Cryogenics and Air-Fryer Chemistries Redefine Industrial Donut Manufacturing

Industrial donut production is overcoming shelf-life and textural limitations through extreme thermal processing and novel hydrocolloid chemistry. Manufacturers are deploying -36°C cryogenic freezing and specific starch-protein matrices to service wholesale and air-fryer markets.

ByMaite Carricaburu

The donut category is undergoing a technical bifurcation driven by advanced preservation methods and alternative cooking formats.

Planet Doughnut has executed a strategic pivot from artisanal retail to centralized industrial wholesale, supported by a £25,000 investment in a new NPD (New Product Development) Kitchen.

The operational key to this transition is the adoption of cryogenic freezing technology. By subjecting finished products to temperatures of -36°C immediately after decoration, the facility creates a thermal lock that allows distinct manufacturing to withstand complex supply chains.

Reccomended reading: Freezing and Thawing on Unbaked Bread Doughs – Bakery Industry Insider

Simultaneously, the “free-from” sector is re-engineering the dough matrix itself.

Crave has introduced vegan, gluten-free donuts specifically formulated for domestic air fryers, removing the need for industrial deep-frying oils entirely.

Technical Mechanisms:

  • Cryogenic Structural Locking: Rapid freezing at -36°C prevents the formation of large ice crystals that damage gluten networks. This preserves the crumb moisture and topping integrity, ensuring the product retains “fresh-made” organoleptic properties upon thawing.
  • Alternative Starch Matrix: Crave’s formulation utilizes a precise blend of potato, tapioca, and corn starches. These starches manage moisture retention and expansion without the rapid dehydration of deep frying.
  • Protein Simulation: Pea protein is integrated to provide the structural scaffolding usually supplied by gluten and eggs, allowing the dough to set and brown via convective heat transfer (air frying) rather than conductive oil heat.

Operational Impact:

For Planet Doughnut, the shift to cryogenics decouples production volume from immediate shelf-life constraints, enabling high-quality distribution to major retailers.

Conversely, Crave’s formulation innovation opens a new “heat-at-home” vertical, leveraging the massive installed base of air fryers to offer a lower-fat, allergen-free product that bypasses the operational costs and hazards of industrial frying lines.

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