Aseptoray technology presentation MDB

3RD WORLD TEA AND COFFEE EXPO 2015, INDIA

WELCOMES ALL OF YOU

By :Mangal Dev Bariwal

PROCESS DESIGN INC

3RD WORLD TEA AND COFFEE EXPO 2015, INDIA

Increasing Trend of Cold Pasteurization Technology for Tea based Beverages RTD/RTS

Juices

ICE Tea variant

Pasteurisation Techniques

Conventional Pasteurization

• Pasteurization temp 950C/15 sec

• 25% of electricity*, 25% reductionof carbon footprint*

Replacing By Cold Pasteurization

• HPP High pressure Processing • ASEPTORAY UV Technique

The Challenge- Thermal Pasteurization

Microorganism in the Juice and Ice tea are normallyinactivated by pasteurization.

High EnergyConsumption

Minor effect onSpores

(TAB)Change

Preservation flavour, aroma , and natural taste Protection of natural colour, nutrient value Antioxidants

TEMP PROFILE OF ICE TEA BEVERAGEProcess: 30~75 →140 (4S℃ ℃ 、 10S、 15S)→85~92 →40 →(10-20 )return℃ ℃ ℃

Hot Fill pasteurisation process for industrialized still /Ice tea drinks 2012*

PROCESS DESIGN INC

117.7 billion gallonsGlobal annual consumption of industrialized still drinks 2012*

Most of it are pasteurized by heat, as it being done since 1864.

* Neves et al, The orange juice business, World consumption of fruit juices,nectars, and still drinks 2012,p 119.

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Thermal Pasteurization Alternatives

Ultra Filtration• High energy consumption

• High cost• Limited to clear liquids

Pulsed Electric Fields• Requires an expensive aseptic filler.

• Does not work on spores.• Still not widely available or accepted.

High Pressure Processing (HPP)• Require highly cost equipment

• Require alignment of the entire process.

What is HPP?

Hiperbaric©2013Hiperbaric.com

PROCESS DESIGN INC

Industrial HPP Equipment


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What is HPP?


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What is HPP?

HPP• Instantaneous transmission

• No pressure gradients

• Identical in every point

• Cold temperature

HEAT• Slow transmission

• Temperature gradients

• Not uniform

• Temperature damagesorganoleptic quality


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HPP by Food Sector

HPP Global Production by 20124: + 700 000 000 Kg


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HPP Products and Applications

Dairy, JUICE and ICE tea• Shelf life extension• Pathogen Destruction

• Functional, bioactive products


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VEGETABLE •Shelf life extension and increased safety• Maintenance of flavor and nutritionBASED• Reduction of PPO in avocado products•Reduction of starch retrogradation in rice.

Country ProductsJapanFruit jams and fruit and vegetable saucesJapan Pre-cooked & hypoallergenic riceUSA Avocado products : guacamole, saucesItaly Fruit jamsUSA Avocado productsMexico Avocado productsMexico Avocado productsMexico Avocado productsCanadaApple products : jam and sauceUSA TofuSpain RTE vegetable mealsUSA Tomato sauces

AustraliaFruit pures & coulisMexico Avocado productsPeru Avocado productsChile Avocado productsPeru Avocado products

N. ZelandAvocado productsChina Fruit jamsMexico Avocado productsEspaña Avocado products

Hiperbaric©2013 Hiperbaric.com

PROCESS DESIGN INC


JUICES• Shelf life, safety, brand protection• Respecting flavor and nutrition

• Premium, cold pressed, never heated

Country ProductFrance Citrus juicesPortugal Apple & citrus blended apple juiceItaly Fruit and vegetable juices

Czech RepublicBroccoli & apple, beetroot, carrot juicesUSA Juices and superfood smoothiesSpain Smoothies & juicesAustralia Smoothies & juices

Northern IrelandWheatgrass & Broccoli sprout juicesThe NetherlandsSmoothies & Juices

