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Republic of the Philippines

BATANGAS STATE UNIVERSITY


The National Engineering University
Alangilan Campus
Golden Country Homes, Alangilan, Batangas City, Batangas, Philippines 4200
Tel Nos.: (+63 43) 425-0139 loc. 2121 / 2221
E-mail Address: ceafa@g.batstate-u.edu.ph | Website Address: http://www.batstate-u.edu.ph

College of Engineering

Department of Chemical Engineering

WRITTEN REPORT #1

FROZEN PRODUCTS

Prepared by:

ANORICO, IVAN JERIC M.


ARRIETA, ANGEL NICOLE A.
MACATIGBAK, NICOLE P.
PEREZ, IVORY GAIL G.
RODRIGUEZ, KRISSY R.
SIMON, CHRISTIAN D.

Submitted to:

ENGR. JULIANA KASSANDRA P. RODIL


Instructor I

NOVEMBER 2022

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I. INTRODUCTION

Frozen food products are a food product that is preserved at low temperatures and lasts
for a long time. In frozen food processing, freezing is a method of preserving food by lowering
the temperature to inhibit the growth of microorganisms. The product market comprises various
food products, including ready meals, vegetables & fruits, potatoes, meat & poultry, seafood, and
soup. Because frozen products are readily available and ready to eat after being fried or cooked,
consumers can prepare meals at home more easily.

Frozen food items are very well-liked because urban workers must result in a time-saving
lifestyle. Right now, the frozen food industry has a lot of potential.Not only we are in the midst
of an epidemic, but we are also in the midst of a practical lifestyle development. In addition to a
time-saving convenience, frozen foods products can be a benefit for individuals with limited
kitchen space or utensils. Not only can frozen foods be more affordable in price, but they also
can aid in reducing food waste.

Generally, frozen products retain their vitamins and minerals and there is no change to
the carbohydrate, protein or fat content. In some cases, frozen foods have more vitamins and
minerals compared to fresh because fresh foods lose vitamins and minerals over time while
freezing preserves nutrients.

II. INTENDED LEARNING OUTCOMES

1. Identifying the types of frozen products.


2. Identifying the different structure and color of frozen products.
3. Describing and applying the different preparation and processing frozen products.
4. Identifying the different process and types of storage for frozen products

III. CONTENT

GREAT BENEFITS OF FROZEN FOOD PRODUCTS

1. Less Wastage
Frozen products help reduce food waste as you use only what you need – which means
it’s good in terms of cost, as well as the environment. In fact, research published in the British

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Food Journal shows that frozen food generates 47 percent less food waste at home than
non-frozen food, so families can save money while still eating healthy meals.

2. So much Convenience
One advantage of frozen products is that it is quite convenient to use. You just have to
open your freezer, get out your favorite food and use it for cooking. Quite often, frozen foods are
already cut and you do not even have to make any efforts in this regard.

3. Labeling
Frozen food products packages tell you exactly what you’re eating. Packages include
ingredient and nutrition information.

4. Free from Preservatives


Frozen products typically contain no preservatives, as freezing itself is a form of
preservation.

5. No Seasonal Restrictions
Seasonal meat, fish etc. are now available to you all year round as freezing allows you to
choose from a vast selection of seasonal ingredients. You even get that ‘just picked’ taste
experience in season or out of season. These foods can be quickly steamed, stir fried, or
micro-waved to be ready in minutes at any time of the year, satisfying any cravings you have.

6. Longevity and Variety


Another upside of frozen food products is that it often has quite a long durability and
typically has a longer shelf life.

7. Cost-Effectiveness
As many consumers are choosing to eat healthier, they are also looking for ways to save
money while grocery shopping. Since freezing allows food to last much longer, consumers are
buying more items at once and storing them in the freezer—saving money in the long run.

8. Frozen food can also save you plenty of time.


Many people in our society nowadays are quite stressed and have to do many different
things. Quite often, there will not be enough time left to create a meal out of fresh food and many
people want to rely on frozen foods instead.

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9. May prevent the spread of bacteria
Fresh foods are often also quite vulnerable to the spread of bacteria.Especially if they
have minor damages, bacteria as well as mold can develop quite easily and your food may have
just rather limited shelf life. In contrast, if you freeze your food, it will no longer be vulnerable to
those unwanted microorganisms and your food will stay edible for much longer.

