Manufacturing News

Putting the Freeze on Flying Cheese

March 28, 2003
/ Print / Reprints /
/ Text Size+

Flying cheese, sausage and even pizza crusts are not the way GLV Foods (Neptune, NJ) envisioned freezing its Upper Krust Pizza brand products. GLV's original in-line freezer with high-speed, non-adjustable fans not only blew cheese off the lightweight crust but sent crusts flying around the freezer as well. Because the company recently moved into a new 23,000-sq.-ft. facility and is producing more than 15,000 pizzas a week, it needed a fast cooling solution.

"With our business growing at a rapid pace, both foodservice and retail, we could not afford the waste and inefficiency our freezing system was causing to overall pizza cost," says Phil Cierzo, company CEO. "We called in Air Liquide for help."

Air Liquide's immediate answer: an in-line nitrogen freezer with variable speed fans freezing ready-to-cook pizzas in 90 seconds. "Freezing at slower rates allows migration of sauce into the dough," adds Cierzo. "Subsequently, such freezing forms large ice crystals destroying the texture and mouthfeel of finished pizza. Rapid freezing prevents this and maintains fresh taste and texture."

Next, Air Liquide developed a unique customized billing system for GLV, which documents freezer belt run-time and calculates cost on a per pizza basis. The supplier's Datal™ hardware/software package helps maintain correct freezer temperature, monitors belt run-time and alerts the user to any discrepancies in usage that could indicate operating problems. The expandable system includes an interface with the supplier for troubleshooting and automatic gas replenishment.

"Actual freezing cost per pizza was about 33 cents on our old system, which includes rental costs of the freezer and gas tank," notes Cierzo. "With new Air Liquide equipment and Datal system, we now pay only a few cents per pizza for freezing, with no additional cost for gas, storage tank or freezer. The system bases calculations on optimum retention time for freezing pizzas and run time of the freezer belt per month. Costing through this method entices us to be as efficient as possible and also gives us a consistent freezing cost allocation within the total cost of production."

Did you enjoy this article? Click here to subscribe to Food Engineering Magazine.

You must login or register in order to post a comment.



Image Galleries

Fabulous Food Plant: Paramount Citrus

Learn more about this fabulous food plant in Food Engineering's article, found here.


Burns & McDonnell project manager RJ Hope and senior project engineer Justin Hamilton discuss the distinctions between Food Safety and Food Defense as well as the implications for food manufacturers of the Food Safety Modernization Act.
More Podcasts

What was your favorite part of FA&M 2014?

View Results Poll Archive


Food Engineering Magazine

Food engineering magazine 2014 april cover

2014 April

Catch a preview of the Powder and Bulk Show in this April 2014 edition of Food Engineering. Also, be sure to check out a coffee stick making a real stir and a major advancement in the the pet food industry.
Table Of Contents Subscribe


Food Authentication Using Bioorganic Molecules

This text provides critical tools and data needed to augment routine food analysis and enhance food safety by aiding in the detection of counterfeit, and potentially deleterious, foods.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications,Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.

Food Master

Food Master Cover 2014Food Master 2014 is now available!


Where the buying process begins in the food and beverage manufacturing market. 

Visit to learn more.


FE recent tweets