Behind the scenes of frozen food – Suzannah's Field Report

In October 2008, Suzannah Archibald was sent to a farm in Lincolnshire to discover how frozen broccoli is produced.

1. How is the broccoli grown and harvested?

At the Lincolnshire Food Products Cooperative Farming Operations at Holbeach Marsh, near Boston, Lincolnshire I was met by the charming and knowledgeable, Ray Francis, the Field Manager. He explains to me that the terrain is all ‘reclaimed marsh lands' - a Grade I silt land with strong moisture absorption, making it ideal for peas/petits pois, sugar beets, and especially broccoli planting. With an under-base of clay, the dirt squishes underfoot, leaving this field operative wishing she'd given in to the proffered wellies! The soil, he continues, is nutrient-rich and allows crops to flourish with abundant periods of sunniness and warmth.

There are 5 rigs in operation at midday. Manual field labourers are strewn across the field, labouriously chopping as well as floretting the fresh broccoli plants for our eventual consumption.

2. What sort of pesticides and sprays are used in the farming process?

A ground herbicide is used, says Ray, but it has been field-tested and is safe for human consumption. Although this herbicide is added to the same soil before planting, before the crops go in, once the crop is established they smother the weeds, overtaking in their agricultural legacy, as plants are prone to do.

"The use of a spray programme starts off with a herbicide (no weeds going towards care) for the plant," Ray adds, and if the crop "needs it" an anti-pesticide is added to broccoli plants' leaves to combat aphids or a herbicide to battle fungal/moisture problems. A fertilizer may also be added if the crop is struggling a bit in the early stages of its growth.

Ray is at pains to make clear that "Each field has a harvest clearance that is performed and cleared prior to harvesting to ensure safety of the crops and that spraying poses no dangers to human consumption."

3. Where and how is the broccoli then frozen?

Moving to the processing plant at Pinguin Foods UK Ltd nearby, I meet the Agricultural Produce Manager Stuart Ashton who gives me a guided tour of the plant. Stuart tells me that the most important thing to note is that, "Everything is packaged same day at the processing plant,"

The blanching (preparation) process of frozen vegetables takes no longer than 2-3 minutes, where the raw vegetables are heated in a blancher, and then chilled immediately in another receptacle

Stuart says, "Whilst, the lifecycle of a plant is its use from field to plant, then to process and eventually into the supermarket, and while just as labour intensive as fresh, organic vegetable produce, it is quite often undersold or beleaguered in the open market"

Dot, one of the Quality Assurance (QA) Processors in the Frozen Foods/Packaging Department said, "It is quite an eye opener, really. The first day I worked here on the line it was with peas. I just couldn't believe how detailed the process was, from truck to plant and eventually to my table. Amazing!"

4. How is the broccoli stored and transported after freezing?

Cold storage can house up to 5,000 tons of palleted, stored frozen vegetables which will be shipped out slowly by as late as next June (2009). This, in turn says Ashton, is processed on a per capita, as need by basis, as determined by Pinguin Foods.

5. How long is it from harvesting to freezing?

Broccoli is a hardy and prolific crop and generally sprouts eight to twelve weeks from being planted. The average time from harvesting of the broccoli to freezing is anywhere from 50 minutes, to several hours.

6. How much wastage is there?

Ray Francis explains, "None. For cutting purposes, did you know that only about 40 per cent of the broccoli is used for processing. The rest of the plant, 60 per cent - the stalk, leaves, roots - are simply chopped up by a agricultural combine, cut down in the field to re-fertilize next year's offerings. Surprising, isn't it?"

7. How many people are involved with the process?

Stuart Ashton says, "In all, only about 6 people ever touch the frozen vegetables that actually comes through the processing plant that's eventually bought by your average British consumer -quite amazing really, when only a handful of years ago it was twice that many people. Machines really are extraordinary, aren't they?"

8. My conclusions.

Stuart says, "Whilst, the lifecycle of a plant is its use from field to plant, then to process and eventually bring into the supermarket, and while just as labour intensive as fresh, organic vegetable produce, it is quite often undersold or beleaguered in the open market"

There is a positive story to tell about the safety, convenience, quality, taste and nutrition of frozen foods v. fresh foods. It doesn't sacrifice quality or time in the processing stage, and if anything flash freezing is simply nature's way of cutting out the needs for artificial preservatives. Freezing produce - the natural way to preserve food!

As I see it, as a consumer, the main differences between organic produce and the frozen foods/vegetables processing station that I'm struck by is mainly this: between products that are for sale at a farmer's market and those that are brought from the field, fresh and lush to be frozen, it's really just the intricacy of the operation. The quality remains formidable, the attention to detail is astonishing, and really, the level or high-quality handling and importance of routine and maintenance one can't help being struck by how few steps are added to freeze this produce and get it to our tables.