Vacuum Cooling for the Food Industry

VACUUM COOLING - WHAT IS IT?

To the supermarket buyer or consumer it is a hallmark of quality to say that the product has been
cooled by a unique process. Where vacuum cooling differs from conventional methods is that
cooling is achieved from within the product rather than by trying to blow cold air over it.

It is the evaporation of water within the product that has the double effect of rapidly removing the
field heat and sealing in the freshness. This is especially effective in reducing the browning effect on
the butts of lettuce - no other process can offer you this marketing edge.

What are the applications?

As with most processes vacuum cooling cannot be applied to every type of products but those it is
suited to are beyond reproach. In general, suitable products should be of a leafy nature or have a
large surface to mass ratio.

Such products include:

 Lettuce  Watercress  Asparagus

 Celery  Beansprouts  Sweetcorn

 Mushrooms  Rolled turf  Spring onions

 Flowers  Babyleaf

 Brocolli  Diced vegetables

WHAT ARE THE ADVANTAGES?

Speed and efficiency are two features of vacuum cooling that are unsurpassed by any other method,
especially when cooling pre-packed, boxed or palletised products. Assuming the product is not
packaged in hermetically sealed packages the effect of bags, boxes or stacking density has virtually
no effect on cooling times. For this reason it is common for vacuum cooling to be carried out on
palletised product just prior to it being despatched. Cooling times in the order of 25 mins ensure that
tight delivery schedules can be met.

As has already been described a small amount of water is evaporated from the product, normally
less than 3%. This figure can be reduced by using a hydro vac facility which is supplied as standard
equipment to our vacuum coolers. In some instances the removal of a small amount of water is an
advantage in further reducing the deterioration of some types of fresh produce.

THE MAIN COMPONENTS OF A VACUUM COOLER

Product Chamber
The size of the product chamber has to be large enough to hold the batch quantity for each cycle
together with a working clearance to allow for badly stacked pallets or a possible future change in
stack dimensions. We offer a range of chambers accomodating single or twin track conveyor
systems. Any combination of batch quantity and pallet size can be designed into our system. The
chamber doors can be hinged, sliding or vertical lift in manual or automatic options.

Vacuum Pump
This is used for the initial pump down of the vessel from atmospheric pressure to the flash point of
water, at 20c that would be 23mb of vacuum. After reaching the flash point the efficiency of the
pump is restricted by the size of the refrigeration plant. In general we would size the vacuum pump
to reach flash point in 5-8minutes, the type of pump normally used being of the oil sealed sliding
vane design.

Refrigeration Plant
Once the pressure reaches flash point water starts to evaporate from the surface of the product. It is
this evaporation that achieves the cooling. In a machine that cools, say, 1000kg of product per cycle
then 1860 m3 of vapour would be created and would need to be pumped from the chamber. In
practice that is far too large for the vacuum pump to handle so a refrigerated coil block is fitted
inside the chamber to recondense the vapour back into water - the refrigeration plant in effect acts
like a vacuum pump. It is the size of the refrigeration plant that has a significant effect on the cooling
cycle time. Generally we will quote on a cycle time of 25 minutes although we can achieve cycle
times as low as 15 minutes.

Conveyor Systems
These play a significant part in cycle times, particularly with larger capacity vacuum coolers. To
achieve rapid turnaround times we offer a variety of systems of manual or power assisted varients.
We are able to offer a variety of solutions to suit any product handling enquiry.

Control System
The control system fitted is sophisticated rather than complicated and requires the operator to press
only one button to start the cooling; the cycle stops automatically on reaching the pre-set
temperature. PLC systems can be fitted to allow for cycle logging features etc. Whatever the chosen
mode of operation, a fail-safe circuit ensures that if a fault is detected by any of the monitoring
devices the system will be shut down in a safe condition.

The quality of practically all food products begins to deteriorate upon harvesting and continues to
decline thereafter. The major effect in vegetable and plant harvesting, handling, processing and
transportation is directed toward the maintenance of as much of the initial quality as possible. In the
case of vegetables quality is aresult of physiological and microbiological activity in the harvested
product. This deterioration is a function of time and temperature; in simple terms the faster it is
cooled after harvesting the better the quality and the longer the shelf life.

Vacuum Cooling is the means to achieve this.

https://www.wec-group.com/vacuum-coolers.html
Vacuum Cooling

What is Vacuum Cooling?

Vacuum cooling is a rapid and more efficient alternative to traditional atmospheric or ambient
cooling. It is a relatively new technology based on reducing the difference between ambient
atmospheric pressure and water vapor pressure in a product.