10. Gives you more flexibility regarding your meal plan


Frozen food can also give you a much higher level of flexibility regarding what you want
to eat in the next few days.

TYPES OF FROZEN PRODUCTS


Ready-to-eat, ready-to-cook, ready-to-drink, and other frozen food categories include
frozen meat and fish, fruits and vegetables, desserts, snacks, and frozen meat. Frozen food is
widely available in supermarkets and on the internet.

Global Frozen Food Market, By Product Type:

● Frozen Ready Meals


● Frozen Fish/SeaFood
● Frozen Meat Products
● Frozen Pizza
● Frozen Potato Products
● Frozen Bakery Products
● Others

Frozen ready meals

Frozen meal, any of the complete meals or portions of meals that are precooked,
assembled into a package, and frozen for retail sale. They are popular among consumers because
they provide a diverse menu and are convenient to prepare. A frozen prepared meal may contain
a meat entree, a vegetable, a starch-based food such as pasta, and sauce. Examples are hotdogs,
chicken nuggets, pre-made burger patties and many others.

Frozen Fish/Seafoods

Frozen fish products are packaged to minimize dehydration and oxidation. Fish fats and
oils are easily oxidized in the presence of air. Fish processors depend on commercial packaging
materials and wraps to minimize dehydration and oxidation. Ice glazes are formed by immersing
or spraying frozen fish filets or other fish products in chilled water immediately after emerging
from cryogenic freezing equipment. In the USA the use of such technology may be restricted
without approved controls on fresh, unfrozen fish products.

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Frozen Meat products

Freezing very largely suppresses the activity of microorganisms and enzymes, so


ensuring longer preservation than for chilled meat. Meat on the carcass, such as sides of pork,
quarters of beef etc. is rapidly frozen in a carcass which is exposed to a blast of cold air. In the
food industry, freezing usually refers to lowering the temperature of a product below -18 °C.
"Chilling" refers to the rapid cooling of a food product from its manufacturing temperature down
to refrigerated or cold temperatures. Fresh is best and should be chilled at 1-4 C, unless frozen is
available.

Frozen Pizza

A definition of a frozen pizza is a prebaked and deep frozen pizza that is rebaked in the
oven. The frozen nature of frozen pizzas means you're going to end up with a different texture
than you might experience with a fresh take-and-bake pizza. Take-and-bake pizzas offer the
convenience of being able to cook the pizza right out of the freezer and into the oven. One of the
best things about frozen vs. fresh pizzas is that you can keep them in your freezer and have them
ready to go at a moment's notice.

Frozen Potato products

The frozen potato is similar to fresh potato but with a lower starch content and retaining a
lower quantity of oil when fried than par-fried frozen potatoes that exist on the market. This type
of potato may be used in catering in general, being particularly recommended for its low calorie
content. Commonly known frozen potato products are french fries.

Frozen bakery products

Frozen bakery products are nothing but bakery products that are cooked and frozen for
future consumption. These products have increased shelf life owing to the cooking and
preservation techniques used.

Other frozen products

The list of frozen food products is quite numerous and it would take a lot more time to
cover all of them so in this part certain frozen products will just be summarized to shorten the
time of the report.

First up are frozen desserts Frozen yogurt is a frozen dessert made of yogurt, similar to
ice cream, but with lower fat amounts. Its formula contains milk, high levels of sugar, and
stabilizers and emulsifiers compared with yogurt to ensure the air-bubble structure during
freezing. Frozen desserts can be very complicated and prone to defects. Attributes including
dryness on extrusion, shape retention during melting, scoopability and texture all depend
extensively on structure. Changes in structure with storage time, especially ice recrystallization,
can dramatically reduce shelf life.

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Frozen vegetables are often considered an affordable and convenient alternative to fresh
vegetables. Studies show that freezing may affect the nutritional value of certain vegetables
differently. Blanching and freezing vegetables for up to 2 months does not significantly alter
their phytochemicals content. However, other cooking methods, such as boiling, stir-frying, and
microwaving can likewise lead to nutrient losses. Frozen vegetables can often be prepared with
minimal effort, making them a quick and convenient alternative to fresh vegetables.

