HPP Fundamentals. Everything You Wanted to Know But Were Afraid to Ask

Transcription

1 HPP Fundamentals Everything You Wanted to Know But Were Afraid to Ask

2 High Pressure Processing (HPP) WHAT is HPP? WHY should I consider using HPP? HOW does HPP work? WHO has embraced this food preservation technology? HOW do I go about getting started?

3 What is HPP? Non-thermal food preservation process that inactivates harmful bacteria and food spoilage microorganisms. Does not break covalent bonds. Small chemical constituents like flavor compounds, vitamins and nutrients are maintained. HPP affects only non-covalent bonds. Can be used to modify macromolecules, to change the functionality of food e.g. unfolding of proteins, gums, gels, other hydrocolloid materials to improve viscosity, creaminess and mouth feel.

4 WHY should I consider HPP? Enhanced Food Safety - inactivates pathogenic vegetative bacteria: Salmonella E. coli 0157:H7 Listeria monocytogenes (Lm) Campylobacter Vibrio & viruses in shellfish Reduce waste by extending product shelf life - kills spoilage organisms (fungi: yeasts & mold) typically increases refrigerated product shelf life >2X

5 WHY should I consider HPP? Protect your brand: producer, retailer, QSR etc. HPP is a game-changing technology! Create new businesses Introduce new products Offer cleaner label products Differentiate - higher quality products vs. heat or chemical preservation methods. HPP retains heat sensitive bioactive components in foods. Respond to market trends e.g. for lower sodium foods Enhances production processes e.g. seafood

6 HOW does HPP work?

7 HOW does HPP work? Airtight/hermetically sealed packages (e.g. bags, pouches, plastic bottles, chubs, trays) are loaded into HPP carrier baskets. Baskets are inserted into the HPP vessel. The vessel enters the system and is sealed by plugs. Potable water is pumped into the vessel creating isostatic pressure (equal pressure all sides) on the packages.

8 HOW does HPP work? Product is held at pressure of 45,000 to 87,000 psi (310 to 600 Mpa) for 1 to 6 minutes depending on the HPP process recipe. Pressure is transmitted uniformly & instantaneously throughout the product Pressure disrupts microbial biochemistry of bacteria and spoilage microorganisms.

9 HOW does HPP work? Vessel pressurizes Baskets Vessel Food Vessel moves loaded moves fills drains food out with on into of water conveyor of 87k vessel frame psi, 6000 bar Water Storage Tank Product in baskets Pre-fill Pump Frame/yoke Intensifier Pumps Conveyor Vessel To Pack Off

10 Additional Processing Notes Hold time is independent of product shape or volume At least one package surface must be flexible as there is a temporary volume change of up to 15% Minimize package headspace to optimize basket fill efficiency & cycle time Foods with high water activity (Aw) HPP best Low ph (more acidic) foods typically permit using lower pressures and shorter hold times The adiabatic/compression heating results in a temporary temperature increase of ~ 3 oc/100 Mpa

11 Discovering the world of HPP RTE Proteins RTC Proteins Salsa Hummus Beverages Dressings Raw Pet Food Tenderization Dehairing Hides Avocado/Guacamole Dips and Sides Wet/Spoonable Salads Ready Meals Seafood Fast Marinating Medical/Pharmaceutical

12 Commercial protein, juice and dressing products

13 Commercial fruit and juice products

14 WHO has embraced this food preservation technology? Applegate RTE proteins Butterball ground turkey Cargill sliced roast beef Hormel - Natural Choice sliced RTE meats Jennie-O - ground turkey chubs Perdue Short Cuts RTE proteins Sadler s BBQ Smithfield RTE ham West Liberty Foods RTE ham & turkey for QSR

15 WHO has embraced this food preservation technology? Aidells Sausage Co. Berks Packing Curly's Foster Farms Godshall's - turkey bacon GoodHeart House of Raeford John Soules Food Wellshire

16 WHO has embraced this food preservation technology? Astra Foods Boar s Head Burger s Smokehouse Dakota Provisions Daniele International Ifantis Greece Johnsonville Sausage Maple Leaf Maple Lodge Farms

17 WHO has embraced this food preservation technology? BluePrint Bolthouse 1915 Drink Daily Greens Earthwater Evolution Fresh/Starbuck s Frubaca Garden of Flavor Genesis Juice So Good Leahy Orchard fruit products Suja

