Cryogenic vs.

Mechanical Food Freezing

Food freezing can be accomplished by either mechanical or cryogenic freezing. In each case, the freezing process, and the
results are fundamentally different.

While mechanical freezing systems are generally characterized by large capital investment, significant energy and preventive
maintenance costs, and high usage of plant space, the cryogenic freezing is often characterized by high cryogen (liquid nitrogen
or carbon dioxide) cost.

The selection of optimal freezing method is not simple, and cannot be justified on “cost to freeze per pound” alone. In theory,
either freezing method can be applied to any type of food. In practice, however, the food processor must carefully balance the
capital cost, operating cost, regulatory compliance cost, and product quality, to determine the best method for the company
and the consumer.

Food Freezing Options

Cryogenic Freezing Mechanical Freezing

Investment Costs Lower cost of capital equipment and Higher cost of capital equipment
simpler, inexpensive installation. and complex and costly
installation.
Operating Costs Higher energy cost with liquid nitrogen Generally lower energy cost.
or carbon dioxide as energy source.
Maintenance Costs Low: High:
• High uptime • All parts of a mechanical
• Low maintenance requirements refrigeration system consisting
• Reduced cleaning requirements of three major pieces: high
horse-power compressor,
condenser, evaporator, and
refrigerant storage must be
inspected annually.
• Ammonia refrigeration systems
with 10,000 pounds or more of
ammonia are a covered process
subject to the requirements
of the OSHA Process Safety
Management Standard (PSM)
1910.119.
Freezing Temperatures Typically, -160°F or lower for Liquid N2 Typically -30°F
and -80°F for liquid CO2.
Food Quality Rapid freezing reduces dehydration Slower freezing, up to 3 to 4
loss to less than 1%, thus preserving times longer than cryogenic
texture and flavor. freezing, can result in surface
dehydration and weight loss and
Product does not stick to belt. does not allow the successful
preparation of Individually Quick
Frozen (IQF) products.

Product tends to stick to belt.

Environmental Considerations Environmentally friendly way of Ammonia is a great refrigerant
freezing food. but it is highly toxic.
 Cryogenic Freezing Mechanical Freezing
Regulatory Compliance Easily meets FDA and OSHA regulatory The EPA, acting under the Clean
requirements. Air Act, requires facilities to
submit Risk Management Plans
(RMPs) if they use, produce or
store a threshold quantity of a
regulated substance.

Implementation of the OHSA

PSMs and EPA RMP programs is
often beyond the capabilities of
an average size food processor.

Near-term regulatory pressures

and cost impact to food
processors are impossible
to predict. There are strong
indications that OSHA is
considering the development of a
National Emphasis Program (NEP)
for ammonia and PSM. This
would mean increased scrutiny
on facilities using ammonia
refrigeration.

Plant Space Usage Lower freezing temperatures mean Higher freezing temperatures
quicker freezing. The dwell time in mean slower freezing, and
the freezer is less so equipment can be equipment is larger due to
smaller and deliver same throughput as reliance on cold air circulation
larger mechanical systems. through the belt, which limits the
belt loading to 80% for effective
operation.

Longer dwell times, typically 3 to

4 times longer than cryogenic,
mean the equipment has to be
proportionally larger to achieve
the same throughput.
Operational Flexibility Can easily be adopted or expanded for Not suitable for product changes.
different production lines. Changing the product type,
or changing the application
Dwell time can be changed from (freezing, surface hardening,
several minutes to several hours, and or chilling) may require a major
freezer temperature from -20°F to modification.
-160°F or lower.

Specifications are subject to change. Please check www.mathesongas.com for most current information.

TB415 09/2021 Printed in USA