Refreezable Giant Ice Blocks for Fresh Produce

Challenge:

In 2015, Ausfab Group was presented with a challenge by a major Australian supermarket retailer. The retailer wanted to reduce the use of crushed ice under fresh produce to minimize the number of ice machines required in each store, reduce power usage and water wastage and decrease in-store labour costs by replenishing crushed ice from the back to store throughout the day.

Solution Development:

Ausfab initially solved this challenge by designing simple hollow plastic tiles, this reduced the volumetric space in the fresh produce tables and achieved the desired result for the client. However, Ausfab’s design team continued to explore ideas of their own volition and eventually developed an innovative concept: A hollow plastic block that could be filled with tap water on-site and frozen overnight in store freezers. These innovative Ice blocks would thereby reduce the frequency of ice replenishment during trading by substantially slowing down the melting rate of the crushed ice on display.

Design and Testing:

Through meticulous 3D modelling and rigorous testing, Ausfab refined the design. To ensure its effectiveness, twelve 3D printed models were installed in a real store for thorough testing.

Exceeding Expectations:

The ice block models surpassed all expectations during testing. They froze solid overnight and remained frozen throughout the entire trading day. The success of this solution prompted plans for large-scale production. Design and manufacture of Injection blow moulding tooling was completed in record time and mass production followed with an initial order of 40,000 units

Game-Changing Results:

The implementation of ice blocks brought significant benefits. It substantially reduced labour costs and the need for frequent ice replenishment. The blocks were easy to handle and install, lasting until the end of the trading day. The usage of crushed ice was reduced by up to 60%. This innovative solution quickly gained traction and was implemented across the retailer’s entire fresh produce network. These items are still in use across this retailer’s national network of stores

Thinking Outside the Box:

Ausfab Group’s innovative thinking and collaborative approach with their customer and suppliers led to a groundbreaking solution. By introducing frozen water-filled ice blocks, they made a remarkable impact. This innovative solution significantly reduced water consumption, energy usage, and labour costs associated with ice replenishment. Ausfab Group not only solved the initial problem but also pushed the boundaries further. Through careful design, testing, and production, they set a new industry standard for fresh produce presentation.

Experience the Difference:

Partner with Ausfab Group to benefit from our innovative solutions that save costs, reduce waste, and improve efficiency. Contact us today to discuss your specific needs and witness the Ausfab Group difference firsthand.