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Agenda
• Beverage Processing – Focus on Thermal
• Key Concept – Global Maximization
• Technical Basis and Approach– Velocity and Shear profiles
– Time and Temperature profiles
• Application to Quality Enhancement– Peach piece crispness / texture
– Volatile Aromas – Flash Cooling / Evaporation
– Flavors – Cooked / Off
– Nutrition – Vitamin C, Thiamin, Lysine
• Case Study: Global Optimization – Soy Milk
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 90002
Mission –
• Provide tangible and material economic benefit
• To Food and Beverage Processors,
• On a Time Effective basis
• Because
– Consumer wants and needs are rapidly changing
– Technology is available
• With Employment of skills and resources on as needed basis
• By:– application of scientific and
engineering principles and practices
– Leverage IT revolution
• computing power
• data access - internet
• value generation
– bridge gap between generation and use of information
2nd May 2012
BevTech 2012, Ashok Dhruv, LLC.
(720) 318 90003
Concept to Commercialization – the journey
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 90004
2nd May 2012
BevTech 2012, Ashok Dhruv, LLC. (720) 318 9000
5
Thaw
Blend
Heat
Cool
FillHold
Non Alcoholic Beverages - Thermally Processed Generic Block Flow Diagram
Safety: F0 – Pasteurization and Microbial kill
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 9000
7
LogRedClB 1.044 104
LogRedClB log e 10( ) LncitocfClB
CitoCfClB 1.00024CitoCfClB eLncitocfClB
LncitocfClB 2.403 104
LncitocfClB0
min
KClB d min
KClB 7( ) 3.534 103
min1
KClB K0ClB e
EClB
Rgas TAvg( ) 460 R
TAvg 8( ) 196.762RExp 101.745ExpEClB
Rgas TAvg 15( ) 460 R
EClB
Rgas
3.73 104
KEClB 3.73 104
Rgas KK0ClB 2 1040
s1
Calculation of Microbial kill :
FTPast 37.228sFTPast0
min
10
TAvg( ) TRef
zd min
4.359minz 10 RTRef 180 R
Calculation of extent of Pasteurization :
Measure of Safety
2nd May 2012BevTech 2012, Ashok Dhruv, LLC. (720) 318
9000 8
Safety: D and z values and Microbial killClostridium Botulinum, Salmonella, Listeria Monocytogenes
2nd May 2012BevTech 2012, Ashok Dhruv, LLC. (720) 318
9000
9
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 r
atio
, ;
Av
g T
emp
deg
F
200
00
Ratio POD( )
%
T Avg( )
R
50
min
Extend shelf life – Enzyme deactivationPrevent enzymatic degradation with time
• Flavor and Aroma
– Volatile or Non ?
– To keep or reject?
– Sources
• Comes from F & V
• Added in formulation
• Generated in process
• Nutrition
– Vitamins
– Minerals
– Essential Amino Acids
• Proteins
– Essential Lipids
• Fats and Oils
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 900010
Safety: Commercial sterility : Log ReductionRetort, Aseptic, Hot Fill, Chilled, Frozen -HTST, UHT, ESL
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 900011
Microbiology
Enzymes
Bio-Chemistry
Organic Chemistry
Heat transfer
Mass transfer
Momentum transfer
Kinetics
Why and How –Application of sound Science and Engineering
Chemical engineering analysis
Apply tenets of chemistry
• Derive Viscosity, Velocity and Shear profiles
• Derive Time – Temperature profile
• Select markers
• Apply kinetics – Microbial, Enzymatic, Bio-chemical
• Integrate over product Volume
Generic Approach
BevTech 2012, Ashok Dhruv, LLC. (720) 318 90002nd May 2012 12
2nd May 2012BevTech 2012, Ashok Dhruv, LLC. (720) 318
9000 15
0 0.094 0.19 0.28 0.37 0.47 0.56 0.65 0.75 0.84 0.940
30
60
90
120
150
180
210
240
270
300Shear rate vs radial distance
Radial diatance, in
Sh
ear
rate
, 1
/sec
300
0.053
r 95( )
r 118( )
r 150( )
r 230( )
K 95r 95( )
s100
poise
K 118r 118( )
s100
poise
K 150r 150( )
s100
poise
K 230r 230( )
s100
poise
R i
in
5.525 103 r
Shear rate calculations :
r TF
PT TF
2 L0 k TF
1
n TF
r in( )
1
n TF
Max TF
PT TF d
4 k TF L0
1
n TF
Avg TF Max TF
n TF
n TF 1
Mechanical damageShear rate > Shear Number
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 9000
16
Measure of Mechanical Damage
1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3110
60
10
40
90
140
190
240
Shear rate, radially
Shear rate, axially
Shear rate as afunction of radius, SSHE
Radial distance, inches
Shear
rate
in p
er s
econ
d
240
110
r in( ) s
z r in( ) s 10
31.5 r
Scarped Surface Heat ExchangerShear rate in radial and axial direction
BevTech 2012, Ashok Dhruv, LLC.
