Frozen Bread Partial Cooking and Rapid Cooling Process
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Solution Overview
Problem
Conventional freezing methods for baked goods, such as bread, require long reheating times, making them unsuitable for immediate consumption and leading to suboptimal product quality due to the use of additives in existing quick-freezing processes.
Innovation Solution
A process involving partial cooking of bread to 90% completion, followed by rapid cooling with liquid nitrogen to -60°C, packaging, and storage at -18°C for at least 12 hours, allowing for quick recovery to edible status within 3 minutes without preservatives or additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional freezing methods are used for baked goods, then the product can be stored and transported, but the reheating time becomes very long (30 minutes) making it unsuitable for immediate consumption
Solution Approach 1:
The invention changes the temperature parameter during freezing by first rapidly cooling to -60°C and then maintaining at -18°C, creating a two-stage freezing process that preserves the bread's structure for quick reheating
Solution Approach 2:
The bread is pre-cooked to 90% completion before freezing, so that only the final 10% cooking is needed after thawing, dramatically reducing the reheating time from 30 minutes to a few minutes
2Loss of time
If liquid nitrogen is used for rapid freezing to reduce reheating time, then the consumption time is improved, but additives must be used which deteriorates the product quality
Solution Approach 1:
The invention uses a two-stage temperature approach: rapid initial cooling to -60°C followed by maintenance at -18°C, achieving quick freezing without requiring chemical additives that would compromise product quality
Solution Approach 2:
The bread is cooked to 90% completion before freezing, using partial cooking to achieve the final product quality after quick thawing, eliminating the need for additives while maintaining texture and taste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid restoration of bread to its freshly baked state with maintained organoleptic qualities, reducing user waiting time and costs while ensuring freshness and eliminating the need for additives.
Implementation Method 1
immediately lowering the temperature of the cooked bread through the use of liquid nitrogen, down to a lowering temperature at most equal to -60 °C
Implementation Method 2
packaging and freezing the bread, through a first sub-step of obtaining a temperature from -10 °C to -11 °C in the bread core
Implementation Method 3
storing and transporting the packaged bread, always at a temperature of at least -18 °C
Data Source
AI summary
A process is described for producing bread, frozen/lowered in temperature, with quick recovery before its consumption, which comprises the steps of: cooking the bread, after levitation, to 90% with respect to its complete cooking; immediately lowering the temperature of the cooked bread through the use of liquid nitrogen, down to a lowering temperature at least equal to -60 °C; packaging and freezing the bread, through a first sub-step of obtaining a temperature from -10 °C to -11 °C in the bread core, and a second sub-step of keeping the bread at a freezing temperature of -18 °C for at least 12 hours; and storing and transporting the packaged bread, always at a temperature of at least -18 °C.