USA Citrus juicesKorea Juices and smoothiesBrazil ZumosItalia SmoothiesUK Apple juicesUSA Coconut waterKorea Citrus juices


PROCESS DESIGN INC

Industrial HPP for the Juice Industry

HPP Juice Brands

HPP:Fruit juicesSmoothies

100

50

0

8 20

2008

100+50+

Vegetable juices 2010 2012 2014 HPP Juice Brands


Case 1, Blueprint - the Cleanse, Detox categoryRaw fruit & vegetal juices, cleanses


Case 2, Evolution Fresh Starbucks - Cold Pressed Fruit

Evolution Fresh (USA)4 x Hiperbaric 420 for juices

Hiperbaric.com

Case 3, Suja Juice - the Explosive Growth

Suja (USA)Hiperbaric 420 for juices

Whole FoodsSupplier of the Year 2014

Hiperbaric.com

Case 4, The UK Cold Pressed Juice Market


Case 5, the Coconut Water

HiperbariHiperbaric.com

Recognisition and LegitimisationTumeric ALIVEBEST FUNCTIONAL BEVERAGE

Harmless HarvestPRODUCT OF THE YEAR

WTRMLN WTRBEST JUICE Tio Gazpacho

BEST SMOOTHIE OR MEAL REPLACEMENT

WTRMLN WTRBEST PACKAGING DESIGN

Hiperbaric©2013 Hiperbaric.com

AseptoRay System

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T

Ie

So, what’s new ?

Standards UV system can not penetrate turbid liquids*Milk : >8000 NTU

Turbid orange juice: 4000 NTU

Clear Apple: 1200 NTU

Water turbidity: 1 NTU

* Ultraviolet Light in Food Technology Principles andApplications, Koutchma et al. 2009

Mechanism of Action

Utilizes optimal wavelength (254nm)in varying exposures to deactivatecontaminants and pathogens whilepreserving nutrients and organoleptic

properties

Transfers UV energy directly andselectively to microbial DNA

Limits secondary effects on liquids

Applications and Markets

Juice Wine Water Milk Soy LiquidProducts Sugar Whey

Juices

ICE Tea variant

The Market

$16 Billion market representing the 9.6

billion liter of juice is sold in the US

annually.

$ 8.8 Billion is 100%

fruit juice.

Per capita in the US this

numbers represent 52.5$

and 30.3 L per year.

Juice Pasteurization

Juices normally undergo two pasteurization processes

First pasteurization to become commercially sterile .

Second pasteurization, prior to filling to avoidrecontamination.

But t͙hermal treatments can not destroy spoilage spores.

Fruit Juice/ Ice tea Beverages RTS : Challenges and what is TAB?

TAB Is a general name for “Thermo Acidopihilic Bacteria”.

Although it is not a safety hazard, it’s presence in consumer products hasbeen widely reported to cause flavor spoilage problems.

33-35% of juice manufactures had TAB associated problems1,2,3.

TAB Spoilage

1. Engineering Aspects of Thermal Food Processing. Editor: Ricardo Simpson , 2009.2. Walker M, Phillips CA (2008) Alicyclobacillus acidoterrestris: an increasing threat to the fruit juice industry? International Journal of

Food Science and Technology 43: 250-260. doi: 10.1111/j.1365-2621.2006.01427.x3. oward I (2006) ACB Workshop October 2005-Review. European Quality Control System (EQCS) Workshop 2006. Available:

AseptoRay SystemPilot Results

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Results: Overview

LiquidSugar

All Bacteria were eliminated.

5 log reduction HACCAP requirement was achieved in allliquids.

No organoleptic change in tested liquids (Milk, Apple juice).

