We’ve been running Alaska Food Company and navigating the transition from small-scale home freeze drying to full commercial operations. Our journey involved scaling up to a Parker 6 commercial unit that processes 1,500 pounds per batch, and we learned countless lessons about facility setup, equipment requirements, and operational workflow along the way.
The reality of commercial freeze drying goes far beyond just buying a bigger machine. We had to figure out storage solutions for massive quantities of raw materials, establish proper moisture-controlled environments, and coordinate everything from three-phase electrical systems to specialized refrigeration requirements. Working with Parker’s team gave us the training and customization we needed, though the process demanded careful planning around facility layout, workflow design, and having the right contractor relationships in place.
Key Takeaways
- Scaling to commercial freeze drying requires careful planning for storage space, workflow processes, and moisture-controlled environments to maintain product quality.
- Installing commercial equipment involves significant infrastructure needs including three-phase electrical, specialized plumbing, and coordination with refrigeration technicians who meet manufacturer standards.
- Commercial freeze dryer manufacturers provide customized equipment built to order along with hands-on training and ongoing support to help operators learn the systems.
Background of Alaska Food Company
Origins and Founding Team
We are Josh and Samantha Weisman, the founders of Alaska Food Company. We started this venture to build a freeze drying business from the ground up. Our journey began with a small home freeze dryer and evolved into operating commercial-scale equipment.
We already owned a construction company, which gave us valuable connections and resources. This background helped us navigate the technical requirements of setting up a commercial freeze drying facility.
Scaling From Residential Equipment to Industrial Operations
We made the decision to go big immediately and acquired a Parker 6, a commercial freeze dryer that processes 1,500 pounds of product. This was a significant jump from our small home unit. We also kept a smaller residential freeze dryer for testing products before running full batches.
The biggest challenge we faced was managing the sheer volume. When you receive 1,500 pounds of potatoes or strawberries, you need proper storage and freezer space. You need enough people to process everything in a day and get it frozen on time.
Key challenges we encountered:
- Managing large-scale ingredient volumes
- Having adequate freezer and storage space
- Coordinating workflow with enough staff
- Maintaining proper equipment setup
We had to think through our entire workflow. There are three distinct points in the freeze drying process: making fresh product, freezing it, then freeze drying it, and finally storing the finished product.
We converted an auto shop from our construction company into a DEC-approved facility. Some things look unusual because it wasn’t originally designed for food production. We started using shipping containers for storage, which is common in Alaska and was our first easy solution.
We learned that moisture control is crucial. When you’re cooking mashed potatoes in the same environment where you’re pulling strawberries out of the freeze dryer, that moisture in the air instantly impacts your product. We initially had everything in one space but realized we needed segregated areas to keep products at peak quality without exposing them to moisture from other operations.
We tore down a garage door and installed two Krona units to solve the moisture problem temporarily. We call that phase two. Our facility remains under construction as we continue making improvements in phases.
Major milestones we celebrated:
- Getting the Parker 6 delivered and installed with a crane
- Completing the plumbing and electrical work
- Meeting three-phase power requirements
- Connecting our refrigeration team with Parker’s technical team
We relied on our construction company’s subcontractor network for the technical work. We recommend getting two or three quotes for electrical and plumbing work. Having a trusted refrigeration technician is essential. We had our refrigeration team meet directly with the Parker team to ensure our technician met Parker standards and could resolve any issues quickly.
We chose Parker based on volume capacity and reliability. They’re based in America and provide excellent support. Every time we’ve called them, they respond quickly and provide all the information we need.
Parker machines are custom built to order, not sitting in a warehouse. They required a down payment to start production. When ours arrived, it had “Alaska Food Company” on a plaque. They customized it specifically for our facility, asking questions about where we wanted outputs positioned and whether we wanted things on the left or right side.
We wish we had known exactly where the machine would go before ordering because moving it later isn’t practical. Parker sent trainers for two days to teach us how to operate the equipment. They provided a detailed manual along with hands-on instruction.
The system is user-friendly, though intimidating at first. There are many buttons and moving parts. You don’t want to push the wrong thing when you have that much product inside. However, the interface is intuitive once you understand it.
Expanding Your Freeze Drying Operations
Transitioning to Industrial-Scale Equipment
We went big immediately with a Parker 6, which handles 1,500 pounds per cycle. The volume capacity was the primary factor that influenced our equipment decision. Commercial units offer greater reliability compared to residential models.
