Frozen Condiment Granulation 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, leading to uneven thawing, waste, and limited versatility in catering and domestic use, with IQF products facing challenges in rapid switching between products and maintaining organoleptic properties.
Innovation Solution
A deep-frozen condiment process involving the formation of granules with a porous surface, averaging 6.0 g or less, produced by a two-step freezing method using a liquid bath at -150°C followed by a second freezing step between -30°C and -90°C, resulting in granules that thaw uniformly and preserve organoleptic features.
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 uneven thawing occurs
Solution Approach 1:
The condiment is divided into small granules with diameters of 0.5-5mm instead of large blocks. This segmentation allows rapid and uniform thawing while maintaining storage stability, as the small granules can be quickly frozen individually and thaw evenly without the uneven thawing problems of large blocks.
Solution Approach 2:
The granules are given a porous surface structure with specific surface area to volume ratio optimizations. This local quality enhancement on the granule surface improves heat transfer during thawing, enabling rapid and uniform thawing while the internal structure maintains stability during storage.
2Ease of manufacture
If deep-frozen condiments are produced as large blocks, then manufacturing simplicity is improved, but dosing precision and versatility deteriorate
Solution Approach 1:
The condiment is processed into small granules that can be easily dosed precisely according to recipe requirements. The granular form allows flexible portioning and mixing while the standardized production process maintains manufacturing simplicity through automated granulation and freezing systems.
Solution Approach 2:
The condiment is transformed into granules with controlled size parameters (0.5-5mm diameter) and porous surface characteristics. These parameter changes enable precise dosing and enhanced versatility in culinary applications while the production process remains straightforward through standardized granulation and freezing operations.
3Productivity
If IQF products are produced on conveyor belts, then productivity is improved, but product switching flexibility deteriorates
Solution Approach 1:
The condiment is granulated into small, uniform particles that can be rapidly frozen on conveyor belts with simple coating or spraying mechanisms. This segmented form allows quick product changes by simply changing the granulation template or freezing parameters, maintaining high productivity while enabling flexible product switching between different condiment varieties.
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 yields granules that thaw rapidly and uniformly, reducing waste and enhancing versatility, while maintaining the quality and hygienic features of fresh condiments, suitable for precise dosing and varied recipes.
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
AI summary
A frozen condiment is described, chosen among the group consisting of sauces, pastes, pates, 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 dropwise, 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.