AIB Baking Technology Part 1:
Control of Freezing and
Thawing
Presented by Tim Sieloff
Coordinator, Baking Training Services
www.aibonline.org/schoolofbaking
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Today’s Topics
 When you freeze
 Advantages/Disadvantages
 Product Types
 Freezing methods
 Formulation considerations
 Frozen “dough” processing
 Thawing Techniques
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May not be used without written permission.
When you Freeze?
 Removal of Heat
Heat In
 Phase change occurs
 Protein denaturing
 Constant chilling
Transfer heat from where
it is NOT wanted to where
it can be tolerated
 Non-freezable water exists
Heat Out
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May not be used without written permission.
Advantages
Stabilizes Production Schedules
 Reduces changeovers.
 Helps meet peak demand
Extends Shelf Life
 Increases potential distribution area.
 Increases potential for variety.
 Reduces stales.
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Disadvantages
 Formulation cost increases
 Packaging cost increases
 Some control over finished product quality is
lost
 Requires more maintenance
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Products for Freezing
 Bread and roll doughs-- #1!

pan breads, hearth breads, soft and hard
rolls, bagels, biscuits, pizza
 Sweet goods (dough and baked)

cinnamon rolls, Danish, puff pastry, donuts
 Dessert items (dough and baked)

cookie dough, brownie batter, muffin
batter, cake layers, cheesecakes
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May not be used without written permission.
Freezing Method: Mechanical Blast Freezer
Temperature
ˉ30 to ˉ50°F (ˉ34°C to ˉ46°C)
Time 45-90 minutes
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Freezing Method: Cryogenic Freezer
 Time: 15-30
minutes
 “Shell Freeze”
 Can over freeze
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Cooling and Freezing Rates are Affected by:
 Specific heat

Porosity

Insulation value

Water content
 Symmetry - size and shape
 Difference in temperature
 Packaging
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Two Stage Freezing Curves
68oF (20oC)
23oF (-5oC)
-4oF (-20oC)
≈ 45 min
Blast freezer
set at -20oF (-29oC)
Hours
Holding freezer set at 10oF (-23°C)
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Two Stage Freezing
Blast or Cryogenic Freezer:
 Sets crust
 Reduces core temperature
Holding freezer:
 Freezes down to desired
 Yeast equilibration
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Sensible Heat/Latent Heat
32oF
Change
of state.
Water to
ice.
Freeze
point of
product.
0
Time
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Formulation considerations
 Ingredients
 Additives
 Production practices
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Processing frozen dough
Most Used Dough System: No-Time Dough
Reasons:
 Shortest processing time
 Best yeast survival
 Better control
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May not be used without written permission.
Frozen Dough Processing
“Mixing”
 To Development
 62 to 68oF
(16 to 20°C)
 Floor Time 0-10 minutes
 Practices used:
Delayed salt
 Delayed yeast

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May not be used without written permission.
Packaging Room
 Product at proper temperature
 Room temp 55-65°F
 Avoid delays
 Freezer ASAP
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May not be used without written permission.
Holding/Storage Freezers:

Freezer temperature:

0 to -10°F (-17 to -23°C)
Proper packaging- prevents moisture loss
 Realistic shelf life
 Avoid multiple freeze/thaw cycles
 Hold for a minimum of 24 hours

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May not be used without written permission.
Distribution
 Proactive NOT reactive!
 Monitoring systems
 Carrier selection
 Handling
instructions
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May not be used without written permission.
Thawing Frozen Dough - Method #1
 Thaw in 40oF (4°C)
retarder
 12-18
hrs.
 Place at room temperature for 30 min.
 Proof at 100 to 105oF (38 to 41oC),
70 to 75% R/H for 1 to 1 1/2 hrs.
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Thawing Frozen Dough - Method #2
 Take from freezer, pan it.
 Proof at 80 to 85°F (27 to
29°C), 70 to 75% R/H for
2 to 3 hrs.
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Recommended Freezing and Storage
Conditions for “Baked Product”
 Minimum packaging material. (wrap delays)
 Freeze soon after packaging.
 Fast freeze.
 Provide air movement over product.
 Space product.
 Freeze to + 20o F core temperature.
 Maintain uniform storage temperature.
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May not be used without written permission.
Freezing Point Values (Baked)
 White bread + 22°F plus or minus.
 Sweet dough + 13°F plus or minus.
 Danish pastry + 5° to 10° F.
 Cheese cake + 28° F plus or minus.
 Chiffon cake + 18° F plus or minus.
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May not be used without written permission.
Frozen Storage Changes That Occur
 Product staling - starch retrogradation.
 Rancidity - fats.
 Moisture loss - dehydration (white ring).
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May not be used without written permission.
Thawing of Baked Products
Objective: Bring product through critical
temperature zone for staling as rapidly as
possible.
Major Problems: Condensation,
incomplete thaw.
Consideration/Requirements:
 Relative humidity
 Air Flow
 Temperature
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May not be used without written permission.
Thawing of Baked Products
Estimated Firming Rate
g/4mm. Comp./hr.
The relation of
temperature to
the estimated
average rate of
firming of
a commercial
white pan
bread.
3
2.5
2
1.5
1
20
40
60
80
100
Temperature in °F
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May not be used without written permission.
Ideal Thawing Conditions- “Baked”
 Temperatures:
110-150o F. (43-65°C)
 Humidity: 50 - 60% relative humidity.
 Air Velocity: 200 - 500 F.P.M.
 Time: variable.
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May not be used without written permission.
Freezing Summary
 Formulation
 Pre-freeze
 Quality Packaging
 Good Control of Logistics
 Awareness of Storage Conditions
 Good Freeze–Thaw Control
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AIB Baking Technology Part 1:
Control of Freezing and Thawing
Any questions can be directed to:
[email protected]
©Copyright AIB International. May not be used without written permission.