 By using a pump, the vacuum cooling system removes dry and humid air from the cooling
environment to create vacuum.

 This accelerates the vaporization of free moisture from the product. 1,2

 High speed bakeries benefit from this technology via reducing cycle times and efficient usage
of production plant floor space.

Origin

Implementing vacuum cooling in the baking industry has emerged in response to bakeries’ need for
reducing the time from the ingredients scaling step through product packaging.

Most high-speed bakeries use no-time dough systems which require about 3 hours to produce
bread. Under vacuum cooling conditions, bakers can reduce the time it takes to produce bread down
to about 2 hours.

How it works

In this process, loaves coming out of the oven at temperatures close to 205°F (96°C) are placed or
conveyed directly into a vacuum chamber. It’s sized based on processing requirements, pieces per
minute produced, and floor usage. Once the product is loaded, the vacuum chamber is then sealed
to prevent gas exchange.

A vacuum pump starts working by removing air from the cooling chamber, hence decreasing the air
(atmospheric) pressure in the chamber. The vacuum created inside the equipment (partial or total)
lowers the boiling point of water in the product. Subsequently, the moisture present in the product
starts to evaporate quickly and steadily. The boiling process requires latent heat of evaporation,
which is withdrawn through the product crumb. This results in a temperature drop and allows the
loaf to cool down.2,3

As the cooling process continues, the vacuum pump drains the water vapor through a condenser
which collects moisture and channels it to a separate location.

Vacuum cooling parameters

 Vacuum pressure of operation

 Cooling time

 Product load (lb/batch or lb/min)

 Product temperature drop

  Condensate amount

Application

The speed by which vacuum cooling works makes it an attractive technology for less stable bakery
products that may be prone to collapse as they cool. This process allows bakeries to avoid the
dependence on prevailing atmospheric conditions, thus achieving consistent results and uniform
cooling at all times. Equipment required for this purpose must be isolated and sealed from the
surrounding area and may be operated in batch or continuous modes.

Batch-mode vacuum coolers

In some cases, vacuum coolers are designed as batch-mode systems that have to be properly
connected and synchronized to the continuous up- and down-stream operations in the bread
production line. When such situations occur, several adjustments must be made in order to prevent
the cooling equipment from becoming a production bottleneck, such as:

 Cycle time management (timing of cooling, holding and transfer times)

 Labor needs in case of semi-automated product handling

 Product holding and transfer equipment

Advantages and challenges of vacuum cooling

Advantages Challenges

 Shorter cooling times (cooling  Greater weight loss since cooling is

from 212°F/100°C to 86°F/30°C
can be achieved in only 3 to 6
min)
 Lower risk of post-bake mold
contamination
 Product can be cooled in a 20
m2 equipment instead of a 250
m2 cooling tower
 Superior crust appearance and
better symmetry as product
shrinkage is greatly reduced
carried out only through moisture
evaporation
 Higher initial investment costs
 Scaling weight at divider and %
absorption must be adjusted
according to finished product
moisture
 Somewhat lower yield per dough
batch since scaling weight is usually
increased to meet declared product
weight

 Product remains crusty to  Higher energy consumption at bakery

reduce chance of collapse  Accelerated staling may occur with
during slicing higher cooling loss

Vacuum cooling vs. traditional spiral cooling

 Vacuum Traditional

Cooling of a pound loaf

Cooling from 100°C (212°F) to 30°C (86°F) can be
requires 60 min and 30
achieved in just 3 to 6 min
minutes for buns and rolls

Large footprint: the product

Compact design: the product is cooled in a 20 m2 piece
is cooled on a 3,200 ft2 (300
of equipment
m2) spiral tower

Mold contamination risk with

Mold contamination risk is reduced given the relatively
airborne spores from drafts is
sterile conditions in the vacuum chamber
high

Crust shrinking is a
Superior crust appearance and better symmetry as
phenomena often difficult to
product shrinkage is greatly reduced
reduce

Slightly higher weight loss since cooling is carried out only Lower cooling loss due to
through evaporation. This can be compensated fully by combination of convection
optimizing the baking/vacuum process, which can result and evaporative cooling
in a higher water content in the final product. mechanisms

Shorter baking times or reduced energy consumption

Standard baking and cooling
during baking to compensate for overall moisture loss in
conditions
the product

Scaling weight at divider and % absorption must be Standard scaling weight and
adjusted according to finished product moisture % absorption

Normal textural shelf-life

Textural shelf-life (product staling) is a challenge if bake
with emulsifiers and specialty
loss is not properly adjusted to vacuum cooling
amylase preparations