STRUCTURE OF FROZEN PRODUCTS


Water becomes less dense when it freezes. When water freezes, the molecules rearrange
themselves to form ice crystals. In a crystal lattice, where the molecules are spaced further apart,
creating a more open structure that is less dense. This expansion of sharp-edged crystals bursts
the rigid cell walls and membranes of plants and animals that maintain the structure of the
organism. This means that frozen foods become softer when thawed, altering the texture and
cooking behavior. The damage can be mitigated if food is frozen very quickly, in a process called
blast freezing. (Ruth, n.d.)

❖ Frozen Meat

Methods of freezing affect the ultrastructure of muscle. Slow freezing tends to produce
large ice crystals extracellularly, while quick freezing gives smaller crystals in and outside cells.
A temperature gradient occurs in large pieces of meat and results in a non-uniform ice
morphology. Experiments with pork M. longissimus dorsi found no difference in drip loss
between samples frozen at −20◦C or −80◦C. Slowly frozen meat lost more weight during
freezing, thawing, and cooking than meat frozen at a faster rate, according to some studies.

Three different freezing methods:


➢ Spiral freezing,
➢ Cryogenic freezing using liquid nitrogen, and
➢ Impingement freezing.

❖ Frozen Fish

A common understanding has been that rapid freezing of fish is undesirable due to
disruption of muscle tissue during sudden cooling and that the cell walls during rapid freezing
can burst under the induced pressure caused by expansion of water during rapid freezing. It has
also been assumed that slow freezing results in formation of large ice crystals that can cause
damage to the cell walls, resulting in drip loss during thawing. However, it has been shown that
the differences in the size of the ice crystals does not provide a full explanation, as the walls of
the fish muscle cells are sufficiently elastic to adapt to the larger ice crystals without excessive

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damage. In addition, the water in fish muscle is bound to the protein in the form of a gel so that
little fluid will be lost during thawing even if the damage of the cell walls has occurred.

To add, during freezing of fish fillets, water sprayed on their surface creates a layer of ice
that provides some protection against oxidation in frozen storage. On the other hand, distributors
may be tempted to add too much water because fish is sold by weight.

❖ Frozen Fruits and Vegetables

Raw fruits and vegetables contain large quantities of water in proportion to their weight
and, consequently, the water phase change occurring in freezing makes these products more
susceptible to ice crystal formation and thawing than other types of food. Due to the cellular
structural characteristics of fruits, they are less resistant to the freezing process than vegetables.
Since frozen vegetables are most often consumed cooked, with thawing and cooking operations
occurring simultaneously, quality aspects tend to be less relevant for frozen vegetables than for
frozen fruits. Consumers expect more from a frozen fruit. There are characteristics of fruits that
are difficult to dissociate from the raw product, which means that the negative impact of freezing
on fruit quality is huge.

Examples of Frozen Fruits and Vegetables (small picture na lang mga 6 images per slide)

❖ Apples ❖ Lima Beans


❖ Avocados ❖ Mangos
❖ Broccoli ❖ Mushrooms
❖ Shredded Cabbages ❖ Peas
❖ Carrot ❖ Pineapples
❖ Cauliflower ❖ Potatoes
❖ Cherries ❖ Sweet Potatoes
❖ Corn ❖ Strawberries
❖ Cranberries ❖ Tomatoes
❖ Edamame ❖ And more…
❖ Grapes

❖ Frozen Bakery and Dessert Products


➢ Partially Baked Products

One of the quality problems for frozen partially baked products is the
quality of the crust in terms of color, glossiness and crispiness. Sometimes,
flaking off of the crust (crust flaking also called crust peeling) is mentioned by
industry.

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➢ Partially Fermented Dough

For freezing of partially fermented dough, the degree of fermentation


before freezing plays an important role here. The structure of the dough, which is
made of closed cells, will collapse due to gas contraction during freezing and. The
volume that is lost has to be recovered during the thawing and baking phases.
Researchers recommend a fermentation ratio of 1/3 - 1/2 between non-frozen
dough and fermented dough in comparison to full fermentation.

➢ Ice Cream Products

For ice cream products, During freezing of ice cream, the fat emulsion that
exists in the mix will partially coalesce or destabilize, establishing a
three-dimensional network of fat throughout the product that entraps air and
provides shape retention and meltdown resistance. The dynamic whipping and
freezing process is also responsible for the formation of a fat network or structure
in the product. Ice cream is both an emulsion and a foam.

