FOOD PRESERVATION

UNIT 2 - FREEZING
FREEZING - INTRODUCTION
 Freezing is the unit operation in which the temperature of a food is reduced below its freezing point and a
proportion of the water undergoes a change in state to form ice crystals. The immobilisation of water to ice and
the resulting concentration of dissolved solutes in unfrozen water lower the water activity (aw) of the food.
 Preservation is achieved by a combination of low temperatures, reduced water activity and, in some foods, pre-
treatment by blanching. There are only small changes to nutritional or sensory qualities of foods when correct
freezing and storage procedures are followed.
 The major groups of commercially frozen foods are as follows:
 fruits (strawberries, oranges, raspberries, blackcurrants) either whole or pure´ed, or as juice concentrates
 vegetables (peas, green beans, sweetcorn, spinach, sprouts and potatoes)
 fish fillets and seafoods (cod, plaice, shrimps and crab meat) including fish fingers, fish cakes or prepared dishes with an
accompanying sauce
 meats (beef, lamb, poultry) as carcasses, boxed joints or cubes, and meat products (sausages, beefburgers, reformed steaks)
 baked goods (bread, cakes, fruit and meat pies)
 prepared foods (pizzas, desserts, ice cream, complete meals and cook–freeze dishes).
 FREEZING – MODE OF ACTION

 The freezing of foods slows down, but does not stop, the physicochemical and biochemical reactions that govern the
deterioration of foods.
 During storage, there is a slow progressive change in organoleptic quality, which does not become objectionable for
some time.
 The loss of quality of frozen foods depends primarily on storage temperature, length of storage time, and thawing
procedure.
 Microbial growth is completely stopped below –18°C, and both enzymatic and nonenzymatic changes continue at much
slower rates during frozen storage.
 The freezing process reduces the random motion and rearrangement of molecules in the matrix.
 Freezing involves the use of low temperatures, and reactions take place at slower rates as temperature is reduced.
 The presence of ice and an increase in solute concentration can have significant effects on the reactions and the state of
the matrix.
 The final influence of temperature on chemical reactions due to freezing could be grouped as: (a) normal stability (a
temperature decrease results in a slower reaction rate, thus better stability when foods are stored); (b)
neutral stability (the temperature has no influence on the reaction rate); or (c) reversed stability (a
temperature decrease results in an increased reaction rate).
 Regardless of the type of aqueous system, concentration during freezing causes the unfrozen portion to undergo
marked changes in physicochemical properties such as ionic strength, pH, viscosity, water activity, surface and interfacial
tension, and oxidation–reduction potential. It is important to note that oxygen is almost totally expelled from ice
crystals as they are formed.
 FREEZING – MODE OF ACTION

 There are three types of cell damage due to freezing: osmotic damage, solute-induced damage, and structural
damage
 Osmotic damage - In slow cooling, ice forms slowly in the external cells. If there is sufficient time, water from
the cells migrates out by osmotic pressure. This results in cell shrinkage and some membrane damage. This water
does not return to the cells on thawing due to the damage to the cell wall, and the consequence is drip loss. The
concentration of the solute increases as freezing progresses. Thus, high solute concentrations of the unfrozen
matrix, in particular high salt, can cause damage to many polymeric cell components and may kill the cell – called
Solute induces damage.. This concentration effect is present irrespective of whether freezing is fast or slow.
Cryoprotectants, such as sugars, are usually added to the aqueous phase to reduce salt-induced damage.
 In addition to the concentration effect, the formation of ice within the cell may cause damage to the delicate
organelle and membrane structure of the cell. – lead to Structural damage. As a consequence, enzyme systems
may be released, leading to a variety of effects, including off-flavor production. This can be prevented by blanching,
a prefreezing heat treatment that denatures enzymes.
 It is possible to design and control a convenient freezing process through the knowledge of the mechanisms of
damage for each particular food item. In general, freezing preservation is far from perfect, and awareness of this
fact is needed if techniques are to be developed to overcome known shortcomings and assure that this method
remains competitive with the other major methods of food preservation. A strategic quality approach (quality
enhancement) may provide a higher success rate for new frozen food products. Product quality improvement and
energy reduction or increased process efficiency are major issues related to the freezing process.
Specific heat
• Is the quantity of heat that is gained or lost by a unit mass of products to
a accomplish a unit change in temperature without the change in state
(kJ/kg C)
Sensible heat
• Is that heat when added or subtracted from material changes their
temperature without change in its phase and it can be sensed
Latent heat
• Is the heat required to change the physical state of materials at constant
temperature
 ICE CRYSTALS FORMING-CRYSTALLIZATION

