Flake ice is indispensable

Flake ice has long played a central role in the food industry. It is particularly used during the production of cooked sausage, where it is added during the cutting process to regulate the temperature of the meat mixture. The ice flakes distribute evenly, ensuring uniform cooling. Thanks to r its large surface area, it transfers cold energy efficiently—a decisive advantage over coarse ice chunks. In addition, the fine structure protects the cutter blades and supports a homogeneous texture in the mixture.

Flake ice is also widely used beyond traditional meat processing: in fish counters, bakeries, and increasingly in the production of vegetarian products. Its dry, pourable structure makes handling and storage easier. With proper insulation, the ice remains loose and free flowing for a long time.

Alongside technical performance, hygiene is a key factor in the production of flake ice. Easy-to-clean designs, ozone-based water treatment, and automatic self-cleaning systems are now standard. These systems are particularly relevant for larger operations where ice machines are installed in intermediate ceilings or on storage silos. In such setups, manual cleaning involves considerable effort. Automated systems handle descaling and cleaning at scheduled intervals, minimizing the risk of microbiological contamination.

Sustainability and new refrigerants

One topic currently attracting particular attention in the refrigeration industry is the replacement of conventional refrigerants with environmentally friendly alternatives. With the revised EU F-Gas Regulation coming into force, new requirements have been set for the use of fluorinated greenhouse gases (F-gases) in refrigeration systems and ice machines. The aim is to reduce emissions of these gases and gradually promote the use of more sustainable alternatives. This regulation is a key element of EU climate policy and supports the achievement of climate neutrality.

F-gases have a high global warming potential (GWP) and are still widely used as refrigerants in many ice makers. The regulation introduces a gradual reduction of the quantities available on the market (“phase-down”) and complements this with targeted bans on certain types of equipment. The phase-down process leads to scarcity and, consequently, rising prices for the affected refrigerants. Particularly impacted are so-called compact units, where the ice-making mechanism and refrigeration system are integrated into a single housing. This design makes switching to alternative refrigerants significantly more difficult, meaning the new regulations have a particularly strong impact here.

As of January 1, 2025, these devices may no longer be placed on the market if they contain fluorinated greenhouse gases with a GWP of 150 or higher. However, a temporary exemption has been granted: compact units with a production capacity of 200 kg to 2,000 kg per 24 hours may still be marketed until June 30, 2026—provided they are properly labeled and comply with the requirements of the regulation.

This regulation particularly affects manufacturers and operators of ice machines that have so far relied on fluorinated refrigerants. It creates a clear incentive to switch to natural refrigerants such as CO₂, ammonia, or propane, which have a significantly lower GWP and will remain permissible in the long term.

The European Union is taking a clear leading role in this transition. By consistently focusing on environmentally friendly alternatives such as propane, CO₂, or ammonia, the market is intended to be sustainably aligned in the long term. This sends a strong signal for climate protection and resource conservation. In other parts of the world, however, different regulations apply: conventional refrigerants remain widespread and may continue to be used for years to come. This highlights that the global approach to refrigerants is still strongly shaped by regional regulations.

Technological solutions for different operational sizes

A new series of compact machines has been developed for small and medium-sized operations, operating with the natural refrigerant propane (R290). With a GWP value of only 3, propane offers an exceptionally eco-friendly alternative. The machines are equipped with safety features, including a patented internal ventilation system and special components for safe refrigerant handling. The series is currently available with daily capacities starting at 85 kg.

For production environments with higher ice demand, various technical concepts are available. One option is split systems, where the ice maker is physically separated from the condensing unit. This design allows flexible installation, especially in areas with limited space. This type of installation will continue to be permitted until the end of 2030 with standard refrigerants such as R449A. Another advantage becomes clear in practical operation: since the waste heat from the condensing unit does not enter the production area, the environment is not additionally heated. This reduces the need for extra air conditioning, lowering overall energy consumption and contributing to more efficient use of refrigerants.

Regardless of this, CO₂ (R744) is gaining increasing importance as a refrigerant. It stands out with an extremely low global warming potential (GWP = 1), is non-flammable, and is available in large quantities as a natural by-product at low cost. In addition, CO₂ offers high volumetric cooling capacity, enabling particularly compact and powerful system designs. Compared to machines operating with R449A, daily outputs can be up to 25% higher. Since it is not affected by the F-Gas Regulation, CO₂ is considered a particularly future-proof refrigerant. These systems deliver high energy efficiency and environmental compatibility, with daily capacities of up to 15 tons—ideal for large-scale operations with continuous ice demand.

In addition to these concepts, hybrid solutions are also becoming increasingly relevant. They are ideal for companies that want to switch to CO2 in the long term but are currently still working with conventional refrigerants such as R449A.
The ice maker is initially operated with R449A and can be converted to CO2 at a later date—for example, in the course of a complete conversion of the plant—without major technical effort. This gives customers investment security and allows them to flexibly shape the transition to a sustainable refrigeration supply.

Efficiency gains through buffer and silo solutions

To optimize production processes, intelligent silo and buffer solutions are increasingly being used. These allow the combination of smaller ice machines with centralized storage and automated discharge—up to fully automated complete systems with pneumatic conveying. This helps save personnel resources and better manage production peaks. In addition, ice production can be precisely adapted to actual demand via modern control systems. By connecting to ERP systems with recipe control, production is carried out in the right quantity and at the right time, avoiding overproduction and ensuring consistently high process reliability.

Conclusion: Flake ice production exemplifies the transformation in food technology—hygienic, efficient, and increasingly sustainable. The new regulatory framework demands innovative solutions for both artisanal businesses and industrial applications.