This PPT about the individual quick freezing of herbs which is semi automated process. gives an idea about IQF and how the freezing of herbs done and their specification
2. FREEZING is the methods of food preservation,
It allows preservation of taste, texture, and nutritional value in
foods.
The freezing process is a combination of the beneficial effects
of low temperatures at which microorganisms cannot grow,
chemical reactions are reduced and cellular metabolic
reactions are delayed.
For preservation of foods for longer periods.
3. The way foods are frozen in the IQF method involves sending
the individual food items on sort of conveyor belt in to a blast-
freezer the item freeze very quickly. Because the food items
separate when they go in, they stay separate after they’ve been
frozen
Products are individually frozen
4. .
The material to be
frozen first cools
down to the
temperature at
which
Nucleation starts
@ pre –cooling
Before ice can
form, a nucleus, is
required upon
which the crystal
can grow; the
process of
producing this is
defined as
Nucleation
@ freezing .
Once the first
crystal appears in
the
solution, a phase
change occurs
from
liquid to solid
with further
crystal
growth
HOW ???
5. Figure 3. Practical definition of the freezing process for foods (Mallet, 1993).
6. To retard the microbial growth
For long shelf life
Good natural color, flavor and
nutritive value can be retained.
Texture usually better than other
methods of food preservation.
Foods can be frozen in less time than
they can be dried or canned.
7. SLOW FREEZING FAST FREEZING
Large ice crystals formed, which
puncture cell walls.
Cellular fluid released(high drip
loss)
Results in shrunken appearance
of thawed food.
High nutritional loss. E.g.- home
freezer.
Small, numerous ice crystals
formed.
Less mechanical destruction of
intact cells of the food.
Low drip loss.
No change to cell structure.
More rapid prevention of
microbial growth.
More rapid slowing down of
enzyme action.
Speedy removal of heat from
food.
Nutritional value maintained
E.g.- air blast freezer etc.
10. Line clearance is required:
washing and sanitization of equipment, processing area with
food grade chemicals (sodium hypochlorite, per acetic acid)
Clean the floor (with soap oil)
Ensure the personnel hygiene (jewellery policy )
Ensure Good Hygiene Practice, Good Manufacturing Practice
11. Raw material are received and checked against raw material
specification provided by either customer or in-house as per
sampling plan
Material is either accepted(A) , rejected(R) or accepted
under deviation (AUD)
NOTE:
a. Material is accepted if it conforms to the specification
b. Material is rejected if doesn’t meets specification
c. Material is accepted under deviation after discussion and
joint agreement between production and quality team.
13. SN RAW MATERIAL PARAMETER SPECIFICATION
1 chives
Colour Green to dark green leaves lighter at base.
shape Stem length > 200-300mm, Long, cylindrical leaves
Foreign taints / smells 5%
Extraneous matter <2%
Dehydration
Max 5%Yellow coloured leaves
Spoiled leaves
2 Dill leaves
Colour Deep green color leaves, green stems.
Bunch size
Bunch length 250 - 350 mm;
Shape
Fine leaves, arranged along thin, round, slightly grooved
stems.
Foreign taints / smells Max 2 %
Diseased Max 5 %
Spoiled leaves
Max 5%Yellow leaves /withering
Sun burn
3 Lemon grass Colour Dark green to light green in colour with woodier stalks
Length 450-550 mm
Dehydration / Shrivel / Wrinkles Max 10%
Diseased nil
14. GRADING AND SORTING: The herbs are given for
cutting of roots and removal of stem part (dill),
extraneous matter, spoiled part, yellow leaves, infestation
and foreign particles.
NOTE: Where the unwanted materials are removed
17. 1.WASHING
Received raw material are then transferred into clean plastic crates and
arranged properly
Washing is done to remove the dirt, dust adhered to the raw material and
to reduce the microbial load.
Herbs (Dill, lemon grass, chives) are washed with max. 0.03% per
acetic acid as per food safety standards which helps in reducing the
microbial load
The level of per acetic acid is verified by per acetic acid strips and
cross checked by titration method
18. Tub washing
It’s a manual method of washing where the raw materials in
crates are dipped in tub which contain 100L of water with
incorporation of 200ml PAA.