1.Nucleation (site for crystal formation and growth)

• Association of molecules into a tiny ordered particles sufficient to survive
and serve as a site for crystal growth. It can be:
• –Homogenous (pure water)
• –Heterogeneous (most foods)
• –Dynamic (spontaneous)

2.Crystal growth (where it is formed)

• Is the enlargement of the nucleus by the orderly addition of molecules.
Crystal growth can occur at temperatures just below melting point while
nucleation starts at lower temperature (supercooling)
• Heat transfer is most responsible for limiting the rate of crystallization due to
the large amount of latent heat needed
 SLOW FREEZING

Rates of cooling of less than 1°C/min

Ice crystals form in extracellular locations

Large ice crystals formation

Maximum dislocation of water

Shrinkage (shrunk appearance of cells in frozen state)

Less than maximum attainable food quality

 RAPID OR QUICK FREEZING

Produces both extracellular and intracellular (mostly) locations of

ice crystals

Small ice crystals

Numerous ice crystals

Minimum dislocation of ice crystals

Frozen appearance similar to the unfrozen state

Food quality usually superior to that attained by slow freezing

Sharp Freezing Quick Freezing
1. It refers to freezing in air with only natural 1. It refers to freezing in air with vigorous circulation.
circulation. 2. Occur when immersed in a refrigerant or by
2. Occur slowly in deep freezer air blast
2. Temperature may vary from –15 °C to –29°C. 2. The temperature of the air is usually between –18°
and –34°C.

3. Takes longer time to freeze depending on
composition, consistency & container of food
held
Time required to achieve sharp freezing is 3-72 hrs.
4. Large ice crystals are formed. More mechanical
damage of food is observed.
3. Time required to achieve above temperatures is 30
min or lower.
4. Small ice crystals are formed hence there is less
mechanical damage of food.

5. Gradual slowing of enzyme action 5. Rapid slowing of enzyme action

Thawed with time Thawed faster

 FROZEN FOOD PROPERTIES

The freezing process has a dramatic influence on the thermal properties of the food product.
Because of the significant amount of water in most foods and the influence of phase change on
properties of water, the properties of the food product change in a proportional manner. As the
water within the product changes from liquid to solid, the density, thermal conductivity, heat
content (enthalpy), and apparent specific heat of the product change gradually as the temperature
decreases below the initial freezing point for water in the food.
 THE THEORY OF FREEZING

Sensible heat is first removed to lower the temperature of

food to the Freezing Point

Heat produced during respiration in case of fresh foods

(Fruits and Vegetables) is also removed.

Then the Latent Heat of Fusion/crystallization of water is

also removed to form ice crystals.

The Latent Heat of Fusion/crystallization of other

components of food (fats) is also removed.
 FREEZING PROCESS

➢ The freezing process mainly consists of thermodynamic and

kinetic factors, which can dominate each other at a particular
stage in the freezing process.
➢ Major thermal events are accompanied by reduction in heat
content of the material during the freezing process as is
shown in Figure. The material to be frozen first cools down to
the temperature at which nucleation starts. Before ice can
form, a nucleus, or a seed, is required upon which the crystal
can grow; the process of producing this seed is defined as
nucleation.
➢ Once the first crystal appears in the solution, a phase change
occurs from liquid to solid with further crystal growth.
➢ Therefore, nucleation serves as the initial process of freezing,
and can be considered as the critical step that results in a
complete phase change
According to International Institute of Refrigeration (IRR), the
freezing process is basically divided into three stages based on
major temperature changes in a particular location in the product,
as shown in Figures for pure water and food respectively.
1. Beginning with the prefreezing stage, the food is subjected to
the freezing process until the appearance of the first crystal. If
the material frozen is pure water, the freezing temperature
will be 0 °C and, up to this temperature, there will be a
subcooling until the ice formation begins. In the case of foods
during this stage, the temperature decreases to below
freezing temperature and, with the formation of the first ice
crystal, increases to freezing temperature.
2. The second stage is the freezing period; a phase change
occurs, transforming water into ice. For pure water,
temperature at this stage is constant; however, it decreases
slightly in foods, due to the increasing concentration of
solutes in the unfrozen water portion.
3. The last stage starts when the product temperature reaches
the point where most freezable water has been converted to
ice, and ends when the temperature is reduced to storage
temperature
PHASE DIAGRAM OF WATER
 FREEZING CURVES FOR:
A- WATER B- BINARY SYSTEM

