Granular Deep-Freezing Process for Rapid Thawing of Fluid Condiments
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Solution Overview
Problem
Current 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 switching between products without interruptions and preserving organoleptic properties.
Innovation Solution
A process involving the deep-freezing of fluid condiments into granules, where drops are first frozen in a liquid bath at -150°C or lower, then further frozen at -30°C to -90°C, and finally refined to achieve uniform, small-sized granules with a hard external surface and soft core, allowing for precise dosing and rapid thawing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If deep-frozen blocks are used, then storage and transport are simplified, but thawing time becomes excessively long (exceeding 15 minutes) and unevenness occurs in the final product
Solution Approach 1:
The invention divides the condiment into small individual portions (granules of 1-5g) rather than large blocks, enabling rapid and uniform thawing while maintaining storage convenience. The granular form allows heat to penetrate quickly and evenly throughout each portion.
Solution Approach 2:
The invention changes the physical parameters of the frozen product by controlling the droplet size (0.5-2mm) and freezing conditions to create granules with specific thermal properties that enable rapid thawing within 3-8 minutes while preserving the condiment's organoleptic characteristics.
2Loss of time
If large blocks are defrosted rapidly, then preparation time is reduced, but burning or dehydratation phenomena occur in outermost parts causing unevenness
Solution Approach 1:
By segmenting the condiment into small granules, the invention ensures that the entire portion can be thawed uniformly and rapidly without creating temperature gradients that lead to burning or dehydratation in outer areas.
Solution Approach 2:
The invention uses a moderate freezing temperature (-18°C to -25°C) that is sufficient to preserve the product but not so extreme as to create excessive hardness or ice crystal formation that would interfere with uniform thawing.
3Quantity of substance
If deep-frozen blocks are used, then storage is efficient, but versatility in dosing and mixing condiments is limited causing waste
Solution Approach 1:
The invention segments the condiment into small, standardized granules that can be easily measured and dosed according to specific recipe requirements, enabling precise portion control and easy mixing with other ingredients without waste.
Solution Approach 2:
The granular form provides dynamic flexibility in usage, allowing the consumer to adapt the quantity used to exact needs while maintaining efficient storage, thus combining the advantages of both block and individual portion formats.
4Loss of time
If IQF process is used, then thawing time is reduced (5-10 minutes), but the apparatus cannot switch between different products without prolonged interruptions for washing and disinfection
Solution Approach 1:
The invention uses temperature-controlled freezing chambers that can be adjusted for different products, and the freezing process itself creates a protective layer that prevents contamination, allowing rapid product changes without extensive cleaning interruptions.
Solution Approach 2:
The freezing apparatus can rapidly adjust temperature parameters and processing conditions to accommodate different condiment products, enabling quick product switches while maintaining the rapid thawing benefit of IQF technology.
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 that offer precise dosing, rapid and homogeneous thawing, preservation of organoleptic properties, and reduced waste, suitable for versatile use in both catering and domestic settings, while minimizing dehydration and phase separation issues.
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, 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 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.