Examples of products that can be vacuum cooled

 Croissants/Puff  Panettone  Hamburger buns

pastry
 Cookies  High volume pan
 Cakes bread

Especially for “difficult” bakery products like gluten-free and low-carb, vacuum cooling can
dramatically increase the structure, quality and freshness/shelf life. Vacuum cooling also works for
pre-bake and bake-off products. Productivity, quality and shelf life will also be improved for these
product groups.

https://bakerpedia.com/processes/vacuum-cooling/

VACUUM COOLING FOR VEGETABLES AND FRUITS

Vacuum cooling is the quickest and most cost-efficient cooling system for vegetables, fruits, flowers
& more. The vacuum cooling technology, which can strongly improve your product quality and at the
same time reduce your cooling costs, is now becoming an acceptable investment for almost all
vegetable growers!

The technology is based on the phenomenon that water starts boiling at lower temperatures as the
pressure decreases. In the vacuum cooler the pressure is reduced to a level where water starts
boiling at 2 ⁰C. The boiling process takes away heat from the product. As an effect, products can be
cooled down through and through to 1 or 2 ⁰C within 20 – 30 minutes. Even (micro-perforated)
packed products can easily be cooled this way!

The quick and uniform cooling (the surface and core of the vegetable reach exact the same
temperature after vacuum cooling!) results in a substantially longer shelf life of your produce. At the
same time you can save on energy costs, as the vacuum cooling process is much more (cost)
effective than traditional cooling technologies.

WITHOUT THE RISK OF FREEZING.

Vacuum pre-cooling extracts heat from the produce by evaporating a little of the products own
moisture, thus reducing its temperature.The system works also perfectly for pre-packed (not air
tight) produce. It is ideal for cooling your produce & flowers directly after harvesting, and is the only
real option for vacuum cooling packed products at airports, both on the departing and arrival side.
Loads with different temperatures are all cooled down to the desired temperature level, without the
risk of freezing.
FEATURES

  Stainless steel cold trap

  German rotary vacuum pump, free of maintenance

  Freezing prevent system

  Friendly touch screen operation system, easy run

  Remote control trouble shooting system

  Plentiful tailor made options

https://www.heuch.com.au/industry/food-processing/vacuum-cooling/vacuum-cooling-solutions-
for-vegetables-and-fruits/
Vacuum Cooling Reduces Waste in Postharvest
Cold Chain Systems
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By Ryoshin Imai, ULVAC Technologies, Inc.

Based on International Trade Administration (ITA) information, global losses in the food
industry accumulate to more than $750 billion on a yearly basis.  The losses are primarily due to
inadequate facilities, improper food safety measures, and insufficient training of personnel
working within the cold chain—a temperature-controlled supply chain developed to extend and
ensure product shelf life.
Every year, poor cold chain systems result in the loss of billions of tons of fresh food—particularly
in developing markets. While there are widespread efforts on improving agricultural processes to
increase food production, nearly half of all food produced never actually makes it to a consumer’s
table. (1)
 

Bringing Benefits to Traditional Cold Chain Systems

During the summer season, vegetables tend to deteriorate quickly once harvested from the field—
or during postharvest stage of the cold chain. In traditional cold chain systems, vegetables are put
into a chilled cooler for preservation, a process that requires approximately 12 hours for the
product to achieve proper temperature. In some instances, as much as 25 percent of food product
in the chilled cooler will decay before arriving at a proper storage area. Fortunately, there is a
process for improving the effectiveness of the postharvest stage—vacuum cooling.
 

Vegetables can deteriorate quickly during the postharvest stage of a cold chain system.

 
Vacuum cooling can be applied shortly after harvesting crops, helping to rapidly cool the product
and preserve shelf life. The theory of the process is to reduce product temperature from ambient
temperature, say 90°F (32°C) during the harvest season, to around 39°F (4°C)—within 30
minutes. The process can be applied to vegetables, fruits, flowers and other food products. It is an
excellent way to preserve and extend freshness, and can also ensure product uniformity. By using
vacuum cooling, in conjunction with other vital pieces of the cold chain, product freshness can be
better sustained.
There are many beneficial features of vacuum cooling process, including:

 There is no time limit for harvesting crops.

 The product is always ready for delivery to supermarkets or dockyards after coming out
from a vacuum cooling chamber.
 Product freshness and cleanliness are ensured.
 There is a higher yield per harvest with the reduction in withered and spoiled product.
 It is possible to harvest in poor weather conditions, such as rain.
 Products can be cooled inside cartons.

