RapidPak Technology
Flash Pasteurization
Packaging
Flash
Solutions
Rv 07-08
Flash Pasteurization
Flash module
Project:
Integrate a steam surface pasteurization (Flash) chamber
into a hotdog packaging machine
Provides an effective kill step
p immediatelyy p
prior to package
p
g sealing:
g
• Destroys bacteria, such as Listeria monocytogenes on product surface
• No negative effect on quality
• Easilyy integrates
g
into existingg pplant layout
y
Packaging
Flash
Solutions
Rv 07-08
Co-Development Project
From research to commercialization…
• Thermal processing
• Pasteurization
• Packaging machine design
• Bio-safety Class II Laboratory
• Original concept, research, and patents
• Research facilities and prototypes (ERRC)
• Process engineering,
Packaging
Flash
Solutions
Rv 07-08
Defining the Problem
•
Shortcoming of Current Hotdog System
Manufacture
Cook
Chill-Peel-Convey-Collate-Load
Kill
•
Add a final Flash kill step
Cook
Chilling to Packaging
Kill
High risk zone
Seal Package
Potential
contamination
Flash pasteurization
Seal
Post-lethality kill
Flash Concept: Surface pasteurize at the last possible moment before packaging
Packaging
Flash
Solutions
Rv 07-08
Machine Configuration
Film Travel Direction
Top film
Bottom film
Discharge
g
Cut
Packaging
Flash
Solutions
Rv 07-08
Seal
Flash Heat
Treatment
Load
Form Fill
Flash cycle
y time
= 1.5 to 2.0 seconds
Machine cycle rate
= 3 seconds / index
Preheat
Film
Flash Pasteurization Head
Steam Inlets
Exhaust Flash Head
Exhaust Flash Head
Product
Steam Injection -- Flash Module
• Inject pressurized steam
• Maximum contact on most difficult area – ends
1 5 second cycle kills 2 to 3 logs of Lm
• 1.5
Packaging
Flash
Solutions
Rv 07-08
Flash
Head
Flash Pasteurization Head
Steam Inlet
Steam
St
Outlet
Flash Equipment – Top View
Packaging
Flash
Solutions
Rv 07-08
Development – Historical to Current
Flash Delivers:
• Food Safety Protection
– > 2.00 log
og reduction
educ o ssignal
g a aandd doub
doublee layer
aye
– < 1.0 log growth at refrigerated temperatures
– > 2.0 log reduction of spoilage bacteria, resulting in increased shelf life,
on average of 20% to 30% increase
– Alternative 1 when combined with antimicrobials
• Product
– No significant difference on basic tastes between flash and non-flashed product
– No significant difference on aromatics between flash and non-flashed
non flashed product
– No significant difference on aftertastes between flash and non-flashed product
– No increase in measurable purge
• Machine
– Use ordinary film / no increase in leakers
– No loss of cycle rate
– Minimal utility usage (250 lbs/hr steam, 2 gpm water)
Packaging
Flash
Solutions
Rv 07-08
Development - Results
• All results confirmed in-house and by independent Deibel Labs
• Full-scale signal and double-layer machines
• Can use live Listeria to validate
Pathogen Testing Lab
Packaging
Flash
Solutions
Rv 07-08
Actual Lab Results – Single Layer
Number
SAMPLE
CFU
Dilution
1
Control 1
4
6
6.60206
2
Control 2
5
6
6 69897
6.69897
3
Control 3
24
5
6.380211
4
Sample 1
5
3
3.69897
5
Sample 2
4
3
3 60206
3.60206
6
Sample 3
1
3
3.00000
Log Kill
Log
g Kill
3.1
10
9
8
7
6
5
4
3
2
1
0
1
2
3
Control
Packaging
Flash
Solutions
Rv 07-08
4
5
6
7
8
Flashed
Product
9
10
11
12
13
14
Storage Studies – Double Layer
* Inhibit Growth Over Refrigerated Shelf Life
Initial Log Kill 2.26
10
9
8
7
6
5
4
3
2
1
0
Control
1
2
Packaging
Flash
Solutions
Rv 07-08
3Week 14
9 Weeks Refrigerated Storage
Samples Taken Weekly
Week
26
5
7Week 38
Log Growth
4
9Week 10
6
11Week12
-0.5
Week 14
9
13
Results to Date
Flash Pasteurization Process
Results Summary
Hot Dogs
Packaging
Flash
Solutions
Rv 07-08
Log reduction of Listeria monocytogenes
(inoculation = 106)
Single Layer
28 mm, 6 hot dogs / pack
2 0 – 3.0
2.0
30
Double Layer
23 mm, 8 hot dogs / pack
2.0 – 3.0
Triple Layer
22mm, 12 hot dogs / pack
2.0 - 3.0
Flash with Antimicrobial Injector
Antimicrobial
Injectors
•
•
•
•
Packaging
Flash
Solutions
Rv 07-08
Flash and antimicrobials work together to increase log kill
Surface apply steam and antimicrobials
Cost savings – pull antimicrobials out of the product
One control system to control Flash and antimicrobial (log data)
Double-Layer Flash Machine
Packaging
Flash
Solutions
Rv 07-08
Single-Layer Machine
Packaging
Flash
Solutions
Rv 07-08
RapidPak Technology
Flash Pasteurization
END
Packaging
Flash
Solutions
Rv 07-08