Rapid freezing promotes small ice crystals, which minimize structure


disruption and water dislocation. Rapid hardening is necessary for product quality,
as it helps to maintain the small ice crystal size distribution. When hardening is
slow, there is too great an opportunity for small ice nuclei formed to recrystallise,
resulting in larger ice crystals and a coarser product. The temperature of the ice
cream when placed in the hardening room should be as cold as possible. Low and
constant storage temperatures maintain this population of ice crystals by
minimizing ice recrystallisation.

Recrystallisation is when the ice crystals that were created during


manufacture undergo morphological changes in number, size, and shape during
storage. It leads to a coarse, icy texture and the defect of iciness. Recrystallisation
is probably the most important change producing quality losses and limitations in
shelf-life. The smaller ice crystals decrease in numbers or disappear while the
larger ones grow even larger.

COLOR OF FROZEN PRODUCTS

❖ Color plays an essential role in how consumers choose food


❖ Often, it is the first factor consumers notice in a food or product’s appearance
❖ Studies suggested that visual taste perception begins in infancy and increases as people
age
❖ For example if something is bright red in color, we instantly assume its tatse is similar to
cherry or cinnamon (Bright red = tastes like cherry or cinnamon)

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❖ If the color is green, we might expect the taste would be something similar to lime or
green apple (Green = tastes like lime or green apple)
❖ Not only that, color is also an indication of freshness
❖ Color changes can occur in frozen foods and are still safe for consumption.
- Bright red-colored meat upon purchase usually turns dark or pale brown depending on its
variety. This may be due to lack of oxygen, freezer burn or abnormally prolonged
storage.
❖ In poultry, freezing doesn't usually cause color changes, yet the bones and meat next to
them can become dark in color. Bone darkening results (it is because) when pigment
seeps through the porous bones of young poultry into the surrounding tissues when the
poultry meat is frozen and thawed
❖ For vegetables and cooked foods, the dulling of color is usually the outcome of excessive
drying due to improper packaging or prolonged storage.
❖ Generally, poultry breast meat will appear red or brown if frozen slowly, while cream or
white appearance if frozen quickly
- Beef, pork and lamb tend to darken during freezing.
- After thawing, the dissimilarity in color disappears.

PREPARATION OF FROZEN PRODUCTS

Factors Affecting the Quality

● Enzymes
- Freezing slows enzyme activity so that many frozen foods, such as meats and
many fruits, will keep satisfied with little or no further treatment.
- Enzymes in vegetables are inactivated by heat during the recommended blanching
process.

● Air
- Oxygen in the air may cause flavor and color changes if the food is improperly
packaged.

● Microorganisms
- Microorganisms do not grow at freezer temperature, but most are not destroyed
and will multiply quickly when the frozen food is thawed and allowed to stand at
room temperature.

● Ice Crystals
- The formation of small ice crystals during freezing is desirable.

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- Fast freezing is the most practical way to form small ice crystals.
- Large ice crystals associated with slow freezing tend to rupture the cells, causing
an undesirable texture change.

● Freezer Temperature
- Maintain a temperature of 0 degrees Fahrenheit or less to keep frozen foods at top
quality.
- The storage life of foods is shortened as the temperature rises.
- Fluctuating temperatures result in growth in the size of ice crystals, further
damaging cells and creating a mushier product.
- Changes in temperature can also cause water to migrate from the product.

● Evaporation of Moisture
- Improperly protected food will lose moisture, color, flavor and texture.
- Ice crystal evaporation from an area at the surface results in freezer burn, which is
a dry, grainy, brownish area that becomes tough.

Processes of Frozen Food Products


1. Pre-treatment
2. Freezing
3. Frozen storage

Types of Pretreatment Process


Blanching
- a process of scalding vegetables or fruits in boiling water or steam for a short time
- it stops enzyme actions which can cause loss of flavor, color and texture

Heat treatments
- helps maintain the firmness of foods while killing microorganisms that may be
present
- common foods that undergo heat treatments include cooked foods, some
vegetables, meats, and fish

Dipping treatments
- foods are immersed in different solutions before freezing
- fruits are generally dipped in ascorbic acid and various sugar solutions to
minimize browning

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- glazing compounds are also used to add a protective layer of coating against
dehydration and oxidation