18 WHO has embraced this food preservation technology? Bolthouse - yogurt-based dressings Cedar Lane Natural Fresherized Foods Wholly Guacamole Frubaca Garden Fresh/Campbell Fresh - salsa Good Foods Group dips & guacamole Hope Foods - hummus Juice So Good - baby food, coffee Leahy Orchard Perfect Fit Meals ready meals Sandridge Foods - wet/spoonable salads Winsoms - chopped specialty onion products

19 WHO has embraced this food preservation technology? Costco Cub Foods HEB Kroger Lunds Byerleys Target Trader Joe s Walmart Whole Foods

20 WHO has embraced this food preservation technology? FreshPet Kitchens Nature s Variety Stella & Chewy s

21 WHO has embraced this food preservation technology? Joey Oyster Motivatit Gold Band Oyster Shucks Maine Lobster

22 HOW do I go about getting started? Go to market quickly by engaging an outsourcer such as Universal Utilize UNL s Food Innovation Center, NFL, Virginia Tech, Ohio State, etc. HPP equipment manufacturers have years of HPP experience Purchase equipment, prepare site, install, startup/debug, staff & maintain your own HPP equipment

23 WHY contract with Universal? HPP is a batch process & doesn t lend itself well to conventional processing lines Universal understands the HPP journey & offers a variety of pack-off services Strategically located HPP processing centers (currently 4) Allows you to quickly respond to changing markets Reduces capital outlays as your business grows Back up your existing in-house HPP capacity

24 High Pressure Processing of Foods Jayne Stratton, Ph.D. The Food Processing Center University of Nebraska Lincoln

25 The Food Processing Center The Applied Research and Engineering Unit Bridge between fundamental research and the food industry Industry Services Acidified Foods Program Customized Training Functional Ingredient Development Fungi & Mycotoxin Research HACCP Consulting Ingredient and Product Analysis Microbiology & Pathogen Testing Microencapsulation Process Validation Process Consulting Post Harvest Processing Consulting High Pressure Processing Studies Water Redirection Reuse Byproduct Utilization

26 The Food Processing Center Initial product testing Initial product evaluation High Pressure Processing Identification of quality & food safety measures Validation Inoculation studies Shelf-life studies Scale-up testing Final product inspection

27 The Food Processing Center High Pressure Processing Equipment Standsted (2L) HPP Hiperbaric (55L) HPP Standsted Continuous HP Homogenizer

28 The Food Processing Center Bench Top HPP Unit - Validation Work HPP Unit - Stansted 9400 Dedicated to investigate the effect of pressure on pathogenic microorganisms Validation of processing parameters against pathogens Coffee - Listeria monocytogenes Standsted (2L) HPP Working pressure 900 MPa

29 The Food Processing Center Bench Top HPP Unit - Validation Work Challenge studies in different types of products Coffee Juice Sport drinks Dry goods including fermented meat products Pet food

30 The Food Processing Center Pilot Scale HPP Units HPP Units Hiperbaric 55L and Standsted Continuous HP Dedicated to investigate the effect of pressure on chemical/physical, functionality, and sensory properties Trials for quality, customer research samples, reformulation tests, and shelf life Hiperbaric (55L) HPP Working pressure 600 MPa Standsted continuous HPP Working pressure 350 MPa

31 The Food Processing Center Pilot Scale HPP Units Lab and pilot scale level studies for your HP processed products Studies for quality Meat: color, texture Coffee: discoloration, clumping Juice & Smoothies: texture Sensory studies Informal testing Consumer testing: Acceptance, difference and preference In-depth descriptive analysis: QDA Professional setup

32 The Food Processing Center Pilot Scale HPP Units Lab and pilot scale level studies for your HP processed products Shelf-life studies Customized microbiological testing Psychotropic and background flora Pathogens HPP - pre-packed vs hot/cold fill

33 The Food Processing Center Staff Curtis Weller, Ph.D. Interim Director Angela Anandappa, Ph.D. Director, The Alliance for Advanced Food Sanitation Jayne Stratton, Ph.D. Research Associate Professor Andréia Bianchinir, Ph.D. Associate Professor Changmou Xu, Ph.D. Research Assistant Professor Julie Reiling Product Developer Jill Gifford National Food Entrepreneur Assistance Program Manager Bethany Jackson Technical Services Manager Kathy Vokoun Dairy Store Associate Steve Weier General Manager, Pilot Plants Russell Parde Associate Pilot Plant Manager Tom Dobesh Laboratory Mechanic

34 The Food Processing Center The place to go Introduce your product with confidence after thoroughly testing and/or developing the production process Evaluation of scale up issues in an unbiased setting Customized testing Processing versatility

35 Q and A - handout

36 HPP is a winning strategy!

37 Thank You