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©Copyright 2016 JOYFUN Food
Views: 100 Author: Site Editor Publish Time: 2025-12-17 Origin: Site
I. Root Causes： Multiple Damage Mechanisms During Transportation
The core challenges in transporting frozen sesame balls essentially stem from the combined systematic damage caused by physical vibration， temperature fluctuations， and packaging pressure：
1. Four Major Causes of Cracking
Thermal stress cracking： Temperature fluctuations cause water-ice phase changes， with volume variations generating internal stress
Vibration fatigue fracture： Continuous vibration during transit causes micro-cracks to propagate
Stacking pressure damage： Excessive static pressure on bottom-layer products
Handling impact damage： Instantaneous impacts from throwing or dropping during loading/unloading
2. Triple Mechanism of Sesame Loss
Vibration sieving effect： Vibration separates sesame from the ball surface
Ice crystal isolation： Surface ice crystal layers reduce adhesion
Electrostatic repulsion： Static electricity buildup in dry environments causes repulsion
II. Systematic Solutions： Closed-loop Management from Production to Receipt
Phase 1： Production-side Pre-protection （Source Control）
Formula Anti-cracking Optimization
Enhanced Skin Extensibility：
Add 0.3-0.5% trehalose： Lowers freezing point， reduces ice crystal size
Composite thickeners： 0.2% guar gum + 0.1% xanthan gum， improves dough water retention
Fat optimization： Use shortening and palm oil blend （ratio 7:3）， improves low-temperature flexibility
Sesame Adhesion Reinforcement：
Dual-coating Process：
First layer： 10% maltose syrup spray， creates adhesive base
Second layer： Sesame + 0.5% food gum （gum arabic） mixture
Electrostatic pretreatment： Pass sesame through electrostatic generator to impart positive charge， enhancing adhesion to negatively charged skin
Improved Flash-freezing Process
Stepped Freezing Curve：
Phase 1： -10°C， 30 minutes （rapid surface setting）
Phase 2： -25°C， 60 minutes （core temperature rapidly drops to -18°C）
Phase 3： -18°C， equilibrium storage
Anti-ice Crystal Technology：
Vacuum pre-cooling： Rapid cooling under vacuum before freezing， reduces free water content
High-pressure assisted freezing： Freezing under 200MPa pressure forms fine ice crystals
Phase 2： Packaging Engineering Innovation
Anti-vibration Packaging Design
Multi-layer Cushioning Structure：
Vibration Test Standards：
Pass ISTA 3A transport tests （including vibration， shock， drop）
Vibration frequency range： 3-100Hz， duration 1 hour
Drop height： Set by package weight （typically 76cm）
Temperature-stable Packaging
Phase Change Material Application：
Integrate PCM panels into packaging inner walls
Phase change temperature point： -15°C （absorbs heat when melting， releases heat when solidifying）
Effective duration： 48-72 hours
Vacuum Insulation Panels：
Thermal conductivity ≤0.004 W/（m·K）
Thickness only 10-20mm， minimizes space usage
Phase 3： Transportation Process Management
Temperature Monitoring System
Smart Temperature Loggers：
Place Bluetooth temperature loggers in each carton
Temperature threshold： -18°C±2°C
Automatic cloud alert for temperature excursions
Cold Chain Vehicle Selection：
Refrigeration unit： Dual independent compressor systems （one active， one backup）
Cargo box： Sandwich panel structure， polyurethane foam thickness ≥80mm
Temperature uniformity： Temperature difference ≤3°C across all box points
Vibration Control Strategy
Vehicle Shock Absorption Modification：
Replace leaf springs with air suspension systems
Install shock-absorbing rubber pads between cargo box and chassis
Loading Optimization：
Honeycomb stacking： Interlocked stacking to disperse pressure
Top restraints： Prevent vertical bouncing during transit
Inflatable bags： Fill cargo gaps for fixation
Phase 4： Handling and Warehousing Standards
Mechanized Handling
No manual throwing： Full implementation of pallet transport
Conveyor buffer zones： Install air-cushion conveyors in loading/unloading areas
Forklift speed limits： In-warehouse forklift speed ≤5km/h
Warehouse Management Standards
Unloading Buffer Area：
Quick unloading to buffer room （temperature -10°C）
Settle for 2 hours before moving to main storage （-18°C）
Avoid “thermal shock”
Rack Pressure Management：
Stacking height ≤5 layers
Reinforced pallets for bottom layers
Regular stock rotation
III. Acceptance Standards and Problem Tracing
On-site Rapid Inspection Methods
Cracking Rate Sampling：
Randomly select 30 pieces per batch
Magnifying glass （10×） inspection for surface cracks
Acceptable standard： Cracking rate 《3%
Sesame Loss Test：
Vibration table test： 10 minutes， frequency 10Hz， amplitude 5mm
