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Promatec Food Ventures: De presentatie Sliced and Processed Meat SPM & Ready Meals 2009
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High Pressure Processing:Principles, technical and microbiological
considerations of an emerging technology
NC Hyperbaric
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INDEX
1) High Pressure Processing: interest of an emerging NTP
2) Principles and effects
3) Value propositions of an innovative technology
4) Commercial applications: FOCUS ON MEAT PRODUCTS
5) Brief economical analysis
6) Conclusion
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� Production and Headquarters in Burgos, Spain
WHO WE ARE
�NC HYPERBARIC designs, manufactures and markets highpressure processing equipment for the food industry
�GLOBAL LEADING SUPPLIER of the technology since 2005
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Evolution of HPP industrial machines installed on continents
Introduction
19901991
19921993
19941995
19961997
19981999
20002001
20022003
20042005
20062007
2008Total
124
116
98
84
69
54
41
31
20
121087775
321
71
4117610
8985
111
26
2336
3312
11
1
22
034
212
13
1211
1
51
211
Oceania
Asia
Europa
Amer ica
Total
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SUCCESSFUL EXAMPLES ALL OVER THE WORLD
HIGH PRESSURE PROCESSING
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Industrial HPP machines number versus food industries
Juices and
beverages
15%
Meat products
29%
Seafood and fish
15%
Others products
6%
Vegetable
products
35%
Introduction
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HPP user companies size profile
� 61 different HPP users companies known all over the world� 50 % are SME < 250 employees
Group > 5000 11; 18%
Very small < 10 3; 5%
10< Small< 50 19; 31%
50< Medium< 250 9; 15%
250< Large< 1250 13; 21%
1250< Very Large< 5000
6; 10%
Introduction
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� To meet the demands of the XXI century consumer, companiesneed to innovate by using the latest non-thermal technologies in contrast to the quality-degrading thermal methods that have beentraditionally used in food industry for product preservation.
� NC HYPERBARIC industrializes High Pressure Processing technology.
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WHAT IS HIGH PRESSURE PROCESSING?
� A food processing technique:
�Discovered end of XIX century�Studied since 1980,�Industrially tested for the first time in Japan in 1990,�Industrially implemented in the World since 2000.
� Consists in submitting food products to pressuresbetween 3000 and 6000 bar for:
�Guaranteeing food safety�New food propositions�Keeping product freshness
Hydrostatischer Druck
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PROCESS
Processed batch
Product loading / unloading
Unprocessed batch
Vessel pre-filling
PRESSURIZATION
Low pressureWater
Low pressurewater
High pressureintensifier
High Pressure Intensifier
Low pressure
Water tank
1)
2)
3)
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Pressure
(MPa)100 200 400300 600500 800700 900
-20
0
20
100
80
60
40
Esterilisation
PasteurisationAssistanceto process
Defrosting
Freezing
Temperature (°C)
Modification of macromolecules
Different HP applications considering pressure andtemperature
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HIGH PRESSURE EFFECT ON WATER
Compressibility of water at + 20ºC(From Brigman, 1912)
0
2
4
6
8
10
12
14
16
18
20
0 100 200 300 400 500 600 700 800 900
Pressure (MPa)
Co
mp
ress
ibil
ity(%
)
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HIGH PRESSURE EFFECT ON MOLECULES
• There is no effect of high pressure (up to 1,000 MPa at roomtemperature) on low molecular weight molecules like vitamins, flavourcomponents, sugar...
• High pressure sometimes irreversibly modifies the 3D structure ofhigh weight molecules like proteins, enzymes and polysaccharides. Itcan change texture and colour of some products (raw meat...).
0
0,05
0,1
0,15
0,2
0,25
0,3
0,35
B1 B6
0
400 Effect of pressure on B1 and B6 in milk
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EFFECT OF HIGH PRESSURE PROCESSING ON RAW MEAT
-Colour changes-Textural changes-Due to modifications in the 3D structure of raw proteins
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Effects of High Pressure onmicroorganisms
Scale of sensibility of microorganisms depending on pressure
1 000
600
200
100
0,1
Resistence of bacterian spores
Destruction of vegetative microorganisms : bacteria, yiest, moulds, parasites
Destruction of mould ascosporesDestruction of viruses
Survival of microorganisms
Life of barophillic microorganisms
Pressure (MPa)
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Listeria monocytogenes
L. monocytogenesin cured ham
1
10
100
1000
10000
100000
1000000
10000000
100000000
0 1 2 3 4 5 6
Time (min)
CFU/g
Serotype 1/2 a
Serotype 1/2 b
Serotype 4 b
Detection limit
HIGH PRESSURE EFFECT ON MICROORGANISMS
Not treated 500 MPa - 10 min
Electron microscopy pictures of Listeriamonocytogenes(from Mackey et al.1994)
Reduction of Listeria monocytogenes in dry ham at 600 MPa and +5ºC (Heinz, 2004 not published)
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HIGH PRESSURE EFFECTS ON MICROORGANISMS
Effects on bacterium spores
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Effect of pressure on survival of larvae of Trichinella spiralis infecting mouse muscle, pressurized for 10 min a 25°C (ONISHI et al., 1993).
