Taking Cold Pizza to the Next Level with Cryogenic Freezing Tunnel

Initial research turned up few new freezing options. Piliouras knew that more of the same type of industry standard freezer was not the long-term answer for Emil’s Pizza. When the team learned about Air Liquide’s ALIGAL FZ cryogenic freezer, however, they knew they had found the solution Emil’s needed. Unlike conventional nitrogen freezers, ALIGAL FZ addresses food plant sanitation concerns by opening so fully that all internal mechanisms are completely visible and accessible, and all surfaces are self-draining and easy to clean. Its innovative, integrated stainless steel and molded gel-coat fiberglass body construction maximizes convection, widens the freezing zone, and increases capacity.

“We spoke with USDA representatives before going with this system,” Piliouras said. “They agreed that the ALIGAL FZ’s top-lift system, which opens with the touch of a button, allows us complete access to see and clean anything and everything, ensuring cleanliness of the freezer.”

Roedl also pointed out that because the unit doesn’t require additional plant floor space for swing-out doors, Emil’s could increase production without increasing plant real estate. Nitrogen usage is minimized through isothermal cryogen injection and enhanced fan performance, offering more flexibility for differing product types. Air Liquide installs the cryogen storage vessel, including piping from the vessel to the ALIGAL FZ freezer. The company also supplies training to on-site personnel so they can operate the unit safely and efficiently.

The results have been significant. In the past year, throughput at Emil’s has increased by 23%, while nitrogen usage has decreased by 30%. Sanitation time and costs have been reduced by 75%. “We save enough in sanitation and maintenance costs alone to cover the cost of the freezer lease,” Roedl said. The ALIGAL FZ tunnel has also helped Emil’s pizza exceed the USDA’s food safety standards. “It’s great to know we are exceeding quality and safety expectations while maintaining the high quality product we are known for,” Piliouras said.

Piliouras also pointed to the trend of increased customer and third party food safety audits. “Our ALIGAL FZ freeze tunnel has been a strong contributing factor in high plant audit scores. We typically receive kudos from our customers and the USDA/FSIS for the selection of new equipment meeting the demand for high food safety standards.”

Roedl agreed. “Selecting the ALIGAL FZ has been an excellent decision for our company. We have been able to increase production and be a leader in food safety, all while lowering costs.”

And although a lot has changed in the 50 years since Emil Kopplin opened his pizzeria, one thing remains the same. “All of us at Emil’s Pizza believe in satisfying our customers with the highest quality, best value, best-tasting frozen pizza available,” Roedl said. “Our new freezing system ensures we can continue to do so with the highest degree of food safety in the industry.”

MaryJane Mudd is a Houston-based writer and director of global communications for a major oil and gas transportation services company.