Process optimisation and quality evaluation of paneer subjected to individual quick freezing using liquid nitrogen

Background, Context or Rationale Paneer's high‐moisture content makes it highly perishable and poses significant challenges in extending its shelf life. While freezing is the most effective preservation technique, conventional freezing is not efficient in terms of time, energy, cost and can negatively affect paneer's texture. Individual quick freezing (IQF) using liquid nitrogen presents a superior alternative by rapidly freezing paneer with minimal structural damage. Aim(s) This study aimed to develop and optimise a process of freezing paneer by IQF using liquid nitrogen and thawing and characterise quality in comparison with conventional method and control. Methods This study evaluated three freezing methods: conventional, liquid nitrogen vapour and liquid nitrogen immersion, along with hot water dip thawing. Paneer was cut into 2 × 2 × 2 cm 3 , 3 × 3 × 3 cm 3 and 4 × 4 × 4 cm 3 cubes, and optimisation focused on freezing time to reach a core temperature of −15°C, along with thawing time, thawing loss, colour, sensory and textural characteristics. Freezing trials were replicated five times, and all analyses were performed in triplicate. A one‐way randomised block design was used, and data were analysed using SPSS with significance evaluated at the 5% level. Major Findings Among the three freezing methods, liquid nitrogen vapour freezing with 2‐cm paneer cubes proved most effective, retaining superior textural and sensory qualities. It reached the target temperature in 2.46 min and thawed in 2.1 min using hot water. Scanning electron microscopy analysis showed much smaller pore size (5.6 μm) compared with conventional freezing (65.6 μm), indicating better structural integrity. Liquid nitrogen vapour also prevented crumbling and cracking seen with liquid nitrogen immersion freezing. Scientific or Industrial Implications Liquid nitrogen vapour freezing is an effective method for producing high‐quality paneer with extended shelf life, higher commercial output and reduced environmental impact, making it a promising technique for large‐scale freezing applications.