Cryoprotection
- cryoprotectants includes sugars, amino acids, polyols, methylamines, and
carbohydrate polymers
- helps prevent adverse changes in foods during the freezing and thawing processes

Types of Freezing Process


Contact freezing
- “convection freezing”
- efficient and often faster than air systems
- energy efficient
- well suited to soft, delicate, liquid or semi-liquid foods

Air-blast freezing
- effective in achieving Individually Quick Frozen (IQF) product pieces

Belt freezing
- uses a disposable plastic film that acts as the conveyor belt traveling through the
freezing tunnel over refrigerated plates
- mainly designed for processing delicate, sticky and hard-to-handle products, and
even liquids can be frozen

Plate Freezing
- plate freezers are contact freezers where a refrigerant is passed through hollow
metal horizontal or vertical plates that are pressed either side of the food being
frozen.
- best suited limited regularly shaped products with a maximum thickness of 50 to
70mm

Cryogenic freezing
Cryogenic food freezing uses liquid nitrogen to effectively freeze the food
products

Immersion freezing
- utilize tanks of non-toxic salt, sugar or alcohol solution in water, or
cryogen (liquid nitrogen)

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- The product is immersed, either wrapped or unwrapped, in the solution
whilst being conveyed through a tank.
- The cooling medium can also be sprayed on to the product.

Droplet freezing
- a liquid is injected in the form of a spray or droplets into a cold gaseous or
liquid environment (usually liquid nitrogen) where they subsequently
solidify into individual frozen droplets.

Thawing
When food is thawed the ice crystals melt, the liquid is either absorbed back into the food
or leaks out from the food. Slow, well-controlled thawing usually results in better return of
moisture to the food and results in a food more like the original food than rapid thawing.
- Thawing in the refrigerator is the safest thawing method.

STORAGE OF FROZEN PRODUCTS


Food and dairy products are by their very nature perishable. Low temperatures should be
used to store them in order to extend their shelf life. For this, deep freezers and cold storages are
employed. In general, a room with a temperature of up to 0°C is referred to as a cold store, while
one with a temperature of 0°C to –22°C is referred to as a deep freeze.
Only around 3 to 7 months at -4°F can some food kinds, such pork, seafood, fried
chicken, animal organs, and spinach, be kept at peak quality. Contrarily, under the same
circumstances, sugared fruits, cattle, the majority of vegetables, and bakery goods may all be
preserved for over a year.

General Storage Conditions

Temperature 0°F (-18°C) or colder for some products or if the product is to be stored for
6 months or longer.

Relative Highest possible, consistent with available equipment and good operating
Humidity procedures, to prevent "freezer burn" and drying out where packaging
material for the food may not be sufficiently protective.

Storage Period

Based on how fast they acquire off flavors and whether they discolor readily, different
types of frozen foods have varying stability in frozen storage. Depending on a wide range of
variables, ranging from but not restricted towards the quality of the primary materials and

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product components, processing, and packaging materials, various lots of the same type of frozen
food may have varying stabilities. When storing most items for a period of time longer than six
months, a temperature of 0°F (-18°C) or below is necessary. The relative stability at 0°F (-18 °C)
for various types of frozen products is represented in the table below.

Guidelines for Frozen Food & Cold Storage Warehousing

Capacity
Capacity is a constant challenge for warehouses, particularly when it pertains to frozen
food and cold storage. It's crucial not simply because refrigeration is required to maintain the
ideal temperature for all the items, as well as because product capacity needs to correspond with
storage facility area. The refrigeration to space ratio must be exact. To ensure that airflow is
maintained, there must also be enough room among stacks and walls. Pallets should be employed
for stacks of goods for this.

Temperature
The next guideline deals with the facility's actual temperature. Maintaining the proper air
temperature for the particular frozen items being held in your facility is crucial, in addition to
making sure the refrigeration to capacity ratio is appropriate.
Every storage compartment must contain two or more precise, calibrated temperature
measuring equipment as well as at least one continuous recording device so that the temperature
may be kept under observation. Every day, management should document the temperatures in
each storage facility, check those logs, and keep them for 2 years.

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Refrigeration
The refrigerated equipment should have a security system that triggers whenever the
machine breaks down, whether due to a power failure or any other emergency, in addition to
being suitable for the size of your warehouse and that the temperature is regularly monitored. If a
malfunction happens after business hours, it is advised to have a backup strategy in place to
prevent the frozen food from deteriorating.