HIGH PRESSURE EFFECT ON MICROORGANISMS
Effects on parasites
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COMMERCIAL APPLICATIONSHIGH PRESSURE PROCESSING
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• Sanitisation and shelf life increase.
• Preservation of colour, flavour and vitamins.
• Reduction of the starch retrogradation of the rice.
• Reduction of PPO activity in avocado.
Vegetable products
HPP commercial products
Country Year Products
Japan 1990 Fruit jams and fruit and vegetable sauces
Japan 1994 Pre-cooked & hypoallergenic rice
USA 1997 Avocado products : guacamole, sauces
Italy 2001 Fruit jams
USA 2002 Avocado products
Mexico 2003 Avocado products
Mexico 2003 Avocado products
Mexico 2003 Avocado products
USA 2003 Sliced onions
Canada 2003 Apple products : jam and sauce
USA 2004 Tofu
Spain 2005 RTE vegetable meals
USA 2006 Tomato sauces
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Country Year Product
Japan 1991 Grapefruit juice
Japan 1992 Mandarin juice
France 1994 Citrus juices
Mexico 2000 Citrus juices and smoothies
Lebanon 2001 Fruit juices
USA 2001 Apple juice
Portugal 2001 Apple & citrus blended apple juice
Italy 2001 Fruit and vegetable juices
USA 2002 Orange juice, lemonade and smoothies
Czech Republic 2004 Broccoli & apple, beetroot, carrot juices
Northern Ireland 2006 Smoothies
Juices and beverages
• Sanitisation and shelf life increase
• Destruction of pathogens microorganisms
• Preservation of colour, flavour & vitamins
of freshly squeezed fruits
Commercial HPP products
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• Shelf life increase• Opening seafood shell • Easy shellfish meat extraction• Sanitization (inactivation of Vibrio)
SOME EXAMPLES:
Shellfish and fish
Country Year Products
USA 1999 Oysters
USA 2001 Oysters
USA 2001 Oysters
USA 2001 Oysters
Canada 2004 Seafood
Canada 2004 Lobsters
N. Zealand 2004 Mussels shucking for meds
Italy 2004 Desalted cod
Spain 2004 Ready-to-eat salmon, hake & tuna
USA 2005 Lobsters
Korea 2006 Shellfish
Canada 2006 Seafood
HPP commercial products
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FOCUS ON MEAT PRODUCTSHPP commercial products
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Total aerobic microflora
0
2
4
6
8
0 20 40Storing days at + 6º C
Lo
g (
CF
U /
g)
Coliforms
0
2
4
6
8
0 20 40
Storing days at + 6ºC
Lo
g (
UF
C /
g)
Lactic acid bacteria
024
68
0 20 40
Storing days at + 6º C
Lo
g (
UF
C /
g
)
HPP treatment of sliced cooked ham at 500 MPa for 8 min at + 8ºC
� Non- thermal post packaging pasteurization (approved by FSIS in USA)
� Safest alternative for sliced meat products
� Significant shelf life extension
� No size / volume effect : whole, sliced, stripped & diced meat products
� Suitable for vacuum-packed or MAP
Efficiency
Why does the meat industry use HPP ?
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1
10
100
1000
10000
100000
1000000
10000000
100000000
0 1 2 3 4 5 6
Time (min)
CFU/g
Serotype 1/2 a
Serotype 1/2 b
Serotype 4 b
Detection limit
Not treated 500 MPa - 10 min
Electron microscopy pictures of Listeriamonocytogenes(from Mackey et al.1994)
Reduction of Listeria monocytogenes in drycured ham at 600 MPa and +5ºC (Heinz, 2004 notpublished)
� Effective lethality on pathogens : Listeria, Salmonella, E.coli …
Why does the meat industry use HPP ?
Safety
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0
5
10Colour
Sliced
Adhesiveness
Crunchy
Elasticity
Tenderness
Juicy
Fibrous
Non processed
HPP
Why does the meat industry use HPP ?
