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A cool way to increase shelf life

21 April 2023

Jon Trembley considers the influence of cryogenic chilling on the sustainability of the food industry.

Mounting challenges continue to impact food and drink manufacturers, including increasing pressure from the impact of climate change, a difficult economic background and evolving regulatory compliance. Shelf lives need to be extended in a bid to reduce food waste, not only to decrease environmental impact but also to ensure that businesses can manage rising costs. 

According to a study by WRAP (Waste and Resources Action Programme), the equivalent of 35% of the UK’s greenhouse gas emissions can be attributed to the way we produce, process and package food and drink. WRAP research states that a 50% reduction in these greenhouse gas emissions by 2030 is possible but only if urgent action is taken.

It is clear then, that environmental sustainability needs to be a key focus for the food industry. This, paired with consumers’ desire to save money and reduce waste, means that the demand for extended food shelf life is growing. The evolution of manufacturing processes in this area is a fundamental part of the response.

Fast cooling
Cryogenic chilling, for example, offers fast cooling which enables manufacturers to process more at a quicker pace. Food items can be chilled to a sustainable temperature and shelf environment within minutes.

This is important because the faster a product is cooled, the faster it becomes microbiologically stable as the growth of bacteria is dramatically slowed. Generally, the lower the temperature, the slower the bacteria will grow. For frozen foods, -18°C delays chemical reactions and puts any bacteria that may be present on pause. The bacteria are still alive but, critically, they stop growing or producing toxins. Rapid cryogenic chilling and cryogenic freezing in this way allows the products to reach that safe holding temperature quickly, resulting in a longer shelf life and reducing waste.

Rapid cryogenic chilling uses the same process method as with cryogenic freezing – by adjusting the nitrogen tunnel or batch freezer parameters (including temperature setpoint, retention time and turbulence fan speeds) to ensure that the product exits the equipment at a chilled temperature rather than a frozen one. By adjusting these settings it is possible to accurately control the process according to the product requirements, ensuring constant and reliable processing leading to greater efficiency.

Tackling food waste and climate change are issues facing the entire food supply chain. But, as the technology demonstrates there are solutions, such as cryogenic chilling, that do not just increase the shelf life of products and help to reduce food waste and environmental impact, they optimise the quality of the product too. 

The end goal for producers is clear – there is a need to cut carbon footprints as much as possible, as quickly as possible, without compromising on the safety or quality of the product. Cryogenic chilling is just one of the ways to meet these environmental goals while keeping costs in check.

Jon Trembley is Technology Manager for Cryogenic Applications at Air Products.


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