On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: F***R Berries Group
Country: Republic of Chile
Region: Maule Region – Core agricultural area in central Chile, Mediterranean climate at the foot of the Andes, primary production area for blueberries and strawberries in the southern hemisphere
Core Products: Freeze-dried blueberries, dried blueberries, freeze-dried strawberries, dried strawberries, mixed berry snacks
Equipment Configuration: Hadof customized vacuum freeze-drying production line (with integrated hot air drying module and low-temperature sugar infusion system)
Commissioning Date: Q3 2023
Chile is one of the world's largest blueberry exporters and a key producer of strawberries in the southern hemisphere. F***R Group, based in the Maule Region, benefits from berry farms irrigated by Andean snowmelt. The harvest season for blueberries and strawberries runs from December to March (austral summer). Historically, 90% of the group's berries were exported fresh via cold chain air freight to North America, Europe, and Asia. However, this traditional model faced severe challenges.
Fresh Fruit Loss & Grade B Predicament: Export standards for fresh berries are stringent – blueberries must be >14mm with intact bloom; strawberries require uniform color and no bruising. Annually, 20%-25% of berries are classified as "Grade B" due to slightly smaller size, minor skin blemishes, or harvest damage. These were sold cheaply to local markets or juice factories, representing a huge waste.
Traditional Sun-drying Unsuitable for Berries: Blueberries and strawberries have 85%-90% moisture and a natural waxy cuticle. Sun-drying is slow, susceptible to mold from coastal fog ("camanchaca"), and direct sunlight degrades heat-sensitive nutrients like anthocyanins and vitamin C (studies show 40%-60% anthocyanin loss after 4 hours above 35°C).
Soaring Global Demand for Healthy Snacks: North American and European consumers increasingly demand high-antioxidant, additive-free freeze-dried berries and natural dried fruit. F***R urgently needed deep processing capacity to transform low-value Grade B fruit into high-value healthy foods.
The client's requirements were precise: maximize retention of blueberry anthocyanins and natural strawberry aroma, products must be additive-free and all-natural, while adapting to central Chile's relatively stable grid but high energy costs.
After comparing US and Australian equipment, F***R Group ultimately chose our company. Our advantage lay in developing a specialized vacuum freeze-drying process combined with low-temperature sugar infusion, tailored for thin-skinned, juicy berries rich in heat-sensitive nutrients.
Solution: Three Custom Designs for Andean Foothill Berry Characteristics
1. "Vacuum Freeze-Drying + Anthocyanin Protection" System
Targeting the heat-sensitive anthocyanins and vitamin C in blueberries and strawberries, we employed advanced vacuum freeze-drying technology.
Low-Temperature Quick-Freezing Locks Freshness: Pre-freezing below -35°C instantly forms fine ice crystals within the berries, preventing cell structure damage.
Vacuum Sublimation Drying: Under 10-30Pa vacuum, ice crystals sublime directly into vapor. Drying temperature controlled between -20°C and 30°C, achieving over 90% anthocyanin retention and significantly higher vitamin C retention compared to traditional hot air drying.
Color & Flavor Preservation: Freeze-dried blueberries retain a deep purple-blue color, strawberries. They rehydrate close to fresh fruit, maximizing the characteristic rich aroma of Andean berries.
2. Flexible Process for Different Berries
For Blueberries (high-antioxidant core): Addressing the waxy cuticle that hinders moisture evaporation, we added a micro-perforation pre-treatment before freeze-drying, combined with low-temperature sugar infusion (using natural fruit juice concentrate instead of white sugar), enhancing flavor while maintaining the "no additives" selling point.
For Strawberries (high-appearance product): Whole-fruit freeze-drying yields products with vibrant red color, seeds visible on the surface, intact shape, light and crispy texture, and excellent rehydration.
The line also integrates a hot air drying module. For some products suited to traditional dried fruit (e.g., dried blueberries), a 55°C low-temperature hot air cycle can be used for lower energy consumption and higher efficiency.
3. Waste Heat Recovery & Clean Energy Utilization
Central Chile has abundant solar resources. We equipped the line with a solar preheating system and waste heat recovery, reducing overall energy consumption by 40% compared to traditional freeze dryers.
Vacuum pumps use variable frequency drives, automatically adjusting power based on load to further reduce electricity costs.
Client Testimonial: The "Value Transformation" from Grade B Fruit to International Premium Snacks
After commissioning, F***R Group's business expanded rapidly.
Capacity & Market Breakthrough
Throughput: Processes 12 tons of Grade B berries daily, converting all previously off-grade produce into premium freeze-dried and dried fruit products. The selling season extends year-round, completely of seasonality.
High-End Market Access: The freeze-drying process helped secure US USDA Organic, EU BRC, and Japan JAS certifications. By 2025, freeze-dried berry exports to North America, Europe, and China grew 400%, with products entering chains like Whole Foods.
Significant Economic Benefits
Product Premium: Freeze-dried blueberries retail for $80-100/kg, 10-15 times the price of fresh fruit. Additive-free dried blueberries also command a 3-5 times premium in Asian markets.
Return on Investment: Group CEO Mr. Fernández calculated: "Those Grade B berries used to go to juice factories for under $1/kg. Now as freeze-dried products, they average over $30/kg. From this alone, we recouped the entire equipment investment in under 18 months. And the vacuum freeze technology earned us trust from high-end clients."
Environmental & Social Responsibility
Zero Waste Goal: Reduces Grade B berry waste by about 3,000 tons annually, increasing resource utilization to 98%, earning Chile's Ministry of Agriculture "Sustainable Development Innovation Award".
Farmer Income: The group purchases all quality-grade berries at guaranteed base prices, including previously low-value Grade B fruit, stabilizing incomes for over 600 surrounding smallholder farmers.
"The sun and snowmelt of the Andes nurture the world's finest berries, but we used to watch nearly a quarter of our harvest sold cheaply just because of 'appearance' issues. Hadof's freeze-drying line showed us that real technology perfectly preserves the inner nutrition and natural flavor of every berry, letting the 'golden fruit' of the Andes reach the world in its most perfect form."
—— F***R Berries Group, CEO Juan Carlos Fernández