A- water B- Binary system

 FREEZING CURVE

Sensible heat

Latent heat

Eutectic
temperature

Supercooling

18
 1. Point AB
FREEZING CURVE

• Food cooled below freezing point (less

than 0)
• At point B water remains liquid although
the temperature is below 0°C.
• This phenomenon is called Supercooling SUPERCOOLING
Going below freezing point without the formation of
ice crystals ( crystallization)

It yields better quality food than if not present

This shows that the undesirable effects of freezing

are due to ice formation rather than reduction of
temperature
2. Point BC
• Temperature rises rapidly to the freezing
point (giving off heat of fusion)
• Ice crystals begin to form
• Latent heat of crystallization is released

20
 ICE CRYSTALS FORMING- CRYSTALLIZATION

Nucleation (site for crystal formation and growth)

• Association of molecules into a tiny ordered particles sufficient to
survive and serve as a site for crystal growth. It can be:
• Homogenous (pure water)
• Heterogeneous (most foods)
• Dynamic (spontaneous)

Crystal growth (where it is formed)

• Is the enlargement of the nucleus by the orderly addition of molecules.
Crystal growth can occur at temperatures just below melting point
while nucleation starts at lower temperature (supercooling)
• Heat transfer is most responsible for limiting the rate of crystallization
due to the large amount of latent heat needed
2
1
ICE CRYSTAL GROWTH
3. Point CD
• Heat is removed as latent heat so that
T=constant
• Major part of ice is formed
• In unfrozen liquid there is an increase in
solute concentration and that is why the
temperature falls slightly
4. Point DE
• One of the solutes becomes supersaturated and
crystallizes out.
• Latent heat of crystallization is realized and the
temperature rises to EUTECTIC point for that
solute
 EUTECTIC POINT

Temperature where there is no further concentration of

solutes due to freezing, thus the solution freezes

Temperature at which a crystals of individual solute exists in

equilibrium with the unfrozen liquor and ice

Difficult to determine individual eutectic points in the complex

mixtures of solutes in foods so term FINAL EUTECTIC POINT
is used
25
 EUTECTIC TEMPERATURES

Ice Cream - 55⁰C

Meat -50⁰C to -60⁰C

Bread -70⁰C
• MAXIMUM ICE CRYSTALS FORMATION IS NOT
POSSIBLE UNTIL THIS TEMPERATURE IS
REACHED

26
FREEZING CURVE

5. Point FG
• Temperature of the ice water mixture falls to the
temperature of the freezer
• Percentage of water remains unfrozen

Food frozen below point E forms a glass

which encompasses the ice crystals.
 GLASS TRANSITION TEMPERATURE,TG

Glass transition temperature:

• Is the temperature at which the products
undergoes a transition from the rubbery
to the glassy state
• Formation of glass protects the texture of
the foods and gives good storage stability

29
 ICE CRYSTALS

• The location of ice crystals in tissue is

the function of

1. Freezing rate
• Slow
• Rapid
2. Specimen temperature
3. Nature of the cell
 RAPID VS. SLOW FREEZING

Rapid freezing

Thawed food

Slow freezing
30
 DESIGNING FREEZING SYSTEMS
❑ The freezing time and freezing rate are the most important parameters in designing freezing systems.
❑ The quality of the frozen product is mostly affected by the rate of freezing, while time of freezing is calculated
according to the rate of freezing.
❑ For industrial applications, they are the most essential parameters in the process when comparing different
types of freezing systems and equipment

Freezing Time: is the time taken to lower

the temperature of the product from its initial
temperature to a given temperature at its
thermal centre.
• Dimensions and shape of product, particularly thickness
• Initial and final temperatures
• Temperature of refrigerating medium
• Surface heat transfer coefficient of product
• Change in enthalpy
• Thermal conductivity of product
The freezing rate (°C/h) for a product or
package is defined as the ratio of difference
between initial and final temperature of
product to freezing time.
At a particular location within the product, a
local freezing rate can be defined as the ratio
of the difference between the initial
temperature and desired temperature to the
time elapsed in reaching the given final
temperature
 PLANK’S EQUATION

