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Requirements of the Raw Material. Small, uniformly sized, free-flowing, unpackaged materials lend themselves to the widest range of freezing conditions. Thus berries, green peas, cut corn, cross-cut green beans, lima beans, and meat chunks can be frozen in bulk or in a box by several different methods. Some products can be frozen by only one or two methods because of their shape and size and packaging requirements, Cauliflower, broccoli, and asparagus must be packaged first, and so freezing is ordinarily limited to plate and air-blast methods, Meat patties and raw shrimp are frozen by a method that permits them to remain stationary on a belt or tray, or in a package. Packaged items could be frozen with cryogen, but the potential of instant freezing would be minimized because of the insulating properties of the box and wrapper.
In order not to become involved in all of the intricacies of the many methods and procedures that are possible, this comparison is limited to only a few products that best illustrate economic differences among basic freezing methods. Thus, we shall attempt to stress principles, not just differences, in application to freezing products for the retail and institutional markets.
Freezing Methods: Making ice is probably the least costly example of commercial freezing and can thus serve as a base. Refrigeration is supplied by the least costly method, and heat transfer, is liquid-toliquid through a metal container holding the water. Thermal losses are minor and no cost is involved in moving air. Because rapid freezing is not essential, the least costly combination of cil temperatures, compressor capacities, and brine circulation can be employed. Ice may sell at $6 a ton wholesale, or 0.3 cent per pound. The actual freezing cost is obviously only a part of this -- perhaps half
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Plate freezing has the similar advantage of heat transfer by conduction. However, food products conduct heat more slowly than water, most plate-frozen foods are in containers, and the plate freezer is more costly to build, install, and operate. Consequently, plate freezing is considerably more costly than our reference process - water freezing. Labor cost is potentially high but can be reduced by automatic loading and unloading. Plate freezing is more limited in what if we can handle than air-blast freezing, but new developments are widening its application.
Air-blast freezing has several advantages. It can be applied to bulk or package freezing, it is adaptable to most products, and it can be operated under a wide range of conditions such as product handling, air temperature and rate of flow, and fluidizing techniques. Labor cost can be quite low" depending upon the product and its requirements. The main disadvantages are the longer time required if the product is packaged first and evaporation losses if the product is frozen bulk. The latter can be reduced considerably under proper operating conditions.
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