If a freeze-dried substance is sealed to prevent the reabsorption of moisture, the substance may be stored at room temperature without refrigeration, and be protected against spoilage for many years. Preservation is possible because the greatly reduced water content inhibits the action of microorganisms and enzymes that would normally spoil or degrade the substance.
Freeze-drying also causes less damage to the substance than other dehydration methods using higher temperatures. Nutrient factors that are sensitive to heat are lost less in the process as compared to the processes incorporating heat treatment for drying purposes. Freeze-drying does not usually cause shrinkage or toughening of the material being dried. In addition, flavors smell, and nutritional content generally remain unchanged, making the process popular for preserving food. However, water is not the only chemical capable of sublimation, and the loss of other volatile compounds such as acetic acid (vinegar) and alcohols can yield undesirable results.
Freeze-dried products can be rehydrated (reconstituted) much more quickly and easily because the process leaves microscopic pores. The pores are created by the ice crystals that sublimate, leaving gaps or pores in their place. This is especially important when it comes to pharmaceutical uses. Freeze-drying can also be used to increase the shelf life of some pharmaceuticals for many years.
In a typical phase diagram, the boundary between gas and liquid runs from the triple point to
The critical point, Freeze-drying (blue arrow) brings the system around the triple point, avoiding the direct liquid-gas transition seen in ordinary drying time (green arrow).
There are four stages in the complete drying process: pre-treatment, freezing, primary drying, and secondary drying.
Pre-treatment includes any method of treating the product prior to freezing. This may include concentrating the product, formulation revision (i.e., the addition of components to increase stability, preserve appearance, and/or improve processing), decreasing a high-pressure solvent, or increasing the surface area. Food pieces are often IQF treated to make it free flowing prior to freezing drying. In many instances, the decision to preterit a product is based on theoretical knowledge of freeze-drying and its requirements or is demanded by cycle time or product quality considerations.
In a lab, this is often done by placing the material in a freeze-drying flask and rotating the flask in a bath, called a shell freezer, which is cooled by mechanical refrigeration, dry ice in aqueous methanol, or liquid nitrogen. On a larger scale, freezing is usually done using a freeze-drying machine. In this step, it is important to cool the material below its triple point, the lowest temperature at which the solid, liquid and gas phases of the material can coexist. This ensures that sublimation rather than melting will occur in the following steps. Larger crystals are easier to freeze-dry. To produce larger crystals, the product should be frozen slowly or can be cycled up and down in temperature. This cycling process is called annealing. However, in the case of food, or objects with formerly-living cells, large ice crystals will break the cell walls (a problem discovered, and solved, by Clarence Birdseye), resulting in the destruction of more cells, which can result in increasingly poor texture and nutritive content. In this case, the freezing is done rapidly, in order to lower the material to below its eutectic point quickly, thus avoiding the formation of ice crystals. Usually, the freezing temperatures are between −50 °C and −80 °C (-58 °F and -112 °F). The freezing phase is the most critical in the whole freeze-drying process because the product can be spoiled if improperly done.
Amorphous materials do not have a eutectic point, but they do have a critical point, below which the product must be maintained to prevent melt-back or collapse during primary and secondary drying.
During the primary drying phase, the pressure is lowered (to the range of a few millibars), and enough heat is supplied to the material for the ice to sublime. The amount of heat necessary can be calculated using the sublimating molecules' latent heat of sublimation. In this initial drying phase, about 95% of the water in the material is sublimated. This phase may be slow (can be several days in the industry), because, if too much heat is added, the material's structure could be altered.
In this phase, a pressure is controlled through the application of partial vacuum. The vacuum speeds up the sublimation, making it useful as a deliberate drying process. Furthermore, a cold condenser chamber and/or condenser plates provide a surface(s) for the water vapor to re-solidify on. This condenser plays no role in keeping the material frozen; rather, it prevents water vapor from reaching the vacuum pump, which could degrade the pump's performance. Condenser temperatures are typically below −50 °C (−58 °F).
It is important to note that, in this range of pressure, the heat is brought mainly by conduction or radiation; the convection effect is negligible, due to the low air density.
The secondary drying phase aims to remove unfrozen water molecules since the ice was removed in the primary drying phase. This part of the freeze-drying process is governed by the material's adsorption isotherms. In this phase, the temperature is raised higher than in the primary drying phase, and can even be above 0 °C, to break any physic-chemical interactions that have formed between the water molecules and the frozen material. Usually, the pressure is also lowered at this stage to encourage desorption (typically in the range of microbars, or fractions of a Pascal). However, there are products that benefit from increased pressure as well.
After the freeze-drying process is complete, the vacuum is usually broken with an inert gas, such as nitrogen, before the material is sealed.
At the end of the operation, the final residual water content in the product is extremely low, around 1% to 4%.
What inspires us to come up with this idea?
These are exciting times for us as a Group. We’ve not only been able to capitalize on the growth of our Catering business, but also expand our offerings in the Ready to eat food business.
With an already existing range of ready-to-eat food products under ‘Mahant Foods Ready-to-Eat’, Make easy, Eat Easy, Maa ki Rasoi a Combining the best of Indian delicacies with the innovative fusion of global tastes, we’re offering a fine dining experience with the convenience of Ready to eat food
We’d be happy to receive your feedback and inquiries, and would like to reassure you that we’re committed to delivering only the best to your platter, from India, and across the world!