On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: C****F
Country: Kingdom of Thailand
Region: Chanthaburi Province – Thailand's largest mango cultivation and export base, known as the "Mango Capital"
Core Products: Whole slice freeze-dried mango, freeze-dried mango powder, freeze-dried mango chunks, organic freeze-dried mango snacks
Equipment Configuration: Hadof custom continuous vacuum freeze-drying production line (industrial dual-chamber system + multi-stage temperature control curve module + anti-oxidation protection system)
Commissioning Date: Q1 2022
Thailand is one of the world's leading mango producers. Chanthaburi Province, with its superior tropical climate and centuries of cultivation experience, produces Nam Dok Mai and golden mango varieties known for their thick flesh, rich aroma, and moderate sweetness. C****F Company has over a decade of experience in mango processing, owning orchards and cooperating with partner plantations covering over 3,000 hectares, with an annual fresh fruit processing capacity of 20,000 tons. When expanding into the high-end snack markets of Europe, America, and Asia, traditional hot air drying and sugar-infusion processes faced multiple challenges:
Quality and Texture Shortcomings: Traditional sugar-infused dried mango required large amounts of white sugar to extend shelf life, resulting in sugar content exceeding 50%, conflicting with current low-sugar health trends. Hot air-dried mango was hard, dry, and fibrous with poor rehydration, failing to meet the demand for a "naturally soft and chewy" texture in high-end tea breaks, baking, and airline catering.
Color and Flavor Loss: The natural carotenoids and volatile ester aromas in mango are highly sensitive to high temperatures. Traditional processing caused browning and over 40% aroma loss, reducing product competitiveness.
Export Compliance Pressure: The EU and North American markets have strict requirements for food additives, microorganisms, and pesticide residues. The old production line could not provide full traceability and clean production verification, resulting in the loss of several major international orders.
C****F Company clearly needed an industrial freeze-drying system that could preserve mango's original color and aroma while achieving low-additive, high-rehydration capabilities. After evaluating multiple international proposals, they ultimately chose Hadof's custom continuous freeze-drying line. We specially optimized the system for mango's high sugar, high moisture, and heat-sensitive pigment characteristics:
Solution: Three Core Designs Tailored to Mango Characteristics
1. "Gradient Pre-freezing + Controlled Temperature Sublimation" Custom Freeze-Drying Curve
Mango flesh has high sugar content and a low freezing point, making it prone to collapse. We established a three-stage precise process:
- Pre-freezing Stage: Rapid crystallization at -38°C forms fine, uniform ice crystals, preventing large ice crystals from damaging cell walls and causing juice loss;
- Primary Drying Stage: Dynamic adjustment of vacuum (45Pa～70Pa) and shelf temperature ensures uniform moisture sublimation, maintaining the sponge-like structure of the flesh;
- Secondary Drying Stage: Gentle heating to 40°C～45°C, achieving final moisture content ≤3.0% while maintaining carotenoid stability. The rehydrated product is golden-yellow with a soft, chewy texture.
This process increased the retention rate of characteristic mango aroma compounds (such as ethyl butyrate, ethyl hexanoate) by 58% compared to traditional hot air drying. The rehydrated product closely resembles fresh mango in taste, achieving industry-leading sensory scores.
2. Anti-Oxidation Protection and Low-Sugar Process
To address mango's susceptibility to oxidation and browning, the production line is equipped with a nitrogen protection system that performs inert gas displacement after slicing and before freeze-drying, effectively inhibiting polyphenol oxidase activity. No additional sugar is needed; the natural sweetness of the mango alone provides the desired taste. The product meets the low-sugar, clean-label trends in Europe and America and successfully passed non-GMO and organic certifications.
3. Energy-Efficient Heat Pump and Waste Heat Recovery System
Considering Thailand's electricity costs and the company's sustainability goals, the freeze-drying unit is equipped with an industrial-grade high-temperature heat pump that recovers waste heat from the refrigeration system for the secondary drying stage. Solar energy is also used to preheat washing water. Overall energy consumption is approximately 25% lower than that of traditional freeze-drying equipment, earning recognition from Thailand's Ministry of Industry as a "Green Industry Demonstration Project."
Client Testimonial: From Traditional Dried Fruit Processor to International Healthy Snack Brand
After two years of stable operation, C****F Company successfully transformed from a traditional sugar-infused dried mango contract manufacturer into a high-end freeze-dried mango own-brand manufacturer.
Market & Certification Breakthrough
- Achieved USDA Organic certification, EU Organic certification, and BRC Grade A certification, with products entering high-end retailers such as Whole Foods Market and Costco;
- Became a supplier of premium snacks for the first-class cabins of three international airlines, with export orders growing at a compound annual rate of 72%.
Significant Economic Benefits
- Loss Control: Traditional sugar-infused and hot air drying resulted in approximately 8%–12% material loss due to browning and sticking; the freeze-drying line reduced total loss to under 1.6%;
- Product Premium: The final selling price of additive-free freeze-dried mango is 3.8 times higher than that of traditional dried fruit. The client achieved equipment investment payback and sustained profitability by the second year of operation.
Sustainable Development
- Through the heat pump and waste heat recovery system, annual CO? emissions are reduced by approximately 150 tons, securing green financing support from Thailand's export credit agencies;
- Utilizes processing byproducts such as mango peels and pits to produce organic fertilizer and biomass fuel, achieving full industrial chain circular utilization.
"In the past, we used sugar to mask the shortcomings of dried fruit. Hadof's freeze-drying technology has truly unleashed the inherent brilliance of mango – every slice of freeze-dried mango retains the sunshine and aroma of Chanthaburi, rehydrating to taste as if freshly picked from the tree. This is the high-value expression of Thai mangoes going global."
—— C****F, Founder and CEO
