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What are the benefits of lower time and temperature in Aseptic? What is the impact on flavor? nutrition? How much? Does it matter? When?
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ASEPTIC LIQUID REFRESHMENTS –FLAVOR AND NUTRITION STABILITY ASEPTI – PACK 2010, CHICAGO.
Sports drinks Energy drinksFortified drinks Teas and Coffee
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Respect for the nature of the product
Reduction of “stressful” processes for the product (high exposure to temperature) that modify (sensory) color, taste and destroy nutrients and active principles.
SELL MORE – SELL BETTER
In reality, the fundamental factor that convinces most beverage companies that Aseptic is the right technology for their business is the (sustainable) commercial advantage deriving from a generally improved product. Aseptic technology as a matter of fact, offers the possibility of extending and controlling with precision the characteristics of the product that adds benefit and value to the consumer.
Inside Aseptic, GEA - Procomac
REPRESENTATIVE PRODUCT TYPES Fruits, Vegetables or
Dairy Milk Yogurt / Buttermilk Soy based 100 %Juices Concentrates Flavored Fortified
With Particulates Drinks
Engineering characteristics
Low or High Viscosity
Newtonian or Non – Newtonian
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LAW DEMANDS – CONSUMER WANTS
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Regulatory Requirement
Log reduction – MicroCanning / Retort
Product / container / cap
Hot fill Product >> Container and
Cap
Aseptic>>>
Sterile “hardest” particle
Consumer Requirement
Sensory Flavor Aroma
Nutrition Vitamins Essential Amino
acids Essential lipids
Ash
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MATHEMATICAL MODELING – EXECUTIVE OVERVIEW …………………………...for no human inquiry can be called science unless it pursues its path through mathematical exposition and demonstration,..........................................................Leonardo da Vinci
…………………....interaction between matter and energy is the ultimate reality………………………....???
E = m c2 >>> Conservation of mass/ energy > Material and Energy balance Initial condition / boundary condition
Word model: Apple, Ripe, Green, Three Green apple > ripe green apple > Three ripe green apples
I have three ripe green apples, I have three ripe green apples? I have three green ripe apples, I have three ripe green apples !
Symbolic model – can you spot one? If m is changed to m/2, E >> E/2
What green is to apples, m and c are to E!A “representation”
CONCEPT TO
COMMERCIALIZATION
8
ASEPTIC PROCESS -
Thaw
Blend
Heat
Cool
FillHold
PROCESS MODELING 101-
Mass and Energy are conserved
Material and Energy balance over element
Extend to system boundary > BC
Should be true from beginning > IC to End of time ? ……….......> infinity
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Ash
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Ashok Dhruv, LLC - [email protected]
COMPREHENSIVE APPLICATION OF - CHEMISTRY, FOOD SCIENCE, PRODUCT AND PROCESS DEVELOPMENT
Application of Basic Heat & Momentum transfer principles with Kinetics: Microbial, Enzymatic, Bio-Chemistry Mathematical models, IT Tools
Results in Objective Measures of Safety, Sensory, Shelf life, Nutrition Yield, Capacity, Quality
Capital and Global Cost Optimization
15
Water and energy
conservation in food processingJuly 2007
Cooling water spray
Heat transfer rate = q
“q” = U * A * (T - t) =
T
t
A
M G C PGT G
= m W C PW t W
Bottle of Gatorade
HOW A BOTTLE : Heats or COOLS
WHY DO YOU LOOSE FLAVOR OR NUTRITION?
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WHY DO YOU LOOSE FLAVOR OR NUTRITION?
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Physical / ChemicalProcess
Equipment
MathematicalConstitutive Eqn.
Ini. & Boundary cond.
Physical laws
Laws of Math
ProductBy-productsWaste streams
Raw materials Utilities Labor
Physical propertiesOperating conditionsAssumptions
Microbial log cycle reductionEnzyme deactivation. amountObjective sensory quality
Physical form
Mathematical form
Ash
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tc x0 y0 z0 p q r
Axp
Ayq
Azr
Bx tc p By tc q Bz tc r Cx x0 p Cy y0 q Cz z0 r
Tf tc x0 y0 z0 ta Ti ta tc x0 y0 z0 460 R
T Avg t fwall T fi t fwall e
4 U cal D min
d2 f C Pf
Ash
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0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 530
50
70
90
110
130
150
170
190
210Time to heat fruit piece in puree
Time of heating, minutes
Tem
pera
ture
, de
g F 130
175
T f tc 0 0 0 R1
T f tcx
in
y
in
z
in
R
1
TAvgF tc R1
3 5
tc
GENERIC APPROACH
Ash
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Ashok Dhruv, LLC
Viscosity model for Pear puree based on data from Dr.Steffe's book, page 370.
