The role is industrial freezing in the food industry is never underestimated, so the need to innovate is a constant for major players involved in the manufacturing of equipment. While freezing methods don’t emerge overnight, fine tuning the existing ones is a constant, stable process.
One freezing technology gaining traction in the food industry is high-pressure processing (HPP). Unlike traditional thermal processing methods that use heat to eliminate bacteria and enzymes, HPP relies on extreme pressures to achieve microbial inactivation while maintaining the food’s fresh characteristics. By subjecting packaged food products to pressures ranging from 100 to 600 megapascals (MPa), harmful pathogens are destroyed without compromising the food’s taste, texture, or nutritional value. HPP has become particularly popular for preserving juices, meats, seafood, and ready-to-eat meals, offering extended shelf life and improved food safety.
Another notable innovation is the development of cryogenic freezing techniques, which involve the use of extremely low temperatures to rapidly freeze food products. Liquid nitrogen or carbon dioxide are commonly employed in cryogenic freezing processes, where food items are exposed to temperatures well below -100°C (-148°F). This rapid freezing helps to minimize the formation of ice crystals within the food, preserving its texture, flavor, and nutritional content more effectively than conventional freezing methods.
Furthermore, advancements in individual quick freezing (IQF) technologies have revolutionized the freezing of fruits, vegetables, and seafood in the food industry. IQF involves rapidly freezing individual pieces of food separately, preventing them from sticking together and preserving their natural texture and taste. This method allows for better retention of nutrients and flavor compared to traditional bulk freezing, where items are frozen in large batches. IQF technology has become increasingly automated, with advanced systems capable of precisely controlling freezing parameters such as temperature, airflow, and processing time, thereby ensuring optimal quality and consistency in frozen food products. As consumer demand for convenient and nutritious frozen foods continues to rise, the adoption of IQF technology is expected to further expand in the food industry.
Pulsed Electric Field (PEF) technology has emerged as a promising method for freezing in the food industry, offering a non-thermal approach to preserve food quality while extending shelf life. PEF involves the application of short pulses of high-voltage electrical energy to food products placed between two electrodes. These pulses create temporary pores in the cell membranes of the food, allowing for the controlled release of water and nutrients during freezing. This process helps to reduce ice crystallization, minimizing damage to the food’s cellular structure and preserving its texture, flavor, and nutritional content. PEF technology is particularly suitable for delicate foods such as fruits, vegetables, and seafood, offering faster freezing rates and improved product quality compared to traditional methods. Additionally, PEF has the advantage of being environmentally friendly, as it requires less energy and reduces the need for chemical preservatives, making it an increasingly attractive option for food manufacturers seeking sustainable freezing solutions.
Enhancing the efficiency and reliability of freezing units
“In an era driven by data and technology, managing and maintaining freezer units around the world has evolved into a seamless, data-driven process,” FPS Food Process Solutions representatives say. “Customers in the food processing industry are constantly searching for higher standards of equipment service and assurance in machine maintenance. Here at FPS, we are exploring how recent advancements in Internet of Things (IoT) technology enable us to provide real-time insights, automated alarming, and remote monitoring capabilities to our customers. At the forefront of this innovation is the FPS Remote Monitoring System (RMS), a solution designed to enhance the efficiency and reliability of our freezing units around the globe.”
They go on to explain that the FPS RMS is a web-based, universal platform that helps customers track, analyze, and report on their freezer’s performance. Powered by Ignition by Inductive Automation and hosted on Amazon Web Services, the system utilizes widely known standardized modules and protocols to ensure the customer’s data is safe and secure. “Central to the FPS RMS is its ability to deliver critical data right to its users’ fingertips. By installing a remote gateway device within the freezer control panel, essential production related information such as motor current, freezer temperature, and alarm status are transmitted to relevant personnel. Plant managers, maintenance teams, and remote service technicians can access real time data from anywhere around the world. This visibility enables proactive decision-making and swift response times to potential issues, ultimately minimizing downtime and optimizing production procedures.”
Additionally, the RMS facilitates comprehensive data analysis, going beyond mere data visualization to provide actionable insights. Through anomaly detection algorithms, the system automatically identifies anomalous events and deviations from production baselines, according to FPS representatives. For instance, by detecting freezer drive fluctuations, relevant personnel can be immediately notified via email to mitigate risks and mitigate costly downtime events.
“In addition to its analytical capabilities, the RMS offers unparalleled support through the Remote Monitoring Control Centre (RMCC). Staffed by support technicians trained in freezer operation and controls, the RMCC operates 24/7 to respond swiftly to customer inquiries and automated notifications. With access to historical trends, alarm history, and real-time video feeds, FPS technologists can offer tailored recommendations to address downtime events effectively, regardless of geographical location. Here at FPS Food Process Solutions, we are leveraging advanced technologies to redefine the standards of efficiency, reliability, and customer satisfaction in the food processing industry. Through the RMS, we strive to empower our clients with actionable insights and unparalleled support, setting new benchmarks for excellence in machinery management and maintenance.”
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