Milk Juice

Results : Liquid Sugar log reduction

Liquid8.0

6.0

4.0

2.0

0.0

-2.0

-4.0

-6.0E.coli

9

E.coli

12Bx 50 BxSeries1

10

E.coli

Series2

Sugar

6.3

6.6

B. Atr.Spores

70 Bx 50 Bx

Water

Water log reduction6

Water5

4

3 4.55.0

2

1

0E.coli

-1

-2

Yeasts B. Atr. Spores

Before After

4.5

2.3

AAT Spores

Apple Juice /Fruit Punched Ice tea

7

6

5

4

3

2

1

0

-1

-2

-3

-4

Clear Apple log reduction

4.8

5.6

AAT Spores Bacillus atrophaeusspores

Before After

Juice

8.9

E.coli

Orange Juice

Juice

7.0

6.0

5.0

4.0

3.0

2.0

1.0

0.0

-1.0

-2.0

Clear Orange log reduction

6.2

3.3

AAT Spores E.coli Bacillus atrophaeusspores

Before After

Turbid Orange log reduction6.0

5.0

4.0

3.0

5.72.0

1.0 1.7

0.0AAT Spores

Before After

5.2

E.coli

Energy consumption

In Conjunction To Pasteurization

• Reducing the pasteurization tempfrom 950C/15 sec to 730C/15 sec

• 25% of electricity*, 25% reductionof carbon footprint*

Replacing Pasteurization

• 4 times less than pasteurization

* Juice pasteurization - Can we do better?, Tetra Pack white paper, Nov 2014

Comparison to other cold pasteurization systems

Pasteurization cost per liter0.35

$0.0800

$0.0700

$0.06000.0500

0.01090.0043

0.0003

AseptoRay Pulsed Electric High Pressure Pasteurization PasteurizationField (PEF) Processing (hot filling) (Cold Filling)

(HPP)

$0.0500

$0.0400

$0.0300

$0.0200

$0.0100

$-

Energy Saving

Assumptions:5000 L/Hr.

Pasteurization temp= 950C1 kWh heat = 1.8 kg steam, 1 kgsteam = 0.07$Regeneration: 85% (cold filling)

Business Model

Two alternative business models:

Go-to-market StrategyPay Per Use

Partnership modelPay Per

Use allowing systemleasing, and pay perliter of product.

Capital +service modelCapital +Service

Buying capital equipment,and service agreement for

UV lamps and maintenance.

System Advantages

Capability to inactivate Thermophilic Acidophilic Bacteria (TAB)

Reduces production and energy costs

Prolongs shelf life

Retains natural ingredients and taste

IP

The company filed a patent in Israel #230375

• Patent application priority date 8.1.14• Second application will be applied in coming months.

IP Protected at USA,EU, China etc.

Applied for PCT at 9.1.15,

• Organic Sugar Cane Sugar no pesticide and no fertilizers and organic manure used for farming

• Brown sugar From Molasses sugar contains Minerals and rich in flavors • Honey Purest and filtered is basically combination of fructose and

Glucose and water• Use of natural Sweetener stevia • Use of fruit sugar, Apple syrup •

Another very Important Increasing trend in Ice tea

PROCESS DESIGN INC

MANGL DEV BARIWALFOUNDER,PROCAESS DESIGN INC Business Partner

Mobile: +91 8000892200

email: [email protected]

PROCESS DESIGN INC

Formulation and Ingredients

We provide Engineering Solutions and Project consultancy and feasibility study Beverages recipe development and formulationBeverages Sample Preparation Ingredient SourcingContract Packaging and Manufacturing Management Food & Beverage Plant Project Management Brewery Plant Design and Construction ManagementMicro brewery, pub breweryDairy plants and Milk based Beverages Plant

PROCESS DESIGN INC

Our services include:

Design calculation, Process/ Utility Equipment sizing

Beverages Process Tanks Design

Plant design and Equipment Design

Process Controls and Automations support

Procurement support for Plant and Machineries

Installation and Commissioning Support

Operational and Quality support for Beverages and Pub

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Beverages Plant construction ManagementPressure Vessels of different capacities.CE Marked Vessels and Filter Housings.Skids with Pump and Piping Components.Clean room Piping Projects as built and tested.Process and Storage Vessels.

MANUFACTURING OF:

PROCESS DESIGN INC.

Date post:	09-Apr-2017
Category:	Engineering
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