In the fast-paced world of ice cream production, where innovation and quality are paramount, cryogenic technology is emerging as a revolutionary force. Utilizing liquid nitrogen or carbon dioxide for rapid freezing, this cutting-edge technique delivers a rich, velvety texture by inhibiting the development of large ice crystals. It also preserves delicate flavours and enhances the overall sensory experience, setting a new benchmark for premium-quality ice cream.
The importance of cryogenic technology lies not just in its ability to improve texture and flavour but also in its operational benefits. Faster freezing cycles increase production efficiency, while the technology’s versatility allows manufacturers to create unique shapes, textures, and fillings—perfect for catering to the growing demand for artisanal and innovative ice cream products.
While cryogenics has gained widespread adoption in global markets, its use in India remains limited, mainly to premium and boutique brands. As consumer demand for high-quality, differentiated products increases, cryogenics could become a game-changer, setting new standards for brands aspiring to lead the market.
Ice Cream Times magazine had a detailed conversation with Ashish Nahar, MD, Nahar Frozen Foods & Ice Cream Pvt. Ltd. and Fun India Dairy (with the Cremica Ice Cream brand), and Murtuza Rajapkar, Founder of The Frost Bite and Company, discussing the transformative potential of cryogenics in ice cream production, the challenges faced by Indian manufacturers, and the significant opportunities this technology presents for the country’s ice cream industry.
ICT-What major role does cryogenic technology play in ice cream production?
Ashish states that cryogenic technology is a game-changer in ice cream production, enabling ultra-rapid freezing with liquid nitrogen or carbon dioxide. This method ensures a smoother, creamier texture by preventing the formation of large ice crystals, a common issue with conventional freezing. This process prevents the formation of large ice crystals, ensuring a smoother, creamier texture compared to traditional methods. It also preserves moisture and flavours, enhancing the overall quality and taste of the product. Further, cryogenics offers greater versatility, allowing manufacturers to experiment with unique shapes, textures, and fillings, which are especially appealing in the premium and artisan ice cream market.
Murtuza articulates that cryogenic technology, particularly the use of liquid nitrogen (LN2), plays several critical roles in ice cream production, including: Cryogenic freezing, particularly using liquid nitrogen, offers several advantages in ice cream production. The process rapidly freezes the ice cream base, creating smaller ice crystals that result in a smoother, creamier texture compared to conventional methods. This rapid freezing also helps retain volatile flavour compounds, ensuring that the ice cream’s flavours are more intense and truer to their original taste, something that can be lost with slower freezing methods. Additionally, liquid nitrogen facilitates efficient air incorporation, influencing the overrun (the amount of air mixed into the ice cream), which produces a lighter, fluffier texture. The method also excels in small-batch production, allowing for greater customization and flexibility, making it easier for manufacturers to experiment with unique flavours and textures. Beyond the technical benefits, the dramatic vapor clouds produced during the freezing process enhance the visual appeal, providing a unique customer experience, especially in artisanal ice cream parlours and food trucks.
ICT-What is the current level of adoption of cryogenic freezing technology in the Indian ice cream industry?
“Cryogenic freezing technology is still emerging in the Indian ice cream industry, with adoption largely limited to high-end and boutique brands. Traditional freezing methods dominate due to their lower cost and established infrastructure. However, as demand for high-quality, innovative ice cream grows in urban markets, more premium manufacturers are adopting cryogenics to differentiate their products. Despite its potential, high costs, limited supply chains for cryogenic materials, and a lack of awareness among smaller producers continue to restrict its broader adoption”, cites Ashish.
Murtuza shares his perspective, stating, “The adoption of cryogenic freezing technology in the Indian ice cream industry is growing but remains relatively niche.”
• Large-Scale Manufacturers: Major ice cream producers in India, such as Amul, Britannia, and Mother Dairy, generally use conventional freezing methods in large, high-capacity machines, primarily because of cost-effectiveness and economies of scale. Cryogenic freezing is not as widely adopted in large-scale production due to high initial costs.
• Artisanal and Small-Scale Producers: However, the technology is gaining popularity in the premium, artisanal, and small-batch sectors. Several high-end ice cream parlours and food trucks have adopted cryogenic freezing to create unique textures, faster production times, and a spectacular presentation for customers. For example, brands like The Creamery, Molecular Ice Cream, Ice Cream Lab and others have capitalized on the dramatic appeal of liquid nitrogen ice cream.
• Growing Awareness: As consumer interest in premium and innovative food products grows, there’s an increasing awareness and adoption of cryogenic technology in India’s ice cream industry, especially in urban centers and among younger, more experimental consumers.
ICT-How does cryogenics improve the texture and quality of ice cream compared to conventional freezing?
Speaking on the topic, Ashish explains, “The texture and mouthfeel is very crucial in ice cream making. Cryogenics enhances the texture and quality of ice cream by freezing it rapidly, preventing the formation of large ice crystals that can cause graininess. This results in a smoother, creamier mouthfeel. The process also improves consistency by controlling air incorporation, ensuring uniform density and texture. Furthermore, cryogenics preserves delicate flavours and aromas by reducing the loss of volatile compounds during freezing. It also minimizes freezer burn, ensuring the product maintains its quality and freshness for longer”.