� No effect on sensorial quality
� Keep fresh taste
� Maintain nutritional value
� Remove chemical preservatives
HPP treatment of sliced cooked ham at 500 MPa for 8 min at + 8ºC
Quality
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Benefits of HPP in the meat industry
�Safe :
� Validated non thermal post packaging pasteurization
� Recognized by FSIS in USA
� Safest alternative for the highest risk products : sliced meats
� Protect the brand
� Natural :
� Preserves natural sensorial quality
� Remove chemical preservatives
� Convenient :
� Shelf life increase
� Different types of packaging can be used
� Innovation :
� New / Unique products
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The NATURAL
appeal
• CLEAN LABEL
• No artificial ingredients: meet new standard of identity
• Consumers associate natural with quality
Exploit capacity
• Increase factory utilisation by square curving production
• Reach new markets from existing factory
• Extend supply chain and leverage existing supplies
Address spoilage
and returns
• Reduced costs from product failures and returns
• Through abuse, lengthy supply chain, or retail overstocking
• Identify 20% of production that is causing 80% of bad goods
Value propositions
HPP: COLD PASTEURISATION FOR PROCESSED MEAT
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FOOD SAFETY • Destruction of pathogens
• Brand protection
• Safest alternative for high risk products: sliced
NPD
OPPORTUNITIES
• New, unique products further than packaging changes
• Think about things that you could not do before
• Access value added niche markets
EXPORTS
• Secure your authorisation to the most demanding
countries
• USA, Japan
• EU becoming more restrictive on Listeria etc
Value propositions
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Country Products
Spain Sliced cooked ham and “tapas”
USA Sliced cooked products and proscuitto ham
USA Poultry products
USA Pre-cooked chicken and beef strips
Spain Sliced cooked chicken, ham and turkey
products, Serrano cured ham
Italy Proscuitto ham, salami & pancetta
Germany Cured and smoked sliced and diced ham
Japan N itrites- free bacon, sausages and sliced meat
USA Ready- to-eat meat based products
Spain Cured meat products & Serrano ham
Canada Cured meat products
USA Whole roasted chicken
USA Sliced cooked turkey and chicken
EXAMPLES AND IDEAS: current HPP commercial products
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• First HPP meat product in the world
• Sliced cooked ham launched in Spain
• “Remains fresh until eaten”
• Products with H.P.P. label
ESPUÑA (Spain)
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ESPUÑA (Spain)
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CAMPOFRIO (Spain)
Starting point: securing export products
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CAMPOFRIO (Spain)
Major current productions: new product propositions
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EXPORT MARKETS
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VISMARA - GRUPO FERRARINI (Italia)
Prosciutto ham & cured products
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ABRAHAM (Germany)German proscuitto ham exported to USA
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NATURAL PRODUCTS
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HORMEL (USA)
• HPP dry cured ham in the US market since 2001
• Large range of HPP sliced RTE ham, turkey and beef
• Vacuum-packed and MAP
• Label “True Taste Technology”
• Info on HPP in the web site and flyer
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HORMEL (USA)
http://www.hormelnatural.com/
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KRAFT – OSCAR MAYER (USA)
• HPP ham, turkey, chicken
• Natural, minimally processed, no artificial ingredients…
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ITOHAM (Japan)for nitrite free meat products
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PERDUE FARMS (USA)
• HPP poultry strips
• MAP in a resealable bag
• No preservatives
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KAYEM FOODS (USA)
NATURAL CHICKEN SAUSAGES
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FOSTER FARMS
(USA)
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TYSON (USA)
RTE Natural Oven Roasted Chicken:Whole birds, breasts, drumsticks, thighs…
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FRESHERIZED FOODS (AVOMEX)
(USA)Ready-to-eat meat meals
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MAPLE LEAF (Canada)for RTE meat based meals with rice, pasta, vegetables
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OUR EQUIPMENTWave 6000 range
� Specially designed for the food industry
� Safe, ergonomic, reliable
� Clean and evironmentallyfriendly
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NC Hyperbaric range
Wave 6000/135
Wave 6000/300
Wave 6000/300 Tandem
Wave 6000/420
Wave 6000/55
Throughput from 250 kg/hour
� Up to 2.5 tons / hour
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Equipment
Equipment price
0
500
1000
1500
2000
2500
3000
3500
4000
0 50 100 150 200 250 300 350 400 450
Equipment volume
Equipment cost (k€)
Wave 6000/55
Wave 6000/135
Wave 6000/300
Wave 6000/420
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0,000
0,020
0,040
0,060
0,080
0,100
0,120
0,140
0,160
0,180
0,200
0 50 100 150 200 250 300 350 400 450
Equipment volume (litres)
Processing cost (€/kg)
Equipment
Equipment size
Wave 6000/55
Wave 6000/135
Wave 6000/300
Wave 6000/420
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THANK YOU FOR YOUR ATTENTION
FRANCISCO PURROY, DVMTechnical Sales Manager
+34 626623049f.purroy@nchyperbaric.es
NC Hyperbaric is represented in the Benelux by:Mark de Boevere
Promatec Food Ventures BV Rootven 24a
NL-5531 MB BladelT: +31 (0)497 33 00 57
E: mark.deboevere@promatecfoodventures.comI: www.promatecfoodventures.com