Q and A - Guidance for Developing HACCP Plans for Specialized Processes at Retail - freeze-drying and fermentation

Sep 1, 2026

Upload by Mason

A Q&A session addressing guidance for developing HACCP plans for specialized processes in retail, with emphasis on freeze-drying and fermentation. It explains freeze-drying principles, microbial risk, and safe handling requirements, including product packaging and rehydration controls. It highlights manufacturer cautions on tray loading, cleaning, storage longevity, and suitability of high-fat/high-sugar foods. The session also compares spray drying vs freeze drying and clarifies how sourdough and injera fit fermentation guidance, including starter safety and lactic-acid controls.

LanguageEnglish

CategoryPresentations

FormatDOCX

Pages9

Reading Time3 min

AccessFree to download

Freeze-drying guidance (Q&A)

Freeze-drying basics and safety controls

Manufacturer cautions and storage practices

Regulatory and HACCP/variance considerations

Spray drying vs freeze drying

Fermentation scope: sourdough and injera

Sous-vide packaging question

Q and A from March 1 Webinar Guidance for Developing HACCP Plans for Specialized Processes at Retail 1] We have a lot of inquiries on freeze-drying - candy, ice cream, meats, full meals, BBQ sauces (made into powders to reconstitute with water for hikers/campers) Freeze-drying is a preservation method that typically involves freezing a food, then reducing the pressure and increasing the temperature to cause the frozen water in the food to sublimate (transition from a solid to a gas). This removes the majority of the water from the food, which inactivates or inhibits the growth of microorganisms. Freeze-drying does not kill bacteria or other microorganisms; they remain viable, but dormant, despite the extreme conditions of freeze drying. Additionally, freeze-dried foods are often packaged under vacuum or in airtight containers, which further reduces the risk of contamination. Nearly any food item can be freeze dried (e.g. fruits, vegetables, herbs, meats (cooked and raw), eggs, dairy, meals, casseroles, desserts). Vegetables should be blanched prior to freeze drying to prevent discoloration. Food high in fat content, high in sugar content, and baked goods such as breads, cakes, and muffins do not freeze dry well and should be avoided. Freeze drying produces high quality foods that are safe as long as they are handled properly prior to freeze drying, dried thoroughly, packaged appropriately, and used or prepared correctly once the packaging is opened. Any bacteria or microorganism on raw foods prior to freeze drying will reactivate upon rehydration. Therefore, food items that are traditionally cooked before eating must also be cooked before eating as a freeze-dried food. Regulatory authorities may require retail firms that freeze dry products to obtain a HACCP plan and variance depending on the food product that is freeze-dried and the process used. For example, freeze dried fruits or vegetables might utilize a chlorine treated flume water to wash the fruit or vegetable product to be processed. The concentration of chlorine might be considered a critical control point. Foods that are considered TCS and ready-to-eat are considered higher risk, and may be more likely to be required by the regulatory authority to have an approved HACCP plan. Here are some cautionary issues from manufacturers to consider including the following: Freeze-drying big chunks of food - The larger the pieces of food, the longer they will take to dry. Not to mention, big chunks of meat may go rancid due to their fat content. For the best freeze drying results, make sure to cut food into small uniform pieces. Doing this ensures that moisture is completely removed and that each piece is fully processed. Combining meat and other foods in the freeze-drying chamber - While it’s fine to freeze-dry different types of food at once, as long as they have similar flavors, avoid mixing raw meat with other products to avoid cross-contamination. Not cleaning your freeze dryer after every use - Neglecting cleaning may lead to clogs and malfunction over time. Not storing freeze-dried foods properly - Freeze-dried products can last up to 25 years depending on how you store them. This is why ensuring proper storage of your foods is crucial to maximizing their longevity. Right after freeze drying, food should be placed in an airtight container to provide protection from light, moisture, and odor. Overloading your freeze dryer trays - Keep in mind that more food means more drying time is required. As a best practice, check the recommended load size for your freeze dryer. Freeze-drying foods high in fat and sugar - A common mistake with freeze drying is doing it on fatty and sugary foods. Because fat goes rancid sooner, your freeze-dried food will last only a few years. If you want to freeze-dry meat (e.g. an already-cooked steak), drain or remove the extra fat prior to processing it. Sugary items like honey and jams will remain sticky even with increased drying time. So, avoid

FAQs

Does freeze-drying kill bacteria and microorganisms?

Freeze-drying does not kill microorganisms; they remain viable but dormant under extreme conditions. Rehydration can reactivate them, so freeze-dried foods must be properly cooked and handled before consumption.

Why should raw meat not be mixed with other foods in the freeze-drying chamber?

Mixing raw meat with other products can increase cross-contamination risk. Freeze-drying different types of food is acceptable when they have similar flavors, but raw meat should be avoided with other items to reduce contamination.

What are common manufacturer cautions when freeze-drying foods?

Key cautions include cutting food into small uniform pieces, not overloading trays, cleaning the freeze dryer after each use, storing products in airtight containers promptly, and avoiding freeze-drying foods high in fat or sugar (or draining excess fat for meat).

What is the difference between spray drying and freeze drying?

Spray drying uses thermal processing to produce powder from a liquid, while freeze-drying is a non-thermal method that combines freezing and vacuum drying to dehydrate heat-sensitive foods.

Sep 1, 2026

Upload by Mason