Parker builds each machine custom to order rather than keeping inventory in warehouses. When our unit arrived, it had our company name on a plaque. The customization process includes specific questions about facility layout, such as output location preferences and whether you want it positioned on the left or right side.
Key considerations for commercial equipment:
- Down payment required to initiate production
- Customization options based on your facility specifications
- Two-day on-site training included with purchase
- Direct phone support from the manufacturer
- Coordination between refrigeration contractors and equipment manufacturer
We made sure our refrigeration team connected directly with the Parker team. This ensured our technician met Parker standards and could resolve any issues quickly. Getting two or three quotes from subcontractors you trust is essential for electrical and plumbing requirements.
The machine looks intimidating at first with numerous buttons and moving parts. We were concerned about pushing the wrong control with that much product at stake. However, the interface is user-friendly once you understand it.
Handling Higher Production Capacity
When you receive 1,500 pounds of potatoes or strawberries, the logistics become significant. You need adequate freezer or storage space if you’re not processing everything immediately. Having enough people available to process and freeze everything within a day becomes critical.
We had to plan for three distinct stages in the workflow. First, you prepare the fresh product. Then you freeze it. Finally, you load it into the freeze dryer and store the finished product afterward.
Workflow planning matters. Make sure you have your equipment in place and run through how your workflow will function before scaling up. We discovered this through direct experience with our operations.
Modifying Production Methods for Larger Quantities
Recipes and the overall process require adjustment at commercial scale. The sheer volume of raw materials demands different handling compared to small-batch production.
We converted an auto shop from our construction company into a DEC-approved facility. Some aspects might seem unconventional because of this conversion. We started with everything done in this space, which also served as our construction yard.
Environmental control became crucial:
- Moisture-controlled rooms preserve product quality
- Cooking in the same environment where you’re removing products from the freeze dryer creates problems
- Moisture in the air instantly impacts your product
- Segregated areas allow products to remain at peak quality
When we made mashed potatoes while simultaneously pulling strawberries out of the freeze dryer, the moisture affected everything. Having separate spaces prevents exposure to elements that compromise your finished product.
We tore down a garage door and installed two Kronaxes to address the moisture issue. This was our phase two solution. We use shipping containers for storage, which is common in Alaska and was our first practical option. A moisture-controlled environment proved more important than we initially anticipated.
Our facility remains under construction with planned expansion already designed. We’re working in phases, slowly enclosing different areas as we refine our operations. We also keep a smaller residential freeze dryer for product testing before committing to large commercial batches.
Building Your Production Space and Systems
Adapting Existing Buildings for Processing Operations
We converted an auto shop from our construction company into a DEC-approved facility. This approach allowed us to start without building from scratch, though some features might seem unusual due to the conversion.
The space needed to accommodate three distinct workflow points. First, we prepare fresh products. Second, we freeze them. Third, we load them into the freeze dryer and store the finished goods.
Creating Climate-Controlled Processing Areas
We discovered that managing humidity levels is absolutely critical to production quality. When cooking products like mashed potatoes while simultaneously removing strawberries from the freeze dryer, ambient moisture immediately affects the freeze-dried items.
Key moisture control considerations:
- Segregated areas prevent cross-contamination between wet and dry processes
- Products maintain peak quality when not exposed to humidity
- Processing multiple items simultaneously requires dedicated spaces
We initially handled everything in one open area. As a phase two improvement, we removed a garage door and installed two Kronaes units to address the moisture problem. Having separate climate-controlled rooms works best when running different products at the same time.
Repurposing Insulated Containers for Refrigeration Needs
We chose to use shipping containers for freezer storage. This solution made sense for our Alaska location as an accessible first option.
We created a walk-in freezer from a shipping container, which remains a work in progress. Our expansion plan includes gradually enclosing additional areas using this phased approach.
Managing 1,500 pounds of potatoes or strawberries requires substantial freezer capacity if you’re not processing everything immediately. You need adequate storage space and enough workers to process and freeze large volumes within a day.
Growing Operations in Planned Stages
We approach expansion through phases rather than completing everything at once. Our facility modifications happen incrementally as needs develop.
Phase One: Basic facility conversion and initial equipment installation
Phase Two: Adding moisture control systems and segregated processing areas
Future Phases: Enclosing additional spaces based on existing designs
Before scaling to large equipment that processes 1,500 pounds per cycle, we tested products on a smaller residential unit. This allowed us to develop recipes and understand workflow requirements before committing to commercial volumes.
