Factory Overview
Profile
Company Name: Zhangjiakou Dingwei Biotechnology Co., Ltd. Legal D-U-N-S Number: 456653698 Established: 2019 Location: Guyuan County, Zhangjiakou City, Hebei Province, China Plant Area: 40,000 m² (approximately 6 hectares)
Guyuan County sits in one of China's traditional core potato production areas. The region hosts four potato flakes manufacturers and five French fries processors, making it an important hub in the global supply chain of potato deep-processed products.
Key Advantages
| Feature | Details |
| 🌍 Location | Core potato growing region — year-round high-quality raw material supply |
| 🏭 Production capacity | 15,000 tons per year (processing); 10,000 tons annual finished product |
| 🥔 Storage capacity | 30,000 tons CA (Controlled Atmosphere) storage for McCain potato varieties |
| 📐 Plant area | 40,000 m² covered (approx. 6 hectares) |
| ❄️ Freezing | IQF (Individually Quick Frozen) tunnel freezing lines — 2 units |
| 🚚 Port proximity | 300 km from Tianjin Port — reduced transit and CIF costs |
| 🏛️ Government status | Key industrial initiative in Zhangjiakou City, Hebei Province (government-supported strategic project) |
Production Lines
Dinweys operates highly automated production lines requiring only 8–10 workers per shift per line.
| Line | Configuration | Daily Capacity | Annual Output |
| Line 1 | 7 mm shoestring + 9 mm straight cut (switchable cutter) | 15 tons | ~5,000 tons |
| Line 2 | 9 mm straight + 10 mm crinkle cut (switchable) | 15 tons | ~5,000 tons |
| Total | 2 parallel lines | Up to 30 tons | ~10,000 tons |
Note: Annual output depends on raw potato seasonality and grade. Nameplate capacity is 15,000 tons; current utilization is ~10,000 tons with room to scale.
Line Configuration Detail
| Processing Stage | Line 1 Equipment | Line 2 Equipment |
| Reception & washing | Trough washer + drum washer + destoner | Same (shared pre-processing) |
| Steam peeling | 8-ton batch steam peeler × 2 | Same (shared) |
| Inspection (manual sorting) | Two-sided belt, 2 sorters per side | Same |
| Cutting | Urschel or equivalent; crinkle/shoestring blades | Urschel or equivalent; straight/crinkle blades |
| Color sorting | Optical sorter with NIR (CCP 6) | Optical sorter with NIR (CCP 6) |
| Blanching | Rotary drum blancher; 88–92°C (CCP 2) | Rotary drum blancher; 88–92°C |
| Dewatering | Vibrating screen + air knife | Vibrating screen + air knife |
| Coating applicator | Optional (batches for coated products) | Optional |
| Par-frying | Continuous fryer; 160–170°C (CCP 3) | Continuous fryer; 160–170°C |
| IQF freezing | Tunnel freezer; −35°C to −45°C | Tunnel freezer; −35°C to −45°C |
| Weighing & packing | Multi-head weigher + vertical form-fill-seal | Same |
| Metal detection | In-line metal detector (CCP 4) | In-line metal detector (CCP 4) |
| Carton packing | Semi-automatic carton erector + sealer | Same |
Facility Layout
Plant Zoning
| Zone | Area | Function | Classification |
| A | Raw potato reception yard (≤ 100 tons/day) | Receiving, weighing, sampling, temporary storage | Dirty (unwashed potatoes) |
| B | Raw material storage (covered) | 5,000 ton capacity; ambient-ventilated bulk storage | Dirty |
| C | Pre-processing hall | Washing, destoning, steam peeling, inspection | Intermediate |
| D | Cutting & sorting hall | Cutting, optical sorting, manual inspection | Intermediate |
| E | Processing hall | Blanching, dewatering, coating, par-frying | Clean |
| F | Freezing & packaging hall | IQF tunnel, weighing, bagging, carton packing, metal detection | Clean |
