What Is a Temperature Excursion and Why Does It Matter for Frozen Foods?

In the frozen food industry, any deviation outside specified temperature ranges is known as a temperature excursion.

Understanding what it is, why it happens, and how to manage it is critical for food safety, compliance, and business performance.

What Is a Temperature Excursion?

A temperature excursion occurs whenever a frozen product or storage environment rises above or drops below its required temperature range for a defined period.

For example:

• Frozen foods are often stored at -18°C or below.

• If a freezer rises to -15°C for an hour, that may count as an excursion, depending on the product and regulatory guidance.

• Similarly, if a freezer drops far below the recommended range, some products can be damaged or lose quality.

Excursions can be short-term spikes (e.g., door left open) or long-term failures (e.g., freezer malfunction).

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Why Temperature Excursions Matter

Temperature excursions are not just numbers on a thermometer- they have real consequences:

1. Food Safety Risks

• Freezing slows bacterial growth but does not kill all pathogens.

• If a product warms above safe limits, pathogens can multiply once thawed, increasing the risk of foodborne illness.

2. Loss of Quality

• Ice crystals can form differently if temperatures fluctuate.

• Texture, flavour, and appearance may be compromised, reducing shelf life.

3. Regulatory Compliance

• UK and EU food safety standards require frozen food businesses to maintain continuous monitoring and take action on deviations.

• Excursions must be logged, investigated, and corrected, especially for audits under BRCGS, HACCP, or EU/UK Food Hygiene law.

4. Financial Impact

• Spoilage from excursions can lead to wasted stock, lost revenue, and expensive product recalls.

• Repeated excursions can harm retailer relationships and brand reputation.

Common Causes of Temperature Excursions

Understanding the source of excursions is key to prevention:

• Equipment failure: Freezers, chillers, or transport vehicles malfunctioning.

• Human error: Doors left open, incorrect temperature settings, or missed manual checks.

• High traffic or storage mismanagement: Overloading freezers, poor airflow, or uneven stacking.

• Power interruptions: Outages, surges, or backup system failures.

• Transport issues: Delays, uncalibrated vehicles, or broken refrigeration units.

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How Businesses Can Prevent and Manage Excursions

1. Automated Monitoring Systems

Wireless temperature sensors provide real-time alerts when temperatures go out of range.

They log data continuously, helping prove compliance and reducing manual checks.

2. Corrective Action Protocols

A clear plan for responding to excursions (e.g., moving stock, repairing equipment, documenting actions.)

3. Regular Equipment Maintenance

Prevents failures and ensures that freezers and chillers operate within specifications.

4. Staff Training

Everyone in the cold-chain should understand the importance of temperature control and know what to do if alarms sound.

5. Auditable Data and Reports

Automated systems create logs suitable for audits, helping businesses demonstrate compliance with BRCGS, HACCP, and UK/EU food safety requirements.

Conclusion: Excursions Are Preventable Risks

Temperature excursions are one of the most common causes of food safety issues and wasted stock in frozen food operations, but they are highly preventable. By combining reliable monitoring, staff training, maintenance, and clear response protocols, businesses can maintain product integrity, protect consumers, and stay compliant.

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Don’t leave your frozen stock at risk.

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JTF’s wireless monitoring solutions alert you instantly to temperature excursions, provide audit-ready logs, and help keep your products safe, 24/7.

Book a free consultation today and see how JTF can protect your cold-chain, reduce waste, and simplify compliance.

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