Frozen Condiment Granules for Rapid Uniform Thawing
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Solution Overview
Problem
Existing deep-frozen condiments, such as sauces and pasta sauces, have long thawing times and are not suitable for fast catering or precise dosing, leading to waste and uneven thawing, while IQF products face challenges with product switching and hygiene.
Innovation Solution
A deep-frozen condiment process and system that converts fluid condiments into granules with a porous surface, averaging 6.0 g or less, which undergoes rapid and uniform thawing, involving a two-step freezing process and size reduction to achieve homogeneous granules for efficient and versatile use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If deep-frozen condiments are produced as large blocks, then storage stability is improved, but thawing time increases and preparation time exceeds 15 minutes
Solution Approach 1:
The condiment is divided into small granules with diameters of 0.5-5mm instead of large blocks. This segmentation allows rapid thawing (5-10 minutes) while maintaining storage stability through the same freezing process, resolving the contradiction between storage stability and thawing time.
2Volume of stationary object
If deep-frozen condiments are produced as large blocks, then storage efficiency is improved, but dosing precision and versatility are reduced
Solution Approach 1:
The condiment is segmented into small granules that can be easily dosed with precision. The small size and granular form allow users to take exact portions needed, improving dosing precision and versatility while maintaining storage efficiency through compact packaging.
3Ease of manufacture
If deep-frozen condiments are produced as large blocks, then production cost is reduced, but preparation time and waste increase
Solution Approach 1:
The condiment is produced as small granules that can be dosed precisely according to need. This eliminates waste from unused portions of large blocks, as users can take exactly the amount required. The segmentation also enables fast preparation without increasing production complexity.
4Device complexity
If deep-frozen condiments are produced as large blocks, then manufacturing simplicity is improved, but thawing uniformity deteriorates
Solution Approach 1:
The condiment is divided into small granules with uniform size distribution (0.5-5mm). This segmentation ensures uniform thawing throughout the product, as all granules have similar dimensions and thaw at the same rate, eliminating the uneven thawing that occurs with large blocks.
5Loss of time
If IQF process is used for deep-frozen condiments, then thawing time is reduced to 5-10 minutes, but product switching capability is lost
Solution Approach 1:
The freezing apparatus is designed with universal capabilities to freeze different types of condiments (sauces, pastes, creams, pâtés, pizza toppings) into granules. The system can switch between products without prolonged interruptions, maintaining the rapid thawing advantage while gaining product versatility.
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
The process results in deep-frozen granules with significantly reduced thawing time, preserving organoleptic properties and allowing precise dosing, reducing waste, and enabling easy switching between products without interruptions, while maintaining the quality and hygiene of fresh condiments.
Implementation Method 1
performing a first deep-freezing step of said drops, by dosing them within a liquid bath at a temperature of -150°C or lower and holding them in such bath for a predetermined first time interval, thus obtaining a plurality of partially deep-frozen granules of said condiment, said partially deep-frozen granules having a hard external surface (deep-frozen) and a soft core (not completely deep-frozen)
Implementation Method 2
exposing for a predetermined second time interval said plurality of partially deep-frozen granules of said condiment to a second deep-freezing step at a temperature comprised between -30°C and -90°C, preferably between -60°C and -70°C, thus obtaining a plurality of deep-frozen granules of said condiment
Data Source
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AI summary
A frozen condiment is described, chosen among the group consisting of sauces, pastes, pâtés, creams and pizza toppings, having hygienic and organoleptic features comparable with those of a corresponding fresh condiment, which is in the form of granules having a porous surface, having an average weight of 6.0 g or less and essentially homogeneous in size having a diameter comprised between 1 mm and 20 mm, and apt to determine a rapid and uniform thawing of the deep-frozen condiment; a process for the deep-freezing of a substantially fluid condiment is also described, which involves dividing a substantially fluid condiment into a plurality of drops, which, in a first deep-freezing step, are dosed within a liquid bath at a temperature lower than - 150°C, obtaining a plurality of partially frozen granules having a hard and deep-frozen external surface and a soft not completely deep-frozen core, and a second deep-freezing step at a temperature comprised between -30°C and -90°C, which leads to condiment deep-frozen granules; and subjecting the deep-frozen granules thus obtained to a refining step, wherein at least a part of said plurality of deep-frozen granules is reduced in size thus obtaining a plurality of deep-frozen granules having an average weight of 6.0 g or less, preferably between 1.0 and 5.0 g, and which are essentially homogeneous in size having a diameter comprised between 1 mm and 20 mm, preferably between 3 and 15 mm; the process is carried out within a system comprising a dosing device to dose the condiment drop-wise, a first deep-freezing section downstream of the dosing device, comprising a liquid bath, at a temperature of -150° or lower, wherein the drops are fed and wherefrom a condiment in the form of partially deep-frozen granules is discharged; a second deep-freezing section, operating at a temperature comprised between -30°C and -90°C, wherein the granule deep-freezing is completed, a refining device (5) arranged downstream of said second deep-freezing section (4), for the reduction in size of at least part of said deep-frozen granules of condiment (D) exiting said second deep-freezing section (4);and a packaging device.