nm1
3 Estimate from data @ 26.6 C or 80 F
T :Temperature in degrees Fm: Moisture content in %km T m( ) e( )
6.243.118 10
3T 460
11.357 1 m( )
Pa s
nm
PPTm T m km T m( ) nm 1
PPTm 80 m6
s
18.422poise
VELOCITY PROFILE INSIDE A (HOLD) TUBE
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RESIDENCE TIME IN THE (HOLD) TUBE
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LogRedClB 1.044 10 4LogRedClB log e 10( ) LncitocfClB
CitoCfClB 1.00024CitoCfClB eLncitocfClB
LncitocfClB 2.403 10 4LncitocfClB0
min
KClB
d min
KClB 7( ) 3.534 10 3 min 1KClB K0ClB e
EClB
Rgas TAvg ( ) 460 R
TAvg 8( ) 196.762RExp 101.745ExpEClB
Rgas TAvg 15( ) 460 R
EClB
Rgas3.73 104 KEClB 3.73 104 Rgas KK0ClB 2 1040 s 1
Calculation of Microbial kill :
FTPast 37.228sFTPast0
min
10
TAvg ( ) TRef
z
d min
4.359minz 10 RTRef 180 R
Calculation of extent of Pasteurization :
HTST, UHT, ESL OR ASEPTIC PROCESSING – FLAVOR AND NUTRITION IMPACTS
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Flavor and Aroma
Volatile or Non ?To keep or reject?Sources
Comes from F & V
Added in formulation
Generated in process
Nutrition
VitaminsMineralsEssential Amino
AcidsProteins
Essential LipidsFats and Oils
LOSS OF VOLATILES: RELATIVE VOLATILITY AND PASTEURIZATION TEMPERATURE 0
4/1
2/2
3
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RELATIVE VOLATILITY OF AROMA COMPOUNDS IN FRUITS AND VEGETABLES
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APPLICATION: LOSS OF FRUIT VOLATILES IN FLASH COOLING
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COOKED FLAVOR AND GUAVA BEVERAGE
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, For a guava beverage the treatment time required for a sensory panel to detect change in cooked flavor was 119 seconds at 90 C, 184 s at 87.5 C and 248 s at 85 C. (JFS, 70, 2005, S149 – S-152).
Process Temperature, C Time, seconds Cooked flavor detection time, seconds
Conventional 63 1,800 0.333 HTST 72 15 0.0073 Cooked Guava Flavor 85 248 Cooked Guava Flavor 87.5 184 UT - Pasteurization 90 .5 0.00119136 Cooked Guava Flavor 90 119 UT - Pasteurization 100 .0.01 0.000066 UHT - Sterilization 138 2 0.2664
Ash
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- ash
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Ash
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- ash
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Ash
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v, LLC
- ash
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Ash
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- ash
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What is the impact on my Nutrition? Let us see what happens to Thiamine, Vitamin B1.The following are equivalent “pasteurization” processes for milk.
Process Temperature, C Time, seconds Thiamin loss, % Nutrient loss reduction, %
Conventional 63 1,800 0.333 0 HTST 72 15 0.0073 97 UT - Pasteurization 90 .5 0.00136 99.6 UT - Pasteurization 100 .0.01 0.000066 99.98 UHT - Sterilization 138 2 0.2664 20
> 90 % reduction in Nutrient loss, does it matter at these low loss values?
Ash
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Ash
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0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
10
20
30
40
50
60
70Temp, Firmness and PG Conc. of peaches
Time, minutes
Tem
p F,
Firm
ness
, N, P
G C
once
ntar
tion
70
0
T MW ( )
R
Firm ( )
PG ( ) 100
10
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0 1 2 3 4 50
20
40
60
80
100
120
140
160
180
200Peroxidase activity drop in heat period
Time in heating MC tube, minutes
Act
ivit
y ra
tio,
; A
vg T
emp
deg
F
200
00
Ratio POD ( )
%
T Avg ( )
R
50
min
HOT FILL VS ASEPTIC PROCESS – BEVERAGES
HOT FILL VS ASEPTIC PROCESS – BEVERAGES
Ashok Dhruv, LLC - [email protected]
VALUE GENERATION - INCREASED REVENUES - GROWTH Elasticity of demand
Price, AdvertisingCompetition
Product features and benefitsSensory perceptions - Product Appeal
Nutrition - Satiating, HealthShelf life - Convenience
Satisfy Consumer
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