Critical planning elements before equipment arrival:
| Planning Area | Required Actions |
|---|---|
| Equipment placement | Determine exact location before delivery |
| Workflow design | Map out complete process flow |
| Output positioning | Specify left or right side placement |
| Storage capacity | Ensure adequate freezer and shelf space |
We secured multiple quotes from subcontractors for specialized work. Having our construction company connections helped us access trusted professionals for plumbing and electrical requirements.
Our refrigeration team met directly with the Parker team to ensure our technician met their standards. This direct connection means we can resolve any issues quickly with qualified support on standby.
Operational Challenges and Solutions
Handling Workflow and Staff Coordination
The volume of raw ingredients creates immediate logistical demands. When receiving 1,500 pounds of potatoes or strawberries, you need adequate freezer and storage space if processing won’t happen immediately.
You must have enough staff available to process everything in a single day and get it frozen on time. Equipment placement matters significantly, so we recommend running through your entire workflow process before committing to a layout.
Key considerations include:
- Securing adequate cold storage capacity
- Scheduling sufficient labor for processing days
- Planning equipment positioning in advance
- Testing workflow before large-scale operations begin
The process involves three distinct stages that require separate spaces and resources. First, you prepare fresh product. Second, you freeze it. Third, you load it into the freeze dryer and store the finished product afterward.
Storing and Freezing High Volumes
We initially used shipping containers for storage, which is common in Alaska and seemed like an easy first solution. However, we learned that moisture-controlled environments are far more important than we initially anticipated.
Originally, we conducted all operations in a converted auto shop that previously served our construction company. This created challenges when cooking in the same environment where we pulled product from the freeze dryer.
The moisture in the air instantly impacts your product. When making mashed potatoes while simultaneously removing strawberries from the freeze dryer, the ambient moisture compromises product quality immediately.
Environmental control requirements:
| Challenge | Solution |
|---|---|
| Multiple products processed simultaneously | Segregated work areas |
| Moisture contamination | Dedicated moisture-controlled rooms |
| Product exposure during packaging | Isolated packaging spaces |
We removed a garage door and installed two units as a temporary fix. Having separate areas prevents product exposure to unwanted elements and maintains peak quality throughout processing.
Recipe and Process Adjustments
Scaling recipes from home equipment to commercial volumes presents unique challenges. The overall process changes significantly when working with 1,500-pound batches instead of small home quantities.
You need to adapt your recipes specifically for commercial-scale production. This isn’t simply multiplying home recipe quantities—the entire approach to preparation, timing, and handling must be reconsidered.
We maintain a smaller residential unit specifically for testing products before committing to full commercial runs. This allows us to refine formulations and processes without risking large batches of ingredients or machine time.
The equipment itself requires understanding beyond basic operation. Getting proper refrigeration contractors involved early helps ensure your setup meets manufacturer standards. We had our refrigeration team connect directly with the equipment manufacturer to establish reliable support channels.
Planning requirements:
- Determine exact equipment placement before installation
- Establish utility connections (plumbing, electrical, refrigeration)
- Obtain multiple contractor quotes for specialized work
- Coordinate between refrigeration technicians and equipment manufacturers
- Test recipes on smaller equipment before scaling up
Moving a large commercial unit after installation isn’t practical, so finalizing your facility layout beforehand saves considerable effort and expense.
Working with Commercial Freeze Drying Equipment
Partnering with a Commercial Manufacturer
We chose our commercial equipment based on volume capacity and reliability. The manufacturer we selected operates in the United States and provides responsive customer support. Every time we’ve contacted them, they answer quickly or return calls promptly with all needed information.
The support extends beyond the initial purchase. We arranged for our refrigeration team to meet directly with the manufacturer’s team to ensure our technician met their standards. This connection means we can resolve any issues immediately if they arise.
Differences Between Home and Commercial Systems
We maintain a smaller residential unit for product testing. However, the commercial equipment operates on an entirely different scale.
Commercial units require three-phase electrical power and significant plumbing infrastructure. We relied on trusted subcontractors to handle these requirements. Getting two or three quotes helps determine the scope and cost of installation work.
Key Infrastructure Requirements:
- Three-phase electrical service
- Specialized plumbing connections
- Refrigeration expertise on standby
- Adequate space for equipment placement
The residential units simply plug in and operate. Commercial systems need professional installation and setup before they can run.