Changing of water once in hour or once after every 5 to 6
number of crates and top up of per acetic acid based on the
suggestion from quality executive
Tub
washing
Herbs
Dipping time 2-3 min
Per acetic acid level
Max 0.03% ( 300
ppm)
20. Slicing is the process carrying out as per the customer /specific
requirement
Slicing size :
After slicing, following parameters are checked:
Chives 5-8mm
Lemon grass 5-8mm
Dill leaves 5-8mm
Chives Long
Fines
Large
Extra large
Lemon grass
Dill leaves
22. The slices are fed to the IQF directly
The frozen slices from the IQF were collected and passed on
to the inspection conveyor belt, where removal of small
pieces, off color and foreign matters are done.
Freezing chamber temperature
Minus 36 degree
centigrade
Ammonia level 300-500 cm
Ammonia temperature
Minus 35-36 degree
centigrade
VFD blower speed 1& 2 Max. 25 Hz
VFD blower speed 3 , 4 &5 Max. 40 Hz
24. From the conveyor slices were collected in white LDPE bag and packing
in HDPE bag and weighed on weighing scale as per the plan
Sealing
Following quality parameters are checked in FG:
Product Temperature
Name of the product
Batch code
Date of manufacturing
Total quantity
Bag number
25. Collection to the bag
Stitching
Final temperature monitoring
Weighing
26. After packing the bag is passed trough the metal detector
Before passing checked against the standard test pieces are
• Ferrous : 2mm
• Non ferrous : 2.5 mm
• Stainless steel : 3mm
27. After packing the product is hand over to freezer room and stored at -18
to -22°C till dispatch .
Issue the frozen slice bag from freezer room (-18°C)as per FIFO
Before the dispatch, following parameters are checked:
Temperature of product
Temperature of vehicle
Product Condition
Vehicle Condition
28. Slicer
IQF chamber
Weighing balance
Hand Stitching machine
Metal detector
29. Automatic Leafy / Root Vegetables Cutting Machine
Variable Speed with Conveyor
Multi Function Machine for Different Products
Easy to Adjust size
Stainless Steel Body
Specification
Voltage: 220v
Power: 1.1 KW
Horsepower: 1.5 HP(corn vegetable 1 HP, leaf vegetable 0.5 HP)
Production: leaf vegetable 400-600 kg/ hour
Root vegetable 300-500 kg/ hour
30. Ideal for Cut Fruits, Vegetable & herbs
Food grade MOC gives high standard of hygiene
Inbuilt VFD for variable belt speed which gives freedom in
handling variety of products
Complete ease of defrost and high degree of sanitation
Very quick freezing time ensure minimal water loss and high
product quality
IQF CHAMBER
31. TWO STAGE BELT FREEZER which
consists of two mesh conveyor belts in
series.
The first belt initially precools.
Second belt for freezing and sensible
cooling (-18 Deg C of below).
Generally operated at -32 to -36°C in
side the chamber with freezing times
from 5 to 7 min.
32. vertical blowing principle.
which blows the air through an evaporator generating an air
temperature of below -30°C. A quick freezing with a product
temperature down to -18°C is achieved.
33. consists of bare tubes or coils over which the metal plates or
fins are fastened.
The shape, size or spacing of the fins can be adapted to
provide best rate of heat transfer
it will defrost itself on the off cycle when the temperature of
the
coil is near 0°C. A finned coil should never be allowed to
frost because the accumulation
of frost between the fins reduces the capacity
34. Ammonia is one of the oldest and most widely used refrigerant .
It is colorless gas
It is highly toxic
Its boiling point at atmospheric pressure is -33.3ºC
and its melting point from solid is
-78ºC ammonia.
It is extensively found in cold storage,
ware house plant, food freezing plant
etc.
35. It is a poisonous gas if inhaled in large quantities.
In lesser quantities, it is irritating to the, nose and throat. This
refrigerant is somewhat flammable when mixed with air in the
ratio of 16% to 25% of gas by volume, will form an explosive
mixture.
The leaks of this refrigerant may quickly and easily detected by
the use of burning sulphur candle which in the presence of
ammonia forms white fumes of ammonium sulphite.
This refrigerant attacks copper and bronze in the presence of a
little moisture but does not corrode iron or steel..
36. designed to detect minute Metal contamination in
products and give accurate results,