Frozen food advances showcase flexibility, efficiency
Over the past few years, the premium frozen food industry has witnessed remarkable growth, according to research platform Mordor Intelligence.
An uptick in consumer interest for top-tier, convenient and nutritious food choices has accelerated demand, with the trend especially pronounced among health- conscious individuals seeking balanced diets and ready-to-eat meals.
To meet this demand, frozen produce processors must focus on flexible, efficient and safe production, which is paramount not only in receiving, inspecting, sorting, washing and cleaning produce but also in peeling, cutting, blanching, cooling and freezing to preserve product quality and extend shelf life.
Hygienic designs are mandatory in food processing facilities, but they are even more crucial in frozen produce operations. These operations must employ strong insulation, accurate temperature control, stainless-steel surfaces, easy-to-clean equipment and proper drainage systems to prevent contamination.
NEXT-LEVEL FREEZING TECHNOLOGY
Current and emerging technologies in individual quick frozen (IQF), cryogenic, tunnel and spiral freezers focus on expanded hygienic equipment design, increased automation and improved operator interfaces.
Recent innovations in freezer technology include air defroster (ADF) and sequential defrost (SD) technologies that remove snow and frost from evaporators during operation, allowing freezers to run for longer periods without defrosting, resulting in less downtime. SD technology also helps frozen produce processors meet sustainability goals, save energy-related costs and lower water usage.
In addition, improved freezer technology helps processors manage inventory, such as predicting and controlling stock levels, while lowering the risk of overproduction or shortages. Plus, today’s clean-in-place (CIP) freezer technology supports a safer working environment by reducing the need for plant floor workers to handle potentially hazardous cleaning chemicals.
While updated freezing technology is key for produce processing applications, sorting and inspection equipment also play a crucial role in produce quality and consistency. The latest optical sorting and inspection equipment features additional cameras and sensors and improved sanitary design. Another technology gaining traction is remote equipment access for quick troubleshooting while delivering defect detection.
According to the 2024 State of the Industry U.S. Packaging Machinery Report, produced by PMMI, The Association for Packaging and Processing Technologies, inspection and testing equipment ensures that products meet quality standards. Recent increases in recalls, especially in the food and beverage industry, are driving companies to invest more in inspection machines such as X-rays and thermal sensors.
SIMPLIFYING LOGISTICS
Food safety and quality are also critical for frozen produce logistics operations. Mordor Intelligence found that managing temperature-controlled supply chains ensures the safe and efficient delivery of frozen food items while maintaining their quality and freshness.
According to the 2024 PMMI report, because of recent recalls, food processors are increasingly requesting more CIP solutions. Processors want machines with fewer touchpoints to minimize contamination risks. For machines that require clean-out-of-place (COP) solutions, there’s a growing demand for easy-to-manage options to accommodate the labor force.
As a result, machine users are taking proactive steps to mitigate contamination risks through their equipment. Machine builders are expecting more requests for CIP solutions and automatic systems to document cleaning times and temperatures, aiding in compliance and reducing the impact of recalls.
But recall issues can also affect the distribution process. Resources for logistics and all other phases of frozen produce processing can be found at PACK EXPO Las Vegas, produced by PMMI, Sept. 29 to Oct. 1 at the Las Vegas Convention Center.
“With the Processing Zone and Logistics Pavilion, PACK EXPO Las Vegas has targeted solutions available to address the current challenges faced by frozen food processors,” said Laura Thompson, vice president, trade shows, PMMI. “Attendees can see the latest solutions to improve production and get their products to market in the safest and most efficient way possible.”
Other pavilions of interest to produce processors include: The Containers and Materials Pavilion and the Workforce Development Pavilion.
Featuring 2,300 exhibitors, the show will present the latest technologies not only for food processing and packaging, but also for facility design, logistics and food safety.
Visit packexpolasvegas.com to learn more and register. Registration is $30 through Sept. 5, after which the price increases to $130.
