IMPACT OF ULTRASOUND ON PROCESS EFFICIENCY IN FOOD INDUSTRY
Mladen Brnčić
Faculty of Food Technology and Biotechnology
Zagreb
Croatia
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Sound waves at frequencies higher than the audible range (16 kHz)
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Power ultrasound (20 -1000 kHz) can be used for IMPROVING PROCESSING EFFICIENCY
Enhancing drying
Enhancing extraction
Enhancing homogenisation
Defoaming
Enhancing emulsification
Viscosity modification
Enhancing oxidation processes
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASOUND PROCESSING OF FOODS PHENOMENON OF CAVITATION The basis of ultrasound benefits
– LIQUIDS - Consequence of L-wave creation
leads to alternate cycles of expansion and rarefaction
Areas of pressure changes causes cavitation occurence during which bubbles are formed with higher surface area under expansion cycle
Cavitational bubble is growing and shrinking during dynamical phases equilibrium during phase within bubble and liquid outside
EXAMPLE - 24 kHz; Critical size of cavitational bubble is 170 µm and in that moment bubble is not able to absorb energy and IMPLODE
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Ability of ultrasound to form cavitation depends on its properties: frequency, intensity, amplitude
Device properties and geometry: Maximal nominal output power, cycle adjustment,
diameter of sonotrodes (probes)
Treated material properties: Viscosity, particle size and particle size distribution,
surface tension, texture and composition
Surrounding conditions: Temperature, moisture, pressure
With very high frequencies ( >1 MHz) it is difficult to achieve cavitation effect and above 2,5 MHz – IMPOSSIBLE
ULTRASOUND PROCESSING OF FOODS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
PHENOMENON OF CAVITATION
STABLE CAVITATIONS
TRANSIENT CAVITATIONS - WATER “COLD BOILING”
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
PHENOMENON OF CAVITATION TRANSIENT CAVITATIONS - “BOILING” (WITH IMPLOSION –
delivering of bubble energy within surrounding microenvironment )
ULTRASOUND PROCESSING OF FOODS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Frequency vs. Intensity
ULTRASOUND PROCESSING OF FOODS
Cavitational paradox LESS FREQUENCY WITHIN ULTRASONIC RANGE – MORE AGRESSIVE EFFECT
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Hi intensity ultrasound (HIU) Applications in Food Technology:
EMULSIFYING
DRYING
EXTRACTION
HOMOGENIZATION
CRYSTALLIZATION
SPRAYING/COATING
FREEZING
CLEANING
INACTIVATION OF MICRORGANISMS
ENZYME ACTIVATION AND INHIBITION
DEFOAMING – AIR BORN
DEBLINDING – AIR BORN
CUTTING – AIR BORN
ULTRASOUND PROCESSING OF FOODS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
RESULTS – 3 DOCTORAL THESIS DEFENDED
SVEN KARLOVIĆ – US ASSISTED DRYING
TOMISLAV BOSILJKOV – US ASSISTED HOMOGENIZATION
MAJA DENT – US ASSISTED EXTRACTION
ULTRASOUND PROCESSING OF FOODS: Drying, homogenization and extraction in foods assisted by
ultrasound
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONICALLY AIDED DRYING
Food drying is one of the oldest, very simple, and very meaningful ways of preserving foods
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
• Microvawe dryer • Tunnel dryer (hand made)
• Experimental research – Doctoral thesis SVEN KARLOVIĆ - defended
• Apple slices – 3 x 2 x 0.5 cm respectively
ULTRASONICALLY AIDED DRYING
• Hypotesis • Improