Freezing Technology in Industrial Bakeries: A Gateway to Improved Efficiency
In the fast-paced world of large commercial bakery plants, freezing technology plays a crucial role in ensuring the efficient production of high-quality baked goods. As demand continues to grow and consumer expectations rise, it is essential for bakery professionals to understand the available freezing technologies and their applications.
Blast freezing is a widely adopted method in large commercial bakery plants due to its efficiency and versatility. In this technique, the baked goods are exposed to a blast of cold air, rapidly reducing their temperature to the desired level. The advantages of blast freezing include shorter freezing times, which help preserve the freshness, texture, and taste of the products. It also allows for efficient handling and storage, as the individually quick-frozen (IQF) products can be easily separated. However, one limitation of blast freezing is the potential for product dehydration if not properly controlled.
Spiral freezing technology has gained popularity in recent years due to its space-saving design and high throughput capacity. In this method, the baked goods are placed on a conveyor belt and gradually cooled as they move through a spiral-shaped freezing tunnel. Spiral freezers offer continuous freezing, allowing for large volumes of products to be processed efficiently. Additionally, they minimize product dehydration and maintain a consistent freezing temperature. However, they may require a significant initial investment and require regular maintenance to ensure optimal performance.
According to Tecnopool representatives, discussing industrial freezing machinery with potential clients requires addressing several issues, such as ensuring that End-Users are properly trained in all aspects regarding operations, cleaning, and maintenance of a spiral freezer before it enters service. Another issue to manage is how to create and grow a relationship of trust with a potential account: a performing industrial food processing machinery is not enough on its own unless an OEM is capable to put in place a dependable aftersales support.
Making sure that industrial bakers can adjust their production to the needs of the market they serve is one of the issues that Tecnopool must address while designing spiral freezers. The industrial process that is currently being used is a good place to start looking in the short term. Optimizing processes to prevent production gaps, pursuing machine efficiency, and avoiding unneeded temperature fluctuations in machines that operate at low temperatures may be a good tactical approach. Additionally, it’s imperative to follow the cleaning and maintenance schedules recommended by the OEMs. For instance, in spiral freezers, dirt can lower the thermodynamic efficiency of heat exchange batteries, and it’s important to monitor the efficiency of drive transmission elements to prevent wasting energy. Bakers may search for equipment that consumes less energy if they are thinking about future investments.
A spiral freezer can offer many ways to reduce its energy requirements. Airflow optimization, lower inertia of moving parts, smaller footprints, and improved designs of thermal exchange batteries are some examples of design features that can help bakers more effectively guard against fluctuations in energy prices. Regarding freezers, technology can surely be of help in maximizing efficiency and uptime, according to Tecnopool experts. A spiral system can integrate a data link and a wide array of sensors to collect and share with the OEM motion and energy consumption data, which can help maintain high efficiency levels of industrial operations.
But when it comes to preventing downtime, what technology is available for avoiding or preventing an unexpected event of such kind? “OEMs prescribe preventive maintenance checklists in their «use and maintenance» manuals. Such checklists focus, most of the times, on moving parts and sensors,” company representatives say. “Cleaning routines are also important. Users of spiral freezers should wash and sanitize their machines with the frequency the OEMs prescribe in their «use and maintenance manuals» which are tailored to the food product being processed. As previously mentioned, proper sensors to gather diverse «operations and consumption data» together with a policy of «data sharing» with the OEM, can surely be of help in supporting bakers maximizing freezer’s uptime,” they conclude.
Cryogenic freezing, which involves the use of extremely low temperatures, has emerged as a game-changer in the bakery industry. Liquid nitrogen or carbon dioxide is commonly used in this process to rapidly freeze the products. Cryogenic freezing offers several advantages, including minimal product dehydration, reduced freezing times, and improved product quality. It also allows for precise control over the freezing process, enabling bakery professionals to preserve delicate textures and flavors. However, cryogenic freezing systems can be expensive to install and operate, requiring specialized equipment and safety measures.
Recent Advancements
Recent technological advancements have paved the way for further improvements in freezing technology. One notable development is the integration of smart sensors and automation systems, which enable real-time monitoring and precise control of freezing parameters. This ensures consistent product quality and reduces the risk of human error. Additionally, the use of advanced insulation materials and energy-efficient designs has enhanced the sustainability and cost-effectiveness of freezing processes.
You can read the rest of this article in the May-June issue of European Baker & Biscuit, which you can access by clicking here.