where λ1 is the latent heat of frozen fraction, k and r are the thermal conductivity and density of the
frozen layer, while h is the coefficient of heat transfer by convection to the exterior. Tf denotes the body
temperature of the product when introduced into a freezer in which the external temperature is Te The
coefficients R and P are geometry of the product frozen. where the letter e denotes the dimension (i.e.
for infinite slab geometry, e is thickness of the slab and for infinite cylinder or sphere e is replaced by r
which denotes the radius of the clylinder or sphere).
 QUALITY OF FROZEN FOODS – FACTORS INFLUENCING
Freezing Rate Microbial Chemical Processing and Cold Chain
and Quality Aspects changes and Packaging Tolerance and
Quality Factors Quality
Physical
changes and
Quality
Rancidity Pretreatments Temperature
Free and Bound Cycling
water
Color, Flavor
Weight loss and Vitamin Storage and
Loss Display
Time-
Recrystallization Temperature
Release of Tolerance
Retrogradation Enzymes Thawing Indicators
Protein
Denaturation Hydrolysis
Freezer Burn
Acetaldehyde
Glass Formation Formation
Functional
Properties
 1. FREEZING RATE AND QUALITY

❑ Generally, fast freezing produces better quality frozen food than slow freezing
❑ The freezing rate affects this process because rapid freezing results in less cell dehydration
(since water has less time to diffuse out of the cell), less breakage of cell walls, and less textural
damage.
❑ The more rapid the crystallization, the smaller the ice crystals, and the lesser the damage caused
by the process of freeze concentration.
❑ Consequently, a reverse situation holds for thawing. Slow heating allows equilibrium to be
reached as the melted water diffuses back through the cell wall.
 2. MICROBIAL ASPECTS

❑ The detrimental effects of freezing on microorganisms may be desirable or undesirable, depending on the types of
food products
❑ In frozen foods without any added beneficial cultures, microbial growth or spoilage is not desirable, whereas care
must be taken to reduce the damage in cells during freezing of foods containing microbial cultures.
❑ The maximum recommended storage temperature at which micro- biological spoilage ceases is registered between
-9°C and -12°C.
❑ Although microbiological spoilage can be avoided at these temperatures, the enzymes present in the product will
still play a part in spoilage
❑ There is considerable variation in the ability of bacteria to resist damage by freezing
❑ In general, Gram-negative bacteria are less resistant to freezing death than are Gram- positive bacteria.
❑ Non sporulating rods and spherical bacteria are the most resistant, while bacterial spores, such as Clostridium and
Bacillus, remain unaffected by freezing. Bacteria in the stationary phase are more resistant than those in the log
phase
❑ Genera commonly encountered in frozen food include Pseudomonas, Achromobacter, Flavobacter, Micrococcus,
Lactobacillus, Corynebacterium-like catalase-positive rods, Enterococci, Streptococcus lactis, S. lactis-like strepto- cocci,
Aerococcus, and Pediococcus
 3. PHYSICAL CHANGES AND QUALITY