Custom Configuration Options
Commercial units are built to order rather than stocked in warehouses. The manufacturer requires a down payment to start production for your specific machine.
Each unit includes customization based on your facility needs. The manufacturer asks detailed questions about output placement, whether you want it on the left or right side, and other configuration preferences. Our unit arrived with our company name on it, which reinforced that it was made specifically for us.
We recommend having your facility layout finalized before ordering. Know exactly where the equipment will be positioned because moving it later isn’t practical.
The manufacturer provides two days of on-site training after installation. They supply a comprehensive manual and ensure you understand operations before leaving. The interface is user-friendly once you get past the initial intimidation of multiple buttons and moving parts.
Setting Up Commercial Freeze Drying Equipment
Managing Delivery and Physical Setup
When our Parker 6 arrived, we needed a crane to swing it into place. That delivery moment was exciting and marked a major milestone in our operation. Commercial freeze dryers aren’t sitting in warehouses waiting to ship. They’re custom built to order after you provide a down payment to start production.
The Parker team asked detailed questions about our facility layout before manufacturing. They wanted to know specifics like whether we preferred the output on the left or right side. Once the machine arrived, it had our company name on a plaque, showing the customized nature of these units.
Key considerations for placement:
- Determine exact location before ordering
- Plan for permanent installation (moving isn’t practical)
- Consider workflow patterns in your facility
- Account for crane access during delivery
Power and Water System Requirements
Fitting out the necessary utilities proved critical. Three-phase electrical power is required for commercial units. We needed proper water connections established as well.
The installation process involves:
| Utility Type | Requirement |
|---|---|
| Electrical | Three-phase power system |
| Plumbing | Direct water line connections |
| Space | Permanent floor space for unit placement |
We made sure all infrastructure was in place before the machine arrived. Running through workflow scenarios helped us identify what utilities needed to go where.
Coordinating With Contractors and Technical Support
We obtained two or three quotes for the electrical work. Having a construction company gave us access to trusted contractors, but getting multiple bids remains important.
Our refrigeration technician met directly with the Parker team before installation. This personal connection ensured our local support met Parker’s standards. Now we can resolve any issue quickly with a refrigeration specialist who understands the equipment.
We keep a refrigeration technician on standby. Parker’s support team answers calls promptly and provides detailed information when we need it. They spent two days at our facility providing hands-on training and supplied a comprehensive manual.
The training covered all operational aspects. While the control panel looks intimidating at first with numerous buttons and moving parts, the system operates in a user-friendly manner once you understand it.
Controlling Humidity and Cold Storage
A moisture-controlled environment turned out to be more crucial than we initially realized. When cooking products like mashed potatoes while simultaneously removing strawberries from the freeze dryer, airborne moisture immediately impacts the finished product.
We started with all production in one space. This proved problematic because different stages of the process create different environmental conditions. Segregated areas allow products to remain at peak quality without exposure to conflicting elements.
Environmental control needs:
- Separate rooms for different production stages
- Dedicated space for removing products from freeze dryers
- Climate control during packaging
- Protection from ambient moisture during processing
We need to manage three distinct points in the workflow. Fresh products must be prepared first. Those products then require freezing before entering the freeze dryer. Finally, finished freeze-dried products need proper storage conditions.
Storage capacity becomes critical at commercial scale. Receiving 1,500 pounds of potatoes or strawberries requires adequate freezer space if you can’t process everything immediately. Walk-in freezers help manage this volume between preparation and freeze drying.
We’re phasing in improvements to our moisture control systems. We removed a garage door and installed two Kronalex units as an interim solution. Additional enclosed spaces are already designed for future expansion.
Having proper cold storage and climate-controlled areas prevents product degradation. The investment in environmental controls protects the quality we work to achieve through the entire production process.
Manufacturer Training and Technical Support
On-Site Instruction and Technical Direction
We received two full days of training directly from the Parker team when our commercial freeze dryer arrived. The manufacturer sent representatives to our facility to ensure we understood how to operate the equipment properly.
The training covered several critical areas:
- Button functions and control panel operations
- Moving parts and mechanical systems
- Product loading procedures
- Troubleshooting protocols
The Parker team provides a comprehensive manual alongside the hands-on instruction. We found the equipment to be very user-friendly once we understood the basics, though it initially appeared overwhelming due to the number of controls and components.