ULVAC Technologies, Inc., a leading supplier of production systems, instrumentation and

vacuum pumps, has introduced vacuum cooling equipment and systems to the agricultural, food
and floral markets. The company provides vacuum cooling systems for use in large-scale farms to
extend product shelf life. The systems are mainly used for fresh agricultural products, including
vegetables, fruits and mushrooms. The company’s vacuum cooling equipment can also be used
for flowers, meats and prepared foods, such as airplane meals. Over ten systems have already
been installed in the United States. 

Vacuum cooling systems can bring tremendous benefits to traditional cold chain systems.

Cold Chain Requirements

As mentioned previously, a cold chain is a temperature-controlled supply chain designed to
maintain the quality of sensitive products. Cold chains comprise storage and distribution
systems, and every step of the chain must be maintained in order to deliver a quality product.
Cold chain system requirements will vary based on differences in the size, type and amount of
products being stored and transported. Agricultural products, like fruits and vegetables, require
cool facilities and storage at about 55°F. Dairy products and meat products are typically stored
just below freezing, at 35°F and 28°F, respectively. Finally, frozen products, such as ice cream,
could require deep freezing, and the required temperatures vary between -10°F to -150°F.
In regards to vegetables and other agricultural products, the postharvest step is the first step in a
cold chain system, and it must maintain the same level of quality as every other step in the
process, such as cold storage in a warehouse or shipping vessel. According to the ITA, “A single
breakdown in the chain can result in catastrophic losses of product.” (1) By addressing the
postharvest step of the cold chain with vacuum cooling technology, product losses can be
dramatically reduced, and product quality can be ensured at the onset of a product’s journey.
 

How Does Vacuum Cooling Work?

The vacuum cooling process begins when a large vacuum chamber is filled with agricultural
product, such as fresh vegetables. Under vacuum, free water in the cell tissues of the vegetables
begins to evaporate at a pressure of around 12 Torr. The vegetables then cool themselves, due to
the removal of the latent heat of the evaporated water. Since it takes 597 calories to evaporate 1
gram of water at 32°F (0°C), the vegetables are cooled to 39°F (4°C) in about 20 to 30 minutes.
The vacuum chamber is then maintained at a low vacuum level.
 

Within 20 to 30 minutes, vacuum cooling systems cool products to 39°F (4°C).

 
As only 2 to 3 percent of the water is vaporized, there is no danger for drying out the vegetable, or
reducing the product’s weight. The large amount of water vapor generated inside the vacuum
chamber is condensed on the surface of a cooling coil, called a cold trap, and removed from the
chamber later. The system uses a refrigerator to maintain the cooling coil at a temperature below
32°F (0°C).
Vacuum cooling machines comprise a vacuum chamber, a cold trap with a refrigerated unit,
vacuum pumps and a control panel. ULVAC offers four models that can cool two to six pallets of
agricultural products per batch. The machine uses reliable vacuum pumps manufactured by
ULVAC Japan. It also incorporates refrigeration units manufactured by Copeland. ULVAC
vacuum cooling equipment features fully automatic control, and end users can simply press the
“start” button to engage the process, which is completed in less than 30 minutes. With LAN
connection, ULVAC can diagnose the machine performance anywhere in the world.
 
 Vacuum cooling systems from ULVAC can cool two to six pallets of agricultural products per batch.

Implementing Vacuum Cooling Systems Globally

Since the development of Japan’s first large-scale experimental system for vegetable vacuum
cooling (under the Cold Chain promotion policy of the Japan Science and Technology Agency) in
1967, ULVAC has delivered many vacuum cooling systems to leading agricultural cooperatives in
Japan. These systems are highly acclaimed for their outstanding efficiency and reliability. In
1997, ULVAC transferred the technology to Hong Kong ULVAC to continue the manufacturing
and promotion of vacuum cooling technology inside China. From 1998 to 2015, Hong Kong
ULVAC has sold over 500 vacuum cooling systems in China, other southeastern Asian countries,
and in North American countries.
When Hong Kong ULVAC started this project in 1998, farmers in Southern China Provinces were
exporting their vegetables in chilled containers to Asian countries, such as Singapore, Malaysia
and Thailand. Due to poor attention to detail at the postharvest stage of the cold chain, about 25
percent of the vegetables decayed before arriving at a client’s site. When ULVAC introduced
vacuum cooling technology to those farmers, they applied it to their export vegetables, resulting
in a reduction in waste from 25 percent to 3 percent.
Since then, Hong Kong ULVAC has also introduced this technology to farmers in Northern China
provinces. These farmers can also reduce the wastage rate when exporting vegetables to Japan
and Europe.
https://www.blowervacuumbestpractices.com/industries/food/vacuum-cooling-reduces-waste-
postharvest-cold-chain-systems