3.1 Free and Bound water 3.2 Weight Loss

❑ Different types of water are present in frozen ❑ Dehydration or weight loss should be
foods. regarded as an important quality
parameter for frozen unpacked foods,
❑ These can be broadly categorized as free and
mainly in animal tissue.
unfreezable water, which does not freeze even
at very low temperatures. ❑ Foods lose moisture during the freezing
process because their surface is exposed
❑ A major cause of product degradation is the
to heat and a moisture gradient exists
amount of unfrozen water present in the
within the environment
frozen matrix.
❑ Weight loss of meat during freezing and
❑ Unfrozen water is known to be reactive,
frozen storage, found a range of 0.28%–
particularly during frozen storage, rendering
2.98% during the freezing process.
the product susceptible to deteriorative and
enzymatic reactions and limiting its frozen shelf
life.
 3. PHYSICAL CHANGES AND QUALITY
3.3 Recrystallization
❑ Ice crystals formed after freezing are unstable
and might undergo changes in time if they have
not been stabilized. Recrystallization is the
process of changes in the number, size and
shape of crystals during frozen storage.
❑ Although the amount of ice stays constant
throughout this process, it can alter and damage
the structure and stability of frozen food
systems
❑ Recrystallization basically involves small crystals
disappearing (melting), large crystals growing
and crystals fusing together
❑ Ice recrystallization during frozen storage
influences the product quality in different ways.
3.4 Retrogradation
❑ Starch retrogradation refers to the
reassociation or the recrystallization of the
polysaccharides in gelatinized starch, i.e.
amylase and amylopectin.
❑ It occurs when starch-based foods are
exposed to freeze/thaw cycles, or when
moisture migration occurs in starchy foods,
impacting textural and nutritional attributes
of foods.
❑ Starch retrogradation is a main mechanism
for staling of bakery products, increasing
firmness of crumb, changing flavor and aroma,
and causing loss of crispness
 3. PHYSICAL CHANGES AND QUALITY
3.5 Protein denaturation
❑ Quality loss during cold storage of meat is
characterized by an increase in loss of water-
holding capacity, a decrease in protein
extractability, a decrease in sulfhydryl groups, and
a slight loss in ATPase activity
❑ In frozen meat, water losses are related to the
denaturation of myofibrillar protein
❑ During freezing, water molecules freeze out and
migrate to form ice crystals, resulting in the
disruption of the organized H-bonding system
that stabilizes the protein structure
3.6 Freezer Burn
❑ Moisture loss by evaporation from the surface of a
product leads to freezer burn, an unsightly white color
that can be mistaken for mold but is resolved on
rehydration during cooking unless it is severe
❑ It is usually in the form of patches of light-colored
tissues, produced by evaporation of water, which leave
air pockets between meat fibers
❑ Dehydration of the product or freezer burn may occur
while freezing an unpackaged food item in blast
freezers unless the velocity of air is kept to about
2.5m/s and the period of exposure to air is controlled.
❑ This dehydration can be controlled by humidification,
lowering of storage temperatures, or better packaging
 3. PHYSICAL CHANGES AND QUALITY
3.7 Glass Formation
❑ The glass transition has a dramatic effect
on frozen food quality. The product is
most stable below TgS, and moisture has
little influence on TgS.
❑ The presence of low molecular weight
(LMW) solutes lowers the TgS, and high
molecular weight (HMW) exerts little
effect.
❑ This means that with increasing maturity,
many vegetables display a decrease in
sugars and an increase in starch, thus
increasing the TgS and the stability of
frozen foods.
3.8 Functional properties
❑ Functional properties on any food product are normally affected by
differences in freezing and thawing methods.
❑ Properties such as rheological (both flow and dynamic), textural,
mechanical, consistency, appearance and sensory attributes and water-
holding capacity have been correlated with freezing and thawing
processes.
❑ The changes in specific functional properties become microscopically and
qualitatively related to structural modifications or rearrangements of the
food items.
❑ Texture is important in frozen vegetables. After freezing and thawing,
firmness decreased, rupture strain increased, and consequently crispness
decreased
❑ Changes in mechanical behavior (wedge penetration, tensile, and
compression) of the material were directly related to the degree of cell
damage by freezing.
❑ Thawing and refreezing could lead to quality deterioration
 4. CHEMICAL CHANGES AND QUALITY

4.1 Rancidity 4.2 Color, Flavor and Vitamin Loss

❑ The most important color changes in fruits and vegetables are

related to three biochemical or physico-chemical mechanisms:
(a) changes in the natural pigments of vegetable tissues
❑ Oxygen is the bugbear of almost all frozen foods, (chlorophylls, anthocyanins, carotenoids), (b) development of
leading to oxidative rancidity (if any unsaturated enzymatic browning, and (c) breakdown of cellular chloroplasts
lipids are present), loss of color, and development and chromoplasts
of off-flavors.
❑ Freezing affects the flavor and aroma of frozen foods. For ex,
❑ Freezing results in a concentration of solutes, freezing of strawberries is usually associated with a reduction in
which catalyze the initiation of oxidative reactions aroma and the development of off-flavor. The decrease in aroma is
and disrupts and dehydrate cell membranes, due to a rapid decomposition and diffusion of esters
exposing membrane phospholipids to oxidation.
❑ Retention of nutritional components in foods is a concern when
❑ Membrane phospholipids are highly unsaturated any type of preservation method is used but freezing is probably
and have been demonstrated to be the initiation the least destructive. The destruction of vitamin C (ascorbic acid)
point of oxidation in muscle tissue occurs during freezing and frozen storage. This loss is influenced
by blanching conditions, types of freezing, package types, and time-
temperature conditions. The loss is mainly due to the oxidation
or to the action of ascorbic acid oxidase
 4. CHEMICAL CHANGES AND QUALITY
4.3 Release of Enzymes
❑ The disruption of plant or animal
tissues by freezing leads to the release
of enzymes bound to the structures
❑ Ex: Beef and pig skeletal muscle
contain two isozymes of glutamic-
oxalacetic transaminase: one in the
mitochondria and other in the
sarcoplasm.
❑ It was found that freezing and thawing
cause a remarkable increase of
glutamic-oxalacetic transaminase
activity in the muscle press juice
4.4 Hydrolysis 4.5 Acetaldehyde Formation
❑ Generally, starch in vegetables does not ❑ The formation of
change significantly during frozen acetaldehyde in frozen
storage vegetables increases during
storage and is thus an
❑ No significant changes in starch of indication of shelf life
beans, peas, okra, or mallow during
storage at -18°C for 1 year. ❑ Acetaldehyde is a product
of aerobic fermentation of
❑ The reducing sugars of these frozen pyruvate in plant tissues.
vegetables were increased during
storage owing to the hydrolysis of both
oligo- and polysaccharides of these
products.
❑ Thus, the amount of reducing sugars is a
good indicator of storage life
 5. PROCESSING AND PACKAGING FACTORS