| G | Cold storage | −20°C to −25°C; 10,000 pallet positions (12 m high) | Cold |
| H | CA storage facility | 30,000 tons; 8 chambers; 7–10°C | Temperature-controlled |
| I | Warehouse & shipping dock | Carton staging; loading dock with refrigerated airlock | Clean |
| J | Utility building | Boiler room, refrigeration plant, water treatment, electrical substation | Service |
| K | QC laboratory | Micro lab, chemistry lab, sensory room, dry storage | Controlled access |
| L | Office & administration | Management offices, meeting rooms, cafeteria | Controlled access |
Air Pressure Differentials
| Zone Transition | ΔP | Purpose |
| E → D (clean to intermediate) | +10 Pa | Prevents raw-zone air from entering clean zone |
| F → E (packaging to processing) | +5 Pa | Slight positive pressure in cleanest area |
| G → all zones | Neutral | Cold storage — sealed doors prevent air exchange |
Equipment List
Core Processing Equipment
| Equipment | Type | Specification | Manufacturer | Quantity |
| Potato washing line | Drum + trough | 15 ton/hr; 3 bar nozzle pressure | Domestic OEM | 1 set |
| Steam peeler | Batch rotary | 8 ton/batch; 12 bar steam; 45 sec cycle | Domestic OEM | 2 units |
| Cutters | Urschel model CC / G-A | 3–10 ton/hr depending on cut size | Urschel (USA/UK) | 4 units |
| Optical sorter | Visible + NIR | 3-ch camera; 6 bar air ejectors | Key Technology / Bühler | 2 units |
| Blancher | Rotary drum | 88–95°C; steam injection; 5 ton/hr | Domestic OEM (304 SS) | 2 units |
| Vibratory dewatering | Vibrating screen | 2-deck; 4 ton/hr | Domestic OEM | 2 units |
| Batter applicator | Spray + tumble | Variable speed; recirculation | Domestic OEM | 1 unit |
| Continuous fryer | Direct gas-fired | 160–180°C; 1.5 ton/hr oil capacity; 30–60 sec residence | Heat and Control (or equivalent) | 2 units |
| IQF tunnel freezer | Belt tunnel | Belt width 1.5 m; air velocity 4–6 m/s; evaporator temp −40°C | GEA / Starfrost (or equivalent) | 2 units |
| Multi-head weigher | 14-head | 60–80 weighments/min; ±2 g accuracy | Ishida / Yamato | 2 units |
| VFFS packaging | Vertical form-fill-seal | HFFS; up to 40 bags/min | Domestic OEM | 4 units |
| Metal detector | Conveyor-style | Ferrous ≥ 1.5 mm, non-ferrous ≥ 2.0 mm, SS ≥ 2.5 mm | Loma / Mettler Toledo | 2 units |
| Carton erector / sealer | Semi-automatic | Up to 12 cartons/min | Domestic OEM | 2 units |
Utility Equipment
| Equipment | Specification | Notes |
| Refrigeration system | Ammonia (R-717); 1,200 kW total capacity | 2 × 600 kW screw compressors (Mycom / GEA); used for IQF + cold storage |
| Boiler | 8 ton/hr steam; 1.2 MPa | Natural gas-fired; provide steam for peeling + blanching + CIP heating |
| Compressed air | 10 m³/min; 7 bar | Oil-free screw compressor; dried and filtered; used for ejectors + controls |
| Water treatment | Reverse osmosis + UV sterilization | 50 m³/day capacity; potable water for processing + CIP |
| Wastewater treatment | DAF (dissolved air flotation) + biological | 300 m³/day capacity; discharge compliant with GB 8978; BOD removal ≥ 95% |
| Electrical supply | 1,600 kVA transformer | Grid-fed; backup diesel generator (400 kVA) for critical loads (freezer + cold storage) |
Utility Specifications
Power
| Parameter | Specification |
| Connected load | 1,600 kVA |
| Transformer | 2 × 800 kVA oil-filled (parallel operation) |
| Backup generator | 400 kVA diesel; automatic start (≤ 15 sec) for freezers and cold storage |
