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A relatively new type of unit is the rotary freezer -- akin to a continuous plate freezer. In one version the cylinder is a double-walled drum with the refrigerant circulating between the walls. The product rides on the outside of the cylinder, and refrigerant-to-metal-to-product contact is maintained. One manufacturer claims a refrigeration requirement of considerably less than air-blast freezing and a floor space area of only one tenth. Evaporation is, of course, virtually eliminated, and maintenance is minimal. Losses from the product sticking to the drum or from breaking when it is removed are claimed to be nil. This unit is not as flexible as air-blast freezing because it is limited to uniform, flat, or round materials easily spread on the belt feeder. It does, however, provide a method for essentially plate-freezing unpackaged foods. A 1-inch thick steak can be frozen in 20 minutes and small shrimp in 4 minutes, it is claimed.
Immersion and spray freezing can be done with liquids, including brine or an alcohol such as propylene glycol. The product must be perfectly protected. turkeys are usually first wrapped in a plastic film. Contact with the liquid freezing medium gives fairly rapid freezing.
Cryogenic media include liquid nitrogen, liquid air, and liquid or solid carbon dioxide. Of these, liquid nitrogen has had the widest commercial development. The extremely rapid or "instant" freezing which is possible by immersion or spray freezing gives a quality for most products that is nearest to the fresh. Evaporation is minimized, but probably the cost of cryogens is high. Installation and maintenance costs are relatively low.
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A new method now under development uses dichlorodifluoromethane (Freon 12) as the medium. This costly refrigerant is recycled in a closed system, and an important cost is the refrigerant that cannot be recovered. Rapid freezing and minimum evaporation are major features. The U.S. Food and Drug Administration on August 31, 1967, approved the use of Freon 12 for freezing foods.
Suppliers of various systems also claim other advantages -- some real, others possibly doubtful. We cannot consider all of them. Each must be judged on the basis of applicable facts.
Freezing Costs. Cost data were obtained from several commercial sources (see Acknowledgments at end of paper). To be comparative, all costs should be calculated on the basis of equivalent assumptions. This was not possible because of the multiple sources used. I believe, however, that in spite of this reservation, the cost differences are valid. More extensive calculations would not change the basic data but only refine them.
In the brief survey made, I found freezing costs ranging from two-tenths of a cent to ten cents per pound of product for the common foods now being frozen. This extreme difference represents not only radically different freezing methods and products but also differences in accounting methods. , The lowest cost figures are generally for air-blast freezing of unpackaged materials and for turkeys usually tightly wrapped in plastic film. Typical costs are a half-cent a pound or less where volume is large, season is long, and operation is efficient. Plate freezing of packages was found to be around a half-cent a pound, with the automatic operation less costly than manual. Freezing costs over a cent a pound were found only in operations involving low capacity, unusual labor requirements, specialized products, or a high-cost freezing medium.
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