5.1 Pretreatments 5.2 Storage and Display 5.3 Thawing

1. Blanching: Most vegetables and some fruits ❑ Packaging, storage, and display ❑ Thawing as a final and obligatory
are blanched before freezing. Blanching also affect the frozen food step of the freezing process is
destroys the permeability of cell membranes, quality. quite important.
destroys cell turgor, removes intercellular air, ❑ Loss of quality in frozen
filling these spaces with water, and establishes a foods is a gradual process; ❑ Thawing properly is essential to
continuous liquid phase. As a result, ice the changes being slow or maximize quality retention and
crystallization can occur through the entire very slow, cumulative, and safety of frozen foods.
matrix of food without interruption during irreversible. ❑ Microbiologically safe thawing
freezing process. It also affects texture, color, ❑ Optimum quality requires process includes: (a) inside a
flavor, and nutritional quality by inactivating care in every stage of refrigerator at temperatures
enzymes. processing, packaging, storage, below 5°C, (b) microwave oven,
2. Heat Treatments and marketing sequence or (c) as part of the cooking
3. Dripping Pretreatments treatment
4. Bacterial Ice Nucleators or AntiFreeze
Proteins
5. Osmotic Concentration
6. Cryoprotection
7. Irradiation
 6. Cold Chain Tolerance and Quality
6.1 Temperature Cycling
❑ The steps in the frozen food cold chain are freezing,
transport by refrigerated vehicle or container, distribution
store, retail display cabinet, the unrefrigerated period
between retail outlet and home, and time in a home freezer
before being consumed in the frozen state, thawed or end
cooked.
❑ Temperature abuse at any of the above steps causes quality
deterioration.
6.2 Time – temperature Tolerance indicators
❑ The concept of time-temperature tolerance
(TTT) to describe frozen food stability is
important.
❑ Physicochemical, chemical, or biological
reactions give an irreversible indication
(usually visible) of the history of the product.
❑ These indicators are placed on the outside of
the packages and combine the time and
temperature conditions to which they have
been exposed
 DEFECTS IN FROZEN FOODS

❑ Freezer burn – fluctuations in temperature

❑ Recrystallization
❑ Drip loss
❑ Loss of functionality – Color, Texture,Vitamins
❑ Rancidity
❑ Dehydration
❑ Chemical reactions
❑ Protein Denaturation

44
 THAWING

Thawing is the process when the frozen material is

allowed to stand at ambient temperature, i.e., above
0°C to become free from ice so that further
mechanical processing such as slicing, cutting,
molding can take place

❑ Meat thawed by microwave indicated low drip loss by

thawing, high cooking loss and high WHC with higher
moisture contents than other thawing methods regardless of
the cut of beef which was thawed by each thawing method
(refrigeration, RT, cold water and microwave).
❑ Sensory evaluation was better for beef thawed by
microwave, regardless of the cut. Therefore, research has
shown that microwave thawing is an appropriate way to
reduce the deterioration of quality by freezing.
 EFFECTS OF THAWING