Material Handling
In order to limit frozen food access to any heat source or humidity that might eventually
impact the quality of the product, material handling and packing procedures, such as casing and
palletizing, should be carried out as much as possible inside the cold storage facility. Frozen food
must be transported swiftly through any loading areas that have not been refrigerated when
products require being transported from storage to shipment or the other way around.

Shipments
A new delivery of frozen goods should have its temperature monitored as it arrives at the
warehouse. Employees should alert management if any frozen goods reach a temperature of 10
degrees Fahrenheit or above, or when the product is harmed in any way, to guarantee particular
handling depending on the product's state. Shipments should be code marked for classification
and recognition before being authorized for storage.

Pallet Retrievers (aka Pallet Changers)


It should come as no surprise that pallet retrievers are on our list of essential pieces of
equipment because pallets are a crucial component of the frozen food and cold storage facility.
These large pieces of machinery make it easier to combine cargoes, replace freezer spacers, and
swap out pallets in a secure manner.
Although model designs vary, many of them make quick and simple storage
modifications by rotating product stacks and pallets using a mix of components. Depending on
the size of the stack you wish to transfer, they can change. When you can readily access the
pallets, freezer spacers, and items to make any necessary modifications to your storage, they
move underneath the stack, above it, and tilt it back.

Freezer Spacers / Plastic Pallets


In the frozen food and cold storage industries, freezer spacers are crucial. By utilizing
these spacers, product freeze time is kept to a minimum, saving on energy expenditures. These
spacers allow cold air to pass through product layers, ensuring even freezing across the whole
pallet load. You can take out the spacers between the stacks of items once the products have
achieved a particular temperature.

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Stretch Wrappers
Stretch wrappers are types of machinery that offer a quick and easy technique to
assemble and wrap plastic film around pallet loads. Choosing the appropriate stretch wrap for
your company and the finest equipment to assist you wrap is very crucial since in the frozen food
sector, stretch wrap also affects how quickly food thaws and freezes.
Depending on the type of stretch wrapper you have, there are certain methods for
applying plastic wrap; nonetheless, these tools are made to assist you wrap pallet loads quicker
and with more tension on the plastic wrap, protecting your food goods from destruction and
theft.

IV. REFERENCES
Ruth (n.d.). “How To Freeze Food Without Ruining It (Dos and Don’ts)”. Retrieved from
paleopantry.org/article-storing-preserving-food-freezing/

James S. (2008). “Frozen Food Science and Technology” Freezing of Meat (pp. 125).

Nesvadba P. (2008) “Frozen Food Science and Technology” Thermal Properties and Ice Crystal
Development in Frozen Foods (pp. 3).
Magnussen O.M., Hemmingsen A.K.T., Hardarsson V., Nordtvedt T.S., and Eikevik T.M. (2008).
“Frozen Food Science and Technology” Freezing of Fish (pp. 163).

Silva C.L.M., Gonçalves E.M., and Brandão T.R.S. (2008). “Frozen Food Science and
Technology” Freezing of Fruits and Vegetables (pp. 165).

LeBail A., Goff H.D. (2008). “Frozen Food Science and Technology” Freezing of Bakery and
Dessert Products (pp. 189, 191, 194 - 195, 201). Retrieved from cold.org.gr/library/
downloads/Docs/Frozen_Food_Science_and_Technology.pdf

N.A. (n.d.) “How Do I . . . Freeze?”. Retrieved from nchfp.uga.edu/how/freeze.html

Garden-Robinson, J. (2017). Food Freezing Basics: Packaging, Loading the Freezer and
Refreezing. Retrieved from
https://www.ndsu.edu/agriculture/extension/publications/food-freezing-basics-packaging-loading
-freezer-and-refreezing

Seidel, K. (2020). A Guide to Frozen Food Processing and Packaging. Retrieved from
https://cablevey.com/a-guide-to-frozen-food-processing-and-packaging/

Current advances in food freezing. Retrieved from


https://www.newfoodmagazine.com/article/15079/current-advances-food-freezing/

Seidel, K. (2021). How to Maintain the Quality and Safety of Frozen Foods. Retrieved from
https://cablevey.com/how-to-maintain-the-quality-and-safety-of-frozen-foods/

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