1. Dough Hardening and Structural Collapse
In traditional freezing systems, the center temperature reduction to -18°C can take up to 90 minutes.
This slow process causes:
Starch retrogradation in dough
Loss of elasticity and softness
Irreversible hardening after reheating
2. Filling Dehydration and Juice Loss
For high-moisture fillings (e.g., meat juice, bean paste):
Slow freezing leads to formation of large ice crystals
Ice crystals rupture cell structures
Juice loss after reheating can exceed 30%
The result is a significant degradation in mouthfeel and product consistency.
CBFI Engineering Approach: From Uniform Freezing to Precision Structural Freezing
The CBFI Spiral Freezer is designed specifically to address the thermo-mechanical sensitivity of filled dough products through controlled airflow dynamics and structural freezing control.
Core Technological Innovations
1. Dual-Helix Vortex Airflow System
The freezer adopts an S-shaped dual spiral transport structure that forces continuous product rotation during freezing.
Combined with -45°C high-velocity airflow, it enables:
Uniform exposure of surface and filling to cold air
Rapid formation of a thin protective ice layer (~1.5 mm)
Reduced moisture loss by up to 60%
Center temperature reaching -18°C in approximately 30 minutes
This significantly reduces ice crystal size, maintaining microstructural integrity of both dough and filling.
2. Controlled Atmosphere Moisture Regulation System
A sensor-driven airflow regulation system is installed along the freezing tunnel to dynamically adjust humidity and pressure conditions.
When dough surface temperature reaches target thresholds, the system:
Stabilizes internal humidity in the optimal range (58%–62%)
Minimizes surface cracking and dehydration
Suppresses enzymatic browning reactions during freezing
This ensures consistent dough texture after reheating.
3. Application-Specific Ice Crystal Control Technology
The system adjusts freezing kinetics based on product structure:
Meat-filled buns: Fine, needle-like ice crystal formation for deep juice retention
Bean paste buns: Porous ice structure to prevent internal pressure rupture and filling overflow
This targeted approach ensures structural adaptation rather than uniform freezing stress.
Industrial Value for Frozen Dough Production
By replacing conventional uniform freezing with structure-aware rapid freezing, the CBFI Spiral Freezer delivers:
Faster core freezing time
Improved texture retention after reheating
Reduced juice and moisture loss
Higher batch-to-batch consistency
Conclusion
The CBFI Spiral Freezer transforms frozen bun production from a basic preservation process into a precision structural preservation system, ensuring that dough and filling maintain their original sensory and functional properties throughout the cold chain.
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