❑ Thawing is the process of taking a frozen product from frozen to a temperature (usually above 0°C)
where there is no residual ice, i.e. “defrosting”. Thawing is often considered as simply the reversal
of the freezing process. However, inherent in thawing is a major problem that does not occur in the
freezing operation.
❑ The majority of the bacteria that cause spoilage or food poisoning are found on the surfaces of many
foods. During the freezing operation, surface temperatures are reduced rapidly and bacterial
multiplication is severely limited, with bacteria becoming completely dormant below -10°C. In the
thawing operation these same surface areas are the first to rise in temperature and bacterial
multiplication can recommence. On large objects subjected to long uncontrolled thawing cycles,
surface spoilage can occur before the centre regions have fully thawed.
❑ Most thawing systems supply heat to the surface and then rely on conduction to transfer that heat
into the centre of the food. A few use electro magnetic radiation to generate heat within the food. In
selecting a thawing system for industrial use, a balance must be struck between thawing time,
appearance end microbiological condition of product, processing problems such as effluent disposal
and the capital and operating costs of the respective systems. Of these factors, thawing time is the
principal criterion that governs selection of the system. Appearance, microbiological condition and
weight loss are important if the material is to be retailed in the thawed condition but are less
important if the food is to be used for further processing.
FREEZER BURN
 METHODS OF FREEZING
Indirect contact Freezing by
with the Contact with a Plate Freezing
refrigerant Cooled Solid
Freezing by
Immersion
Contact with a
Freezing
Cooled Liquid Fluidized Bed
Freezing
Cabinet
Freezing by Freezing
Contact with a Belt Freezing
Cooled Gas Air-Blast
Direct Freezing
contact with Spiral Freezing
the
refrigerant Liquid Nitrogen
Cryogenic
Tunnel Freezing
Freezing
Solid Carbon-di-
oxide

Emerging Dehydro
Freezing Freezing and
Techniques IQF
 1. BY CONTACT WITH COOLED SOLID - PLATE FREEZING

❑ In this type of freezer, materials being frozen are separated from the
refrigerant by a conducting material, usually a steel plate.
❑ Indirect contact freezers generally provide an efficient medium for heat
transfer, although the system has some limitations, especially when used
for packaged foods due to resistance of package to heat transfer.
Additionally, corrosive effects may occur due to interaction of metal
packages with heat transfer surfaces
❑ In this method, the product is sandwiched between metal plates and
pressure is usually applied for good contact. Plate freezers are only
suitable for regular shaped materials or blocks. When the product has
been frozen, hot liquid is circulated to break ice seal and defrost. Spacers
should be used between the plates during freezing to prevent crushing or
bulging of the package.
❑ This type of freezing system is only limited to regular-shaped materials or
blocks like beef patties or block-shaped packaged products. A typical plate
freezer is shown in Figure 13b.
 2. BY CONTACT WITH COOLED LIQUID - IMMERSION FREEZING

❑ In this method, food is immersed in a low-temperature brine to

achieve fast temperature reduction through direct heat exchange.
❑ The product is immersed in this solution or sprayed while being
conveyed through the freezer, resulting in fast temperature
reduction through direct heat exchange
❑ The fluids usually used are salt solutions (sodium chloride), sugar
solutions, glycol and glycerol solutions, and alcohol solutions.
❑ The solutes used must be safe to the product in terms of health,
taste, color, and flavor, and the product must be denser than
fluids. Dilution from the foods may change the concentration,
thus it is necessary to control the concentration to maintain a
constant bath temperature.
❑ To ensure that the food does not come into contact with liquid
refrigerants, flexible membranes can be used to enclose the food
completely while allowing rapid heat transfer.
❑ Methanol or ethanol can also be used. Although the methanol
will be removed during cooking, it is poisonous whereas ethanol
is safe.Alcohols also pose a fire hazard in processing plants.
3. BY CONTACT WITH COOLED GAS – 3.1 CABINET FREEZING

❑ In this method, cold air is circulated in a cabinet where

product is placed in a tray.
❑ The moisture pick-up from the product surface may deposit
on the cooling coils as frost, which acts as an insulation.
❑ A cabinet freezer with air velocity at least 5 m/s generates
high heat-transfer rates
 3. BY CONTACT WITH COOLED GAS – 3.2 AIR BLAST FREEZING

