Product Storage and Refrigeration

There are many ways that contribute to the proper management of a business’s operating costs, while also ensuring the freshness of the products that reach the consumer.
A few small changes can bring significant annual benefits to businesses, as they help eliminate unnecessary expenses.
Some of these changes involve proper product recording, reevaluating wholesale items, and the correct use of raw materials.

• Product Storage and Refrigeration

One of the most popular methods for preserving bakery and pastry products — which also helps reduce a business’s operational costs — is freezing them at low temperatures. Deep freezing refers to the rapid cooling of products. This offers many benefits, as it extends the product’s shelf life, maintains its safety, preserves its physicochemical stability, and keeps it fresh.

For this reason, storing products at very low temperatures has become an integral part of the bakery and pastry industry. As the shelf life of products is protected against all types of spoilage, freezing is often the preferred method in many cases.

• How deep freezing works

A complete freezing system cools the food product with cold air until it reaches the desired temperature. To achieve proper freezing, the product must be exposed to low temperatures for a short but sufficient period of time. As the temperature of the product drops, its liquid components transform into a solid state. Rapid freezing can halt any oxidative changes in the ingredients, prevent bacterial growth, and preserve the product’s freshness. If the freezing process is slow, ice crystals form inside the product — which can negatively affect its texture and quality.

• Why choose it

Deep freezing products — whether at their initial stage or in their final form — helps the business in many ways. Freezing methods in bakeries are used to schedule night shifts, provide flexibility in production planning, and ensure the availability of ready-made products for sale and delivery. It also helps the business prepare for upcoming holidays, festive periods, and days when an increase in demand for specific products is expected.

• Freezing bakery and pastry products

The freezing process for breads and pastry items is an ideal choice.
The freezing of ready-made and semi-prepared doughs today offers excellent opportunities for efficient and cost-effective production.
It also allows products to be transported over long distances (for example, in the case of a chain of stores) while maintaining their exceptional quality. The products that are typically frozen include: unbaked products — sweet and savory bakery items, semi-prepared bakery products such as tarts, puff pastries, tsourekia, etc., ready-made products such as ice creams, cakes, pastries, etc.

• What you need to consider

Under freezing conditions, for plain white breads, yeast levels typically range from 1.3% to 1.8%; for other types of bread from 1.8% to 2.5%; and for small breads or products rich in fats and sugars from 3% to 8% respectively. The hydration level of bakery products should be reduced by 1% to 2% for all product types. For storing products in the freezer for more than 7 days, a bread improver is required. Products with high concentrations of soluble substances such as sugars, salt, and fats depress the freezing point of the dough. As a result, longer freezing times or greater energy consumption may be needed to lower the product’s temperature. Thus, certain types of products may require different freezing conditions and processes from others.

At +7°C to –7°C, the likelihood of product quality deterioration is generally lower compared to room temperature.
At –30°C to –40°C, deep-freeze storage takes place.
It is necessary for products to reach this temperature to maintain their structure.

• Defrosting process

The defrosting process must be smooth and not abrupt. Proper thawing requires more time and gradual exposure to temperature changes. Begin by transferring products from –30°C to –18°C into a +5°C environment for up to 24 hours. Finally, place them in the proofer at +20°C to +35°C until the dough is fully matured.

A key detail: All freezing procedures require proper planning.
This helps keep frozen-food storage costs as low as possible.

Dimitris Fragkogiannis
Baking Technical Consultant, Loulis Mills – Kenfood

At Loulis Mills, for seven generations, we have always supported professionals in the industry, focusing on continuous education, development, and up-to-date information.
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