One significant advantage we experienced was the manufacturer’s responsiveness. Every time we called them, they were quick to answer or return our calls with the information we needed. This level of support proved essential as we scaled our operations.
We also established a direct connection between our refrigeration technician and the Parker team. This arrangement ensures our local contractor meets Parker standards and can resolve any issues quickly when they arise.
User Experience and Learning Curve
The first impression of a commercial freeze dryer is intimidating. There are numerous buttons, moving parts, and controls that require attention.
We were genuinely concerned about making mistakes during operation. With significant amounts of product loaded into the machine, pushing the wrong button could result in substantial losses.
However, the actual learning process proved manageable. The interface operates similarly to familiar technology, making it easier to adapt than we initially anticipated. The combination of the detailed manual and direct manufacturer training helped us become comfortable with operations relatively quickly.
The customization aspect also contributed to our learning experience. Parker built our unit specifically for our facility, including personalized features like our company name on a plaque. They asked detailed questions about our setup preferences, such as output placement and configuration options. This customization meant the machine integrated well with our workflow once we understood its operation.
Building Connections and Expanding Together
Becoming Part of the Freeze Dry Network
We want to take a moment to talk about an important resource available to you. There’s a dedicated community specifically designed for people passionate about freeze drying, regardless of where you are in your journey.
The Freeze Dry Network exists as a concentrated space where members share ideas and work together to advance the freeze drying industry. This community brings together individuals who want to learn from each other’s experiences and support one another through challenges.
What the network offers:
- A tight-knit group of like-minded individuals
- Opportunities to exchange practical knowledge
- Encouragement from people who understand your journey
- Resources to help move the industry forward
We encourage you to join this community if you’re interested in connecting with others who share your passion for freeze drying. The network welcomes everyone from beginners just starting out to experienced operators running commercial facilities.
Collaborative Growth in the Freeze Drying Industry
The freeze drying industry benefits when people share their experiences and learn from one another. We’ve found that connecting with the right partners and resources makes a significant difference in building a successful operation.
When we work with commercial equipment manufacturers, we prioritize companies that offer strong support systems. Parker has proven to be reliable and responsive whenever we need assistance. Their team answers calls promptly and provides all necessary information.
Key partnership elements:
- Manufacturing support: Equipment gets custom-built to order rather than shipped from warehouse stock
- Personalized service: Machines arrive with your company name and customized features
- Training programs: Manufacturers send teams for multi-day on-site training sessions
- Technical coordination: We arrange direct meetings between our refrigeration contractors and the equipment manufacturer
We also maintain relationships with trusted subcontractors. Our refrigeration team meets directly with the Parker team to ensure everyone understands the equipment standards. This coordination means we can resolve any issues quickly when they arise.
Having multiple quotes from contractors helps us make informed decisions about installations. We recommend working with at least two or three subcontractors you trust for electrical and refrigeration work.
The equipment may seem intimidating at first with numerous buttons and moving parts. However, manufacturers provide comprehensive manuals and user-friendly interfaces. The training and documentation they offer make the learning curve manageable, even when handling large volumes of product.
Major Developments and Accomplishments
Critical Points in Business Development
Receiving our Parker 6 unit marked a significant moment for us. We needed a crane to swing the machine into place, which made the entire installation process memorable.
Completing the plumbing and electrical installations represented another major step forward. The three-phase electrical requirements demanded careful attention to detail.
We established a direct connection between our refrigeration team and the Parker team. This relationship ensured our refrigeration technician met Parker standards, allowing us to address any issues quickly.
Growing Our Operations and Recognizing Progress
Volume capacity drove our decision to select a commercial freeze drying company. We needed equipment that could handle substantial production levels reliably.
The support system proved valuable throughout our journey. Phone calls were answered promptly, and we received all necessary information without delays.
When we ordered our Parker 6, we learned these machines are built to order rather than stocked in warehouses. Our unit arrived with an Alaska Food Company plaque on the front, demonstrating the customized nature of the equipment.
Parker asked detailed questions about our setup:
- Output location preferences
- Left or right positioning
- Facility-specific configurations
The training process included:
- Two-day on-site instruction
- Comprehensive manual
- User-friendly interface design
We found the operation intimidating initially due to the numerous buttons and moving parts. The stakes felt high with substantial product quantities inside the machine. However, the equipment functions with iPhone-like simplicity once we became familiar with it.
We maintain a smaller residential freeze dryer for product testing. This allows us to refine recipes before committing to large-scale production runs.