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Freeze drying

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Freeze drying

Freeze drying, also known as lyophilization or cryodesiccation, is a low temperature dehydration process that involves freezing the product and lowering pressure, thereby removing the ice by sublimation. This is in contrast to dehydration by most conventional methods that evaporate water using heat.

Because of the low temperature used in processing, the rehydrated product retains many of its original qualities. When solid objects like strawberries are freeze dried the original shape of the product is maintained. If the product to be dried is a liquid, as often seen in pharmaceutical applications, the properties of the final product are optimized by the combination of excipients (i.e., inactive ingredients). Primary applications of freeze drying include biological (e.g., bacteria and yeasts), biomedical (e.g., surgical transplants), food processing (e.g., coffee), and preservation.

The Inca were freeze drying potatoes into chuño since the 13th century. The process involved multiple cycles of exposing potatoes to below freezing temperatures on mountain peaks in the Andes during the evening, and squeezing water out and drying them in the sunlight during the day. The Inca people also used the unique climate of the Altiplano to freeze dry meat.

The Japanese koya-dofu, freeze-dried tofu, dates to the mid-1500s in Nagano and the 1600s on Mount Koya.

Modern freeze drying began as early as 1890 by Richard Altmann who devised a method to freeze dry tissues (either plant or animal), but went virtually unnoticed until the 1930s. In 1909, L. F. Shackell independently created the vacuum chamber by using an electrical pump. No further freeze drying information was documented until Tival in 1927 and Elser in 1934 had patented freeze drying systems with improvements to freezing and condenser steps.

A significant turning point for freeze drying occurred during World War II when blood plasma and penicillin were needed to treat the wounded in the field. Because of the lack of refrigerated transport, many serum supplies spoiled before reaching their recipients. The freeze-drying process was developed as a commercial technique that enabled blood plasma and penicillin to be rendered chemically stable and viable without refrigeration. In the 1950s–1960s, freeze drying began to be viewed as a multi-purpose tool for both pharmaceuticals and food processing.

In 2020, freeze dried candy saw a major surge in popularity due to viral popularity on social media with freeze dried versions of popular candies such as Skittles, Nerd Gummy Clusters, and SweeTarts appearing in stores.

Freeze-dried foods became a major component of astronaut and military rations. What began for astronaut crews as tubed meals and freeze-dried snacks that were difficult to rehydrate, were transformed into hot meals in space by improving the process of rehydrating freeze-dried meals with water. As technology and food processing improved, NASA looked for ways to provide a complete nutrient profile while reducing crumbs, disease-producing bacteria, and toxins. The complete nutrient profile was improved with the addition of an algae-based vegetable-like oil to add polyunsaturated fatty acids. Polyunsaturated fatty acids are beneficial in mental and vision development and, as they remain stable during space travel, can provide astronauts with added benefits. The crumb problem was solved with the addition of a gelatin coating on the foods to lock in and prevent crumbs. Disease-producing bacteria and toxins were reduced by quality control and the development of the Hazard Analysis and Critical Control Points (HACCP) plan, which is widely used today to evaluate food material before, during, and after processing. With the combination of these three innovations, NASA could provide safe and wholesome foods to their crews from freeze-dried meals.

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