blowers that deliver powerful drying with significantly lower energy consumption than traditional dryers.
Modular Integration
Seamlessly fits into existing conveyor lines, allowing continuous operation without disrupting production.
Implementation
- Phase 1 – Site Assessment:
Nexgen’s engineering team conducted an on-site evaluation to identify high-moisture bottlenecks in the packaging area and mapped optimal airflow paths for maximum efficiency - Phase 2 – System Design & Installation:
Custom air knives were installed along their conveyor system at critical points post-wash and pre-packaging. The system was calibrated to provide high-velocity airflow for rapid moisture removal while maintaining product integrity. - Phase 3 – Operator Training:
Staff were trained on safe operation, daily maintenance, and adjusting air pressure for varying batch sizes and product types. - Phase 4 – Performance Optimization:
Nexgen provided post-installation audits and fine-tuned the system’s airflow and positioning to ensure consistent drying efficiency across all product types.
Results
60% Reduction in Drying Time
Rapid and uniform drying significantly increased line throughput and reduced bottlenecks.
Zero Contamination Incidents
Improved moisture control led to cleaner surfaces and eliminated microbial growth risks.
30% Energy Savings
Replacing heat-based dryers with high-efficiency air knives reduced overall power consumption.
Improved Packaging Quality
Dry, residue-free trays and products improved sealing consistency and export quality standards.
Enhanced Worker Efficiency
Minimal manual intervention freed operators for quality checks and production oversight.
Client Testimonial
“Nexgen’s Air Knife Drying System has completely transformed our production flow. Drying that used to take several minutes per batch now happens almost instantly. The hygiene standards have improved, and our packaging process runs smoother than ever before”
– Production Head, Leading Food Processing Company
Conclusion
By implementing Nexgen’s Air Knife Drying System, the food processing company achieved faster, cleaner, and more efficient drying throughout its seafood processing line. The solution eliminated moisture-related issues, improved product hygiene, and increased production capacity, all while lowering operational costs.
Facing similar drying or contamination challenges? Contact Nexgen Machines today to discover how our Air Knife Drying Systems can optimize your processing line for speed, hygiene, and reliability.
Note:
For confidentiality reasons, the actual name of our client has not been disclosed in this case study. Instead, we have used the name “ASF Food Manufacturing Company” to represent the project. The insights, challenges, and results shared here are based on a real industrial application of Nexgen Hygiene Systems’ Air Knife Drying Technology. This approach allows us to maintain client privacy while showcasing the measurable impact of Nexgen’s solutions in improving hygiene, efficiency, and production performance in the food processing sector.