Fruit and Vegetable Cooling Solutions

Maximize Product Quality With Rapid, Energy-Efficient Post-Harvest Cooling

Immediate temperature reduction after harvest is the single most powerful lever for preserving freshness, extending shelf life, and preventing costly spoilage. Modern hydrocooling systems – especially BUCO Falling Film Chillers – deliver unmatched cooling speed, energy efficiency, and hygiene standards that directly improve product quality and operational profitability.

Why Fast Cooling Matters for Your Operation

Protect Quality, Reduce Waste, and Maintain Product Weight

From the moment produce is harvested, heat accelerates enzymatic activity and microbial growth. Rapid post-harvest cooling – particularly via cold water – removes field heat far faster and more uniformly than air or vacuum cooling.

Key advantages of hydrocooling over air and vacuum cooling:

• Up to 15× faster cooling for superior freshness and firmness
• Minimal weight loss compared to up to 3% in air-cooled systems
• Significantly lower energy costs per ton of cooled produce
• Higher product uniformity, even for dense or irregular items

This method is especially valuable in warm climates or peak harvest windows, where timing directly impacts product quality and bottom-line results.

Advanced Hydrocooling With BUCO Falling Film Chillers

Achieve Rapid, Hygienic Cooling From 25°C to 2°C in just a few minutes

BUCO Falling Film Chillers bring industrial-grade precision to post-harvest cooling. Their design ensures extremely efficient heat transfer, reliable continuous operation, and consistent temperature control—even at large throughput volumes.

Core Performance Benefits

• Cooling from 25°C to 2°C in a few minutes per ton
• Uniform cooling at scale, ideal for asparagus, broccoli, carrots, lettuce, and more
• Reduced product losses, delivering better yield and retailer satisfaction
• Hygienic cooling surfaces that meet international industry standards

With minimal water volume per ton and low energy consumption, BUCO hydrocoolers deliver a measurable return on investment from day one.

Flexible Integration for Seamless Operations

Designed to Fit New or Existing Conveyor Systems

BUCO Falling Film Chillers can be installed as turnkey systems or integrated into your current process line.

Ideal for cooling produce that is:

• Loose
• Boxed
• Crate-stacked
• Tray-stacked

Whether at the packhouse, harvest site, or distribution center, these systems ensure smooth handling and continuous throughput – even during peak harvest loads.

Engineering Solutions Tailored to Your Requirements

Custom Configurations Backed by Proven Thermal Calculations

Every crop and operation has unique cooling needs. Our engineering team develops system configurations that precisely match your throughput, energy goals, and operational constraints.

We provide:

• Thermal calculations for all fruits and vegetables
• Custom-designed Falling Film Chillers with optimized belt speeds and water flow
• Complete system builds, including conveyors, motors, panels, and controls
• Integration support for upgrades or new installations

This ensures every system performs at maximum efficiency – technically, economically, and operationally.

Hygiene, Maintenance, and Reliability Advantages

Open, Self-Cleaning Design for Lower Operating Costs

BUCO hydrocoolers excel in environments where hygiene is non-negotiable.

Superior Hygiene Features

• Open construction for easy access during operation
• Falling water film creates a natural self-cleaning effect
• No hidden corners or seals that can trap dirt
• No wear-prone spare parts – keeping maintenance near zero

Industrial-Grade Construction

All components are manufactured from high-grade stainless steel, ensuring compliance with global hygiene regulations and long-term performance – even with ice water or contaminated liquids.

Cooling Performance That Scales With Your Workflow

High Efficiency, Low Pressure Drop, Continuous Operation

BUCO Falling Film Chillers consistently outperform conventional post-harvest solutions:

• Cooling down to as low as 0.5°C
• Exceptional heat transfer efficiency
• Very low risk of icing, fouling, or cross-contamination
• Designed for 24/7 industrial operation with minimal supervision

How to Select the Right Cooling System

A Practical, Engineer-Focused Checklist

Before choosing a configuration, assess:

• Expected product volume per hour
• Desired inlet and outlet temperatures
• Integration with existing conveyor systems
• Required hygiene and cleaning procedures
• Energy consumption and long-term operating costs

This ensures you select the most cost-efficient hydrocooling strategy for your facility.