| Typical consumption (processing) | 250–350 kWh / ton of finished product |
| Annual consumption | ~3,000–3,500 MWh |
Water
| Parameter | Specification |
| Source | Municipal supply + supplementary borehole (treated) |
| Daily consumption (processing) | 800–1,200 m³/day (peak); includes washing, blanching, CIP, cooling |
| Water per ton of product | 8–12 m³ / ton of finished fries (includes washing water) |
| Treatment capacity | RO plant: 50 m³/day (makeup water for boiler + processing); UV sterilization on process water |
| Discharge standard | GB 8978 Grade 1 (COD ≤ 60 mg/L; BOD ≤ 20 mg/L; SS ≤ 20 mg/L; NH₃-N ≤ 8 mg/L) |
Steam
| Parameter | Specification |
| Boiler capacity | 8 ton/hr saturated steam at 1.2 MPa |
| Fuel | Natural gas |
| Typical consumption (steam peeling) | 0.15–0.20 ton steam / ton raw potatoes |
| Typical consumption (blanching) | 0.10–0.15 ton steam / ton product |
| Condensate return | ~80% (energy recovery) |
Refrigeration
| Parameter | Specification |
| Total refrigeration capacity | 1,200 kW |
| Refrigerant | Ammonia (R-717) |
| IQF freezer load | 600 kW (average; peaks at 800 kW during full production) |
| Cold storage load | 350 kW (room temp −20°C to −25°C; 10,000 pallet space) |
| CA storage cooling | 250 kW (room temp 7–10°C; 30,000 tons) |
Water Treatment System
Process Water Treatment
| Stage | Description |
| Intake | Municipal water + borehole water blended in balancing tank |
| Coarse filtration | Multi-media filter (sand + anthracite; 25 µm) |
| Fine filtration | Cartridge filter (5 µm) |
| UV sterilization | 254 nm UV; 40 mJ/cm² dose; 50 m³/hr flow rate |
| Distribution | Dedicated HDPE pipework to all production points; no dead legs |
Wastewater Treatment
| Stage | Description | Efficiency |
| Screening | Bar screen + rotary drum screen; remove solids > 3 mm | Solids removed |
| DAF (Dissolved Air Flotation) | 300 m³/day; chemical coagulation (PAC + polymer); float removal | TSS removal ≥ 85%; oil/grease ≥ 90% |
| Anaerobic treatment | UASB reactor (upflow anaerobic sludge blanket); 24 hr HRT | COD reduction 60–70% |
| Aerobic treatment | Activated sludge with fine bubble diffusers; 12 hr HRT | COD reduction ≥ 90% |
| Clarification | Secondary clarifier; sludge recycling | |
| Discharge | Complies with GB 8978 Grade 1 standard | |
Infrastructure Details
| Element | Specification |
| Building construction | Steel frame + insulated sandwich panels (foam core, 100 mm walls, 150 mm freezer roof) |
| Floor loading | 5 kN/m² (production); 20 kN/m² (cold storage); 30 kN/m² (CA store) |
| Cold storage insulation | PIR foam panels; 150 mm walls; 200 mm ceiling; U-value ≤ 0.15 W/m²K |
| CA storage insulation | PIR foam panels; 150 mm walls; U-value ≤ 0.18 W/m²K |
| Loading docks | 6 dock levelers with dock shelters; 2 dedicated refrigerated docks |
| Vehicle scale | 60-ton capacity; electronic weighbridge |
Location Advantage
| Route | Distance | Transit Time |
| Factory → Beijing | 200 km | ~2.5 hours by road |
| Factory → Tianjin Port | 300 km | ~3.5 hours by road |
| Factory → Qingdao Port | 700 km | ~7 hours by road |
| Factory → Shanghai | 1,300 km | ~14 hours by road or via Tianjin Port sea route |
| Nearest expressway | Zhangshi Expressway (S10) | 5 km from factory gate |
The factory's location in the Guyuan plateau (1,400 m elevation) provides natural insulation — cooler ambient temperatures from September to May reduce cold storage energy costs by an estimated 15–20% compared to coastal or lowland plants.
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