Cryogenic freezing improves ice cream quality in several key ways, says Murtuza:
• Faster Freezing = Smoother Texture: Cryogenic freezing uses liquid nitrogen’s extremely low temperature (-196°C) to rapidly freeze the ice cream base. This prevents the formation of large ice crystals, which can result in a grainy texture. Instead, it creates smaller ice crystals, resulting in a smoother, creamier mouthfeel and preserving the flavour more effectively than traditional slow freezing methods.
• Better Air Incorporation: The quick-freezing process also helps in efficient air incorporation. With conventional ice cream machines, air can be incorporated unevenly during the slow freezing process. Liquid nitrogen freezing allows for more consistent overrun, producing lighter, fluffier ice cream with a better texture and a more desirable feel.
• Flavour Preservation: Rapid freezing locks in the flavour and preserves volatile aroma compounds that could otherwise dissipate during slower, conventional freezing. This results in more vibrant and intense flavours.
• Minimal Ice Crystals and Ice Cream Fat: Cryogenic freezing also allows for better control of fat content and texture consistency, which is critical for making high-quality premium ice cream.
ICT-Are there significant cost or energy-saving benefits associated with cryogenic freezing?
“Yes Definitely…cryogenic freezing offers efficiency and potential cost savings, particularly for manufacturers targeting premium segments, replies Ashish. “Cryogenic freezing speeds up production, which can help manufacturers make more ice cream in less time, improving efficiency. These systems also need less maintenance compared to regular freezers, which can save money over time. However, the cost of making and transporting liquid nitrogen might reduce some of these savings. Despite the initial investment, the improved product quality and shorter production cycles often make cryogenics a worthwhile investment for premium brands”.
Murtuza remarks, “While cryogenic freezing offers numerous quality advantages, it does not necessarily lead to significant cost savings or energy efficiency in traditional large-scale ice cream production. Here’s why:
• High Initial Investment: The cost of liquid nitrogen and the investment in cryogenic equipment can be quite high. Setting up cryogenic freezing involves specialized equipment (dewar flasks, storage tanks for LN2, etc.), which can be expensive. For large-scale producers, this could be a barrier to adoption.
• Energy Efficiency Concerns: Cryogenic freezing relies on liquid nitrogen, which is made through a process that uses a lot of energy. So, while it improves ice cream quality, it might not be more energy-efficient than traditional freezing methods. The production and transportation of liquid nitrogen also add extra energy costs.
• Small-Batch Advantage: The real benefit of cryogenic freezing lies in its speed and flexibility for small-batch, artisanal, or high-end ice cream producers, where the ability to freeze faster and customize textures outweighs the higher operational costs.
For large-scale manufacturers, conventional freezing methods (e.g., batch freezers or continuous freezers) are more cost-effective, especially in terms of energy consumption and long-term investment.
ICT-What challenges do Indian ice cream manufacturers face when implementing cryogenic solutions?
“Indian ice cream manufacturers face several challenges when adopting cryogenics. High setup costs and limited access to cryogenic materials, especially in smaller towns, make implementation difficult. Operating cryogenic systems requires skilled personnel, adding to labour costs. Strict safety regulations and compliance standards for handling cryogens further complicate adoption. Also, consumer awareness about the benefits of cryogenic freezing is low, making it harder to justify higher price points. Despite these challenges, cryogenic technology holds immense potential for brands seeking to innovate and cater to the growing demand for premium-quality ice cream in India”, expresses Ashish.
Murtuza too concludes his reply, “Several challenges exist when implementing cryogenic solutions in India’s ice cream industry:
1. High Initial Capital Investment: The upfront cost of setting up cryogenic freezing systems can be prohibitively high, especially for small and medium-sized businesses. The equipment and storage tanks for liquid nitrogen require significant investment.
2. Supply Chain for Liquid Nitrogen: Liquid nitrogen is not always readily available in all parts of India. Transport and storage of liquid nitrogen are critical concerns, especially in remote areas. Ensuring a steady supply can add complexity and cost to the operation.
3. Lack of Awareness and Technical Expertise: Cryogenic freezing is a specialized technology, and knowledge gaps exist in terms of operation, safety, and maintenance. There may be a need for training to ensure that workers can handle liquid nitrogen safely and operate the equipment efficiently.
4. Safety Concerns: The handling of liquid nitrogen requires proper safety protocols, as it is extremely cold and can cause severe frostbite or asphyxiation if not handled correctly. Ensuring the safety of workers and customers can be challenging, especially in unregulated or small-scale environments.
5. Energy and Operational Costs: Liquid nitrogen is energy-intensive to produce, and the associated costs might not be offset by the benefits in terms of energy efficiency or cost reduction in large-scale ice cream production. Manufacturers may struggle to justify the investment in cryogenic freezing if the primary focus is on cost-effective mass production.
6. Regulatory Challenges: In some regions, the use of liquid nitrogen may be subject to regulations and standards, particularly in food safety. Manufacturers need to adhere to food safety norms related to cryogenic processing to ensure that products are safe for consumption.
Conclusion
Cryogenic technology in ice cream production offers distinct advantages in terms of texture, flavour, and efficiency, especially for small-batch or premium ice cream producers. However, its adoption in India is still limited by high costs, supply chain challenges, and technical hurdles. While the artisanal sector is increasingly adopting it for its innovative appeal, large-scale manufacturers may continue to rely on more conventional methods due to their cost-effectiveness and energy efficiency.