(720) 318 9000
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
Time – Temperature Profile
2nd May 2012 18
BevTech 2012, Ashok Dhruv, LLC.
(720) 318 9000
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 530
50
70
90
110
130
150
170
190
210
Time to heat fruit piece in puree
Time of heating, m inutes
Te
mper
atu
re,
deg
F
130
175
T f tc 0 0 0 R1
T f tcx
in
y
in
z
inR
1
TAv gF tc R1
3 5
tc
Local and InstantaneousTime – Temperature Profile
2nd May 2012 19
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 900020
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
70
Temp, Firmness and PG Conc. of peaches
Time, minutes
Te
mp
F,
Fir
mn
ess
, N
, P
G C
onc
enta
rtio
n
70
0
T MW( )
R
Firm( )
PG( ) 100
10
Sensory perception - Texture – Peach firmnessCombine time – temperature with Enzymatic Kinetics
2nd May 2012BevTech 2012, Ashok Dhruv, LLC. (720)
318 9000 21
Removal of volatiles depends on the relative volatilities of the compound in question, as
shown by graph below:
Application: Loss of Volatile AromaFlash Cooling
2nd May 2012BevTech 2012, Ashok Dhruv, LLC. (720)
318 9000 22
Application: Loss of Volatile AromaFlash Cooling
2nd May 2012BevTech 2012, Ashok Dhruv, LLC. (720)
318 9000 23
Quality – Grapefruit juiceHMF and Non Enzymatic Browning Index
From Journal of Food Science, Volume 59, No 1, page 155, 1994.
Beverage Processing – Unit operations: Evaporation
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 900024
Evaporation – Formation of “Off” FlavorsHydroxy Methyl Furfural as marker
BevTech 2012, Ashok Dhruv, LLC.
(720) 318 9000
Quality – Hydroxy Methyl Furfural FormationIn Process and Storage
2nd May 2012 25
BevTech 2012, Ashok Dhruv, LLC.
(720) 318 9000
Nutrition – Vit. C / Ascorbic AcidIn Evaporation by Stage
2nd May 2012 27
NutritionVitamin B1 – Thiamin kinetics
2nd May 2012BevTech 2012, Ashok Dhruv, LLC.
(720) 318 900028
Calculation of Nutrition destruction :
Based on Vitamin B1 - Thiamin, Kinetics
K0B1 2.19 109
s1
EB1 1.18 104
Rgas KEB1
Rgas
1.18 104
K
ExpEB1
Rgas TAvg 15( ) 460 RExp 32.187 TAvg 8( ) 196.762R
KB1 K0B1 e
EB1
Rgas TAvg( ) 460 RKB1 7( ) 1.074 10
3min
1
LncitocfB10
min
KB1 d min LncitocfB1 7.046 104
CitoCfB1 eLncitocfB1
CitoCfB1 1.000705
LogRedB1 log e 10( ) LncitocfB1 LogRedB1 3.06 104
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
What is the impact on my Nutrition? Let us see what happens to Thiamine, Vitamin B1.The following are equivalent “pasteurization” processes for milk.
> 90 % reduction in Nutrient loss, does it matter at these low loss values?
BevTech 2012, Ashok Dhruv, LLC.
(720) 318 9000
Case Study: Safety, Shelf-life, Sensory, Nutrition -Optimizing conditions for Thermal Process for Soy Milk
2nd May 2012 30
9958 E. Maplewood Ave., Englewood, CO 80111
http://www.productivityandgrowth08.com
BevTech 2012, Ashok Dhruv, LLC.
(720) 318 900031
Ashok Dhruv, LLC(720) 949 – 6498 (Off)
(720) 318 – 9000 (Mobile)
Questions
Thank You
2nd May 2012