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Because of its consistency and texture, raw meat is very difficult to cut to specification at high volumes. Therefore, meat processor Tönnies needed to stabilise the product surface, without freezing the entire portion. Doing this would still allow the product to be labelled and marketed as fresh, while also making the cutting process easier and uniform.
Tönnies first tried cryogenics to rapidly chill the meat, which was unsuccessful. In cryogenics, liquid nitrogen is sprayed on the product.
Because the gas is sprayed, it is very difficult to measure and can result in uneven freezing, which is an unacceptable method.
"We needed a process that would meet the very tight specifications of our customer, while maintaining the highest level of quality," says Josef Tillmann, technical director of Tönnies.
Years of experience and advancements in freezing technology proved FMC FoodTech was up to the task of creating a viable solution for Tönnies. FMC FoodTech introduced Tönnies to the Advantec impingement freezer and chiller, an suitable freezer for rapidly chilling products.
After comprehensive testing at FMC FoodTech's laboratory in Helsingborg, Sweden, an innovative procedure was developed to stabilise the outer surface of the meat product.
In this process, the meat product is frozen in the Advantec at an air temperature of -22 to -40°F at very high air velocities.
An even ice zone is then formed on the outer surface of the product to a depth of 08 to 0.2inches. This reduces the enthalpy just enough to give an equalisation temperature in the range of 32 to 36°F.
Another important feature of this process is that there is only minimal dehydration and weight loss.
However, to ensure that this was the right chilling method for Tönnies, FMC FoodTech and Tönnies worked together to conduct extensive testing at a Tönnies facility. There it was discovered that this process does not affect the taste of the meat or the way the meat can be prepared for consumption, whether it is fried, grilled or roasted.
"What impressed me about FMC FoodTech is that they took the initiative to create a new procedure based on our needs and our customer's requirements," says Tillmann. "This new process is an advancement in meat chilling because it allows the product to be cut evenly and quickly, while still maintaining the quality of fresh meat."
One of the most important features of the process is the volume at which it can be produced. Currently, Tönnies has five Advantec freezers that produce approximately 4400 pounds per hour, per line for a total of 22000 pounds per hour.
The Advantec freezer and its ability to rapidly chill meat products enable Tönnies to streamline its costs and generate more revenue with mass production capabilities.
"This new process is a perfect example of how FMC FoodTech works with its customers to develop new techniques and procedures that help them improve their own customer offerings," says Peter Pokorny, sales manager at FMC FoodTech. "At FMC FoodTech, we will work with any of our customers to develop the best solution for their needs."
In addition to meat, this process can also be used on bread, egg and candy products. For more information on this procedure or other freezing applications.
For more information, www.fmctechnologies.com