Weight method： Calculate loss rate from weight difference before/after vibration
Acceptable standard： Loss rate 《2%
Problem Tracing System
Carton QR Codes：
Contain： Production batch number， freezing time， packing time， transport vehicle
Scan to view complete temperature/humidity curve
Root Cause Analysis for Damage：
Vibration Test Standards：
Pass ISTA 3A transport tests （including vibration， shock， drop）
Vibration frequency range： 3-100Hz， duration 1 hour
Drop height： Set by package weight （typically 76cm）
Temperature-stable Packaging
Phase Change Material Application：
Integrate PCM panels into packaging inner walls
Phase change temperature point： -15°C （absorbs heat when melting， releases heat when solidifying）
Effective duration： 48-72 hours
Vacuum Insulation Panels：
Thermal conductivity ≤0.004 W/（m·K）
Thickness only 10-20mm， minimizes space usage
Phase 3： Transportation Process Management
Temperature Monitoring System
Smart Temperature Loggers：
Place Bluetooth temperature loggers in each carton
Temperature threshold： -18°C±2°C
Automatic cloud alert for temperature excursions
Cold Chain Vehicle Selection：
Refrigeration unit： Dual independent compressor systems （one active， one backup）
Cargo box： Sandwich panel structure， polyurethane foam thickness ≥80mm
Temperature uniformity： Temperature difference ≤3°C across all box points
Vibration Control Strategy
Vehicle Shock Absorption Modification：
Replace leaf springs with air suspension systems
Install shock-absorbing rubber pads between cargo box and chassis
Loading Optimization：
Honeycomb stacking： Interlocked stacking to disperse pressure
Top restraints： Prevent vertical bouncing during transit
Inflatable bags： Fill cargo gaps for fixation
Phase 4： Handling and Warehousing Standards
Mechanized Handling
No manual throwing： Full implementation of pallet transport
Conveyor buffer zones： Install air-cushion conveyors in loading/unloading areas
Forklift speed limits： In-warehouse forklift speed ≤5km/h
Warehouse Management Standards
Unloading Buffer Area：
Quick unloading to buffer room （temperature -10°C）
Settle for 2 hours before moving to main storage （-18°C）
Avoid “thermal shock”
Rack Pressure Management：
Stacking height ≤5 layers
Reinforced pallets for bottom layers
Regular stock rotation
III. Acceptance Standards and Problem Tracing
On-site Rapid Inspection Methods
Cracking Rate Sampling：
Randomly select 30 pieces per batch
Magnifying glass （10×） inspection for surface cracks
Acceptable standard： Cracking rate 《3%
Sesame Loss Test：
Vibration table test： 10 minutes， frequency 10Hz， amplitude 5mm
Weight method： Calculate loss rate from weight difference before/after vibration
Acceptable standard： Loss rate 《2%
Problem Tracing System
Carton QR Codes：
Contain： Production batch number， freezing time， packing time， transport vehicle
Scan to view complete temperature/humidity curve
Root Cause Analysis for Damage：
IV. Cost-Benefit Analysis
Preventive Investment vs. Loss Costs
| Measure | Cost Increase per Carton | Expected Damage Reduction | ROI Period |
|---|---|---|---|
| Improved Packaging | ¥2.5/carton | From 8% to 3% | 2 months |
| Temperature Monitoring | ¥0.8/carton | From 5% to 2% | 1.5 months |
| Vehicle Modification | ¥0.3/carton | From 4% to 1.5% | 3 months |
| Total | ¥3.6/carton | From 17% to 6.5% | 2.2 months |
*Note： Based on monthly transport of 10，000 cartons at ¥200/carton value， monthly savings： 10，000×200×（17%-6.5%）=¥210，000*
V. Industry Best Practice Case Study
Case： Chain Restaurant Group Solution
Problem： 15% cross-province transport damage rate， severe sesame loss
Solution：
Packaging upgrade： Custom blister trays + air cushion buffers
Carrier screening： Require ISTA test reports
Receipt inspection： Portable vibration table for sampling
Results：
Transport damage rate reduced to 4.2%
Customer complaints decreased by 70%
Annual savings exceeding ¥1.5 million
Conclusion： Building a Resilient Supply Chain
Preventing cracking and sesame loss during frozen sesame ball transportation is not about improving a single link， but requires building a full-chain resilient system from production formula → packaging engineering → transport management → warehousing/handling. Through quantified standards， technological innovation， and process control， companies can fully control transport losses within 5%， improving customer satisfaction while achieving significant cost savings.
The future trend will be intelligent prevention—real-time monitoring of cargo status via IoT sensors， AI algorithms predicting damage risks， and automatic adjustment of transport parameters. Transportation will no longer be just “moving goods，” but part of an “active preservation system.”