❑ The air blast freezer is one the oldest and commonly used freezing equipment due to its temperature stability
and versatility for several product types. In general, air is used as the freezing medium in the freezing design,
either as still air or forced air.
❑ Freezing is accomplished by placing the food in freezing rooms called sharp freezers. Still, air freezing is the
cheapest way of freezing and has the added advantage of a constant temperature during frozen storage, which
allows usage for unprocessed bulk products like beef quarters and fish.
❑ However, it is the slowest method of freezing due to the low surface heat transfer coefficient of circulating air
inside the room.
❑ An improved version of the still air freezer is the forced air freezer, which consists of air circulation by
convection inside the freezing room. However, even modification of the sharp freezer with extra refrigeration
capacity and fans for increased air circulation does not help control the air flow over the products during slow
freezing.
 3.2 AIR BLAST – 3.2.1 FLUIDIZED BED FREEZING

❑ A fluidized bed freezer consists of a bed with perforated

bottom through which refrigerated air is blown vertically
upward.
❑ The air velocity must be greater than the fluidization
velocity.
❑ This freezing method is suitable for small particulate food
bodies of fairly uniform size, e.g., peas, diced carrots and
potatoes, corns, and berry fruits.
❑ The high degree of fluidization improves the heat-transfer
rate and results in good use of floor space.
 3.2 AIR BLAST – 3.2.2 BELT FREEZING

❑ The first mechanized air-blast freezers consisted of a

wire mesh belt conveyor in a blast room for
continuous product flow.
❑ Uniform product distribution over the entire belt is
required to achieve uniform product contact and
effective freezing.
❑ Controlled vertical airflow forces cold air up through
the product layer, thereby creating good contact with
the product particles and increasing the efficiency.
❑ The principal current design is the two-stage belt
freezer. Temperatures used usually are -10°C to -4°C
in the precool section and -32°C to -40°C in the
freezing section
 3.2 AIR BLAST – 3.2.3 SPIRAL FREEZING

❑ A spiral belt freezer consists of a long belt wrapped

cylindrically in two tiers, thus requiring a minimal floor
space.
❑ The spiral freezer uses a conveyor belt that can be bent
laterally.
❑ It is suitable for products with a long freezing time (generally
10 min to 3 h),and for products that require gentle handling
during freezing.
❑ It also requires a spatial air-distribution system
 3.2 AIR BLAST – 3.2.4 TUNNEL FREEZING

❑ In this process, products are placed in trays or

racks in a long tunnel and cool air is circulated
over the product
❑ In order to allow air circulation, optimum
space is provided between layers of trolley,
which can be moved continuously in and out of
the freezer manually or by forklift trucks.
❑ This freezing system is suitable for all types of
products, although there are some mechanical
constraints including the requirement of high
manpower for handling, cleaning, and
transportation of trays
 4. CRYOGENIC FREEZING

❑ Cryogenic freezing is a relatively new method of freezing in which the food is exposed to an
atmosphere below -60 °C through direct contact with liquefied gases such as nitrogen or carbon
dioxide.
❑ This is a very fast method of freezing; thus, adequate control is necessary for achieving quality
products. It also provides flexibility by being compatible with various types of food products and
having low capital cost
❑ The rapid formation of small ice crystals greatly reduces the damage caused by cell rupture, preserving
color, texture, flavor, and nutritional value. The rapid freezing also reduces the evaporative weight loss from
the products, provides high product throughput, and has low floor space requirements

The product can be exposed to a cryogenic medium in three ways:

• The cryogenic liquid is directly sprayed on the product in a tunnel freezer,
• The cryogenic liquid is vaporized and blown over the food in a spiral freezer or
batch freezer, or
• The product is immersed in cryogenic liquid in an immersion freezer
CRYOGENIC FREEZING – LIQUID NITROGEN AND SOLID CARBON DI OXIDE
➢ Liquid nitrogen, with a boiling temperature of -196 °C at
atmospheric pressure, is a by-product of oxygen
manufacture. The refrigerant is sprayed into the freezer
and evaporates both on leaving the spray nozzles and on
contact with the products.
➢ The system is designed in a way that the refrigerant
passes in counter current to the movement of the
products on the belt giving high transfer efficiency.
➢ Typical food products used in this system are, fish fillets,
seafood, fruits, berries
➢ Also called Dry Ice
➢ When the gas is released to the atmosphere at -70 °C,
half of the gas becomes dry-ice snow and the other half
stays in the form of vapor.
➢ This unusual property of liquid carbon dioxide is used in
a variety of freezing systems, one of which is a pre-
freezing treatment before the product is exposed to
nitrogen spray
5. EMERGING FREEZING TECHNIQUES

❑ Dehydro Freezing

❑ Individual Quick Freezing (IQF)