Technical Overview: BUCO Falling Film Chiller Hydrocooling

Feature	Benefit
Cooling speed	Up to 15× faster than air or vacuum cooling
Weight loss	Negligible, vs. up to 3% in air/vacuum systems
System hygiene	Open design, cleanable during operation
Materials	100% stainless steel, food-grade
Maintenance	No seals or spare parts; self-cleaning plates
Energy efficiency	Low kWh per ton, high heat transfer
Application versatility	Suitable for all fruits/vegetables and stacking forms
Engineering support	Custom thermal calculations, optimized system design

Ready to Boost Your Post-Harvest Quality?

Request Your Custom Cooling Solution Today

A tailored hydrocooling system can significantly increase your product quality, reduce losses, and improve your supply chain reliability. 

Request your personalized quote or engineering consultation now.

Our experts will help you configure the optimal BUCO hydrocooling solution for your operation.

FAQ: Fruit and Vegetable Hydrocooling & Falling Film Chillers

What is hydrocooling and why is it superior to traditional cooling methods?

Hydrocooling uses chilled water to rapidly remove field heat from fruits and vegetables. Compared to air or vacuum cooling, it cools up to 15 times faster, minimizes product weight loss, and delivers highly uniform results. Because water absorbs heat far more efficiently than air, hydrocooling ensures consistently high product quality – even for dense or irregularly shaped produce.

Which fruits and vegetables benefit the most from hydrocooling?

Hydrocooling is effective for nearly all produce that tolerates moisture. It is especially beneficial for crops that are highly sensitive to temperature and hydration levels, such as:

• Asparagus
• Broccoli
• Carrots
• Lettuce
• Stone fruits
• Sweet corn
• Leafy greens
  These products retain firmness, color, and weight more effectively when cooled with water instead of air.

How quickly can BUCO Falling Film Chillers cool produce?

BUCO Falling Film Chillers achieve extremely fast cooling performance—typically reducing product temperatures from 25°C to 2°C in a few minutes per ton. This rapid cooling helps preserve freshness, extend shelf life, and protect product texture during handling and transport.

Can hydrocooling systems be integrated into existing conveyor lines?

Yes. BUCO Falling Film Chillers are designed for seamless integration with both new and existing conveyor systems. Whether produce is loose, boxed, tray-stacked, or crate-stacked, the systems can be customized to support continuous, high-throughput operations without interrupting existing workflow.

Are hydrocooling systems hygienic and easy to clean?

Absolutely. BUCO systems feature an open, accessible design with no hidden corners, seals, or spare parts that could harbor residues. The falling water film creates a natural self-cleaning effect, allowing quick rinsing and sanitation—even during operation. This reduces downtime and supports strict hygiene compliance.

How energy-efficient are Falling Film Chillers?

Falling Film Chillers are engineered for high heat transfer efficiency and low energy consumption. The water film allows extremely effective cooling with minimal kWh usage per ton. This results in lower operating costs and a faster return on investment compared to air or vacuum-based cooling systems.

Can hydrocooling damage sensitive fruits or vegetables?

No. When designed correctly, hydrocooling is gentle, consistent, and highly controlled. BUCO systems regulate water temperature, flow rates, and contact time precisely, ensuring optimal cooling without mechanical stress. This approach protects delicate surfaces and reduces post-harvest losses.

Does hydrocooling increase the risk of contamination?

Properly engineered hydrocooling systems actually reduce contamination risks. Water can be filtered, treated, or recirculated through sanitation systems, maintaining high hygiene levels. Stainless-steel construction prevents corrosion, supports CIP routines, and meets international food-safety standards.

How much maintenance is required?

Maintenance demands are minimal. There are no seals, no rotating spare parts, and no inaccessible components. Most routine work involves basic cleaning and monitoring water quality – tasks that can be performed quickly by on-site personnel. The self-cleaning water film further reduces buildup and extends the system’s lifespan.

Is hydrocooling suitable for large-scale industrial operations?

Yes. Hydrocooling – especially with Falling Film Chillers—is specifically designed for high-throughput environments where large harvest volumes must be cooled rapidly and reliably. The systems are scalable and operated 24/7 with low pressure drop and consistent performance.

What information is needed to design a custom cooling solution?

To engineer an optimal hydrocooling system, we evaluate:

• Type of produce
• Throughput volumes per hour
• Inlet and outlet temperature goals
• Belt speeds and handling methods
• Installation footprint and integration points
• Required hygiene protocol and water treatment standards
  This ensures that the final design delivers maximum energy efficiency, cooling speed, and operational reliability.

How soon can I get a consultation or quote?

Our engineering team can provide a preliminary consultation quickly. After reviewing your operational data, we supply a customized proposal, including thermal calculations, system layout, and performance estimates – ensuring you receive a solution tailored to your cooling objectives.