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Baking Science and Technology 2

Topic:
Cooling, Freezing & Refrigerating system in
baking industry

Presented to:
Dr. Shabir Ahmad
Presented by:
Salman Khalil
Ali Ahmad Bhatti
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What is cooling in baking?

 Bread cooling is a mass and heat transfer unit operation.

 During cooling, baked bread loses moisture and dries out.
 This loss is due to differences in water content between the crumb and the crust.
 Crumb (higher moisture content).
 Crust (lower moisture in exterior part that is exposed to convective cool air currents).
 The baked loaves are allowed to cool in racks to about 32 to 35°C
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Cooling process

 There are two distinct mechanisms involved in cooling a loaf.

 The first is by heat transfer, mainly by convection to the surrounding air.
 Also done by radiation and conduction to the structure of the cooler.
 The second is by evaporation.
 Moisture evaporates from the crust.
 The energy to evaporate it is drawn from the crust.
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Cooling principle

Principle of cooling is that;

 Ventilate the heat from the product or room temperature and take over with the cool.
 Apart from that, the cooling system sets stable temperatures at desire.
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Bakery Cooling Systems

1. In-Pan Tunnel cooler (for products in pan)

2. Spiral Cooler Conveyors
3. Tray Coolers
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1. In-Pan Tunnel Coolers

 In-Pan Tunnel Ambient or Conditioned Coolers used for cooling products in foils or pans.
 These tunnel Coolers have a mesh belt conveyor surface.
 Typically are a direct horizontal transfer from a tunnel oven.
 Conditioning Units are available for conditioned cooling when required.
 Cooling Temperature is controlled with the System PLC.
 PLC (computers used to control different electro-mechanical processes).
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1. In-Pan Tunnel Coolers
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2. Spiral Coolers

 Spiral Bread Cooler Systems are in Single or Double configurations.

 Available for ambient or conditioned cooling environments.
 Spiral belt surfaces utilize with high open area for increased airflow.
 Temperature is controlled through the provided PLC.
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2. Spiral Coolers
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3. Bakery Tray Coolers

 Tray coolers mechanically are similar to the Tray Proofer

 Tray coolers can easily accommodate changes in pan sizes
 They have ability to utilize space efficiently
 Tray coolers can be located on a different floor of the bakery and discharge and load on
another floor
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3. Bakery Tray Coolers
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Advantages & Disadvantages of cooling

Advantages
 Reduce food loss
 Reduce food spoilage
 Reduce food waste
 Improve productivity
Disadvantages
 More costlier
 More maintenance and care require
 In case of system failure will result damage to
ultimate product
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Freezing System

It is a unit operation in which temperature reduced to -18 C or below for preservation of

nutritional value of food.
Working Principle:
 Basic working principle of a freezing system is evaporation. When liquid evaporates it
causes surrounding area to cool
Types of freezing system:
1. Direct-contact system
2. Indirect-contact system

1. Direct-contact freezing system
Air-blast freezing system
 Still or forced air is used
 Temperature is between 30-
40 C at velocity 1.5-6.0 m/s
 In batch equipment product
is stack in tray and in
continues equipment it is
stack in trolley’s
Immersion freezing system
 Consist of tank having cool
freezing media like; glycol,
glycerol etc
 Product is immersed or
sprayed result in rapid
temperature reduction
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Fluidized-bed freezing
system
 Used to freeze particulate
foods of uniform size and
shape
 Product is placed on mesh
conveyor belt and moved
through freezing zone in
which cold air is directed
upward

2. Indirect-contact freezing system
Plate freezing system
 Products placed between
stacked parallel plates and
then pressure applied to the
overall stacks to minimize
the thermal contact
resistance between the
plates and product
Horizontal-plate freezing
system
 Stack of plates is placed
inside a steel frame and
each plate connected to the
adjacent plate allowing the
plates to be moved apart to
form a gap for cartons to be
placed between two
adjacent plates.
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Vertical-plate freezing
system
 Product is placed directly
between the plates and then
pressure is applied to assure
proper thermal contact. Once
the process has been
completed, the plates can be
opened to remove the
product.
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Advantages & Disadvantages of freezing

Advantages Disadvantages
 Inhibit the growth of microorganisms hence  System is costlier
help in preservation of foods  Maintenance required
 Retains product taste, texture  Difficulty in cleaning belts
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Refrigerating System

Refrigeration is referred to as a process in order to achieve and maintain a temperature below

that of outer atmosphere with an aim to cool some product or space to the required
temperature.
Working Principle:
 Liquid refrigerant circulate through the coil, change into a gas through compressor
 After this it flows into the condenser and then it returns into the liquefied
 After this the liquefied refrigerant passes through the expansion valve, where its pressure
gets dropped before it returns to the evaporator coils in order to absorb more heat and
turn back into a gas.

Types of refrigeration system
Steam-jet refrigeration Vapor-compressed
system refrigeration system
 Uses water as refrigerant  Operate by boiling a
refrigerant in the evaporator
 This system employs a
at a relatively low pressure,
steam ejector or booster extracting heat from a low-
instead of mechanical temperature source. The
compressor
resulting vapor is
compressed to a higher
pressure
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Vapor-absorption
refrigeration system
 Kind of refrigeration in which
after evaporation vapors of
refrigerant are absorbed in an
absorber solution.
 Consist of absorber, pump,
generator, condenser,
evaporator.

Advantages & Disadvantages of refrigeration
Advantages
 Design and manufacture of refrigeration
systems are simple
 There are no complicated parts
 Maintenance cost is low
 Refrigerant used is non-toxic, non-flammable,
non-corrosive
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Disadvantages
 Refrigerant which is use causes damage to
environment if not properly disposed
 Running cost is high because the Coefficient
of Performance (C.O.P) is very low
 Per One Ton of refrigeration, quantity of
refrigerant used is high compared to other
systems
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