Transforming surplus produce into value
A significant source of food waste is discarded fruits and vegetables, which are often rejected due to imperfections rather than quality issues. Instead of being placed into waste streams, these can be puréed, freeze-dried and chopped into small pieces, creating natural ingredients for products such as mueslis or granolas, cake decorations, snack bars and more. This process gives new life to surplus produce and enables manufacturers not only to reduce waste but to add valuable new revenue streams to their businesses.
"Food waste isn’t just a loss – it’s an opportunity,” says Peter Zichy, Area Sales Manager, Freeze Drying, at GEA. “With freeze-drying technology, we can take surplus fruits, vegetables and other perishables and transform them into high-value, long-lasting products. This not only reduces waste but also helps create new revenue streams for producers while ensuring more food reaches people who need it."
A natural and sustainable preservation method
Freeze drying is one of the most effective ways to preserve food without the use of chemicals or additives. By gently removing moisture through the process of sublimation (conversion from a solid to a gas with no liquid phase), freeze-dried products retain their original shape, color, taste and nutrients – meeting consumer demand for natural foods that are so-called clean-label products.
Reducing waste and environmental impact
Freeze-dried products offer a practical solution to global food waste and supply chain challenges. Unlike fresh or refrigerated foods, they do not require a cold chain, which makes them ideal for regions with limited infrastructure. This extends food availability while lowering energy use and carbon emissions associated with refrigeration and transport.
"One of the biggest advantages of freeze-dried food is that it requires no refrigeration, drastically cutting energy use during transport and storage,” says Zichy. “This makes it a game-changer for both resource and cost-efficiency – helping to reduce emissions while ensuring food stays fresh for longer, no matter where it’s needed."
Additionally, freeze drying reduces food weight by 70% to 90%, significantly cutting shipping costs and environmental impact. Through the process of making food preservation more efficient, freeze drying contributes to a more resilient and sustainable food system.
GEA offers deep freeze drying expertise
With decades of experience in freeze drying technology, GEA provides tailored solutions for the food and beverage industry, from pilot-scale systems to fully automated large-scale processing lines. Our technology is designed to be user friendly, while helping to maximize plant reliability, reduce product loss and achieve top product quality. At our dedicated test center in Copenhagen, Denmark, we collaborate with customers to optimize processes both new and existing, test new applications and develop innovative freeze-drying technologies that are application specific and in line with individual needs and requirements.
Innovating for the future
By turning surplus food into valuable ingredients, supporting sustainable food preservation and enabling new product innovations, freeze drying is helping to shape a more efficient, less wasteful food industry. At GEA, we continue to push the boundaries of food processing technology, leading to ever higher levels of food preservation to better support global population growth.
Benefits of freeze drying
- Efficiently uses surplus ingredients to better support a growing population
- Extends food availability while lowering energy use and carbon emissions
- Retains, to the greatest possible extent, the original shape, color, taste, texture and nutrients
- Is lightweight for easy handling and transportation
- Requires no refrigeration during transport and storage
- Has a long shelf life
- Allows for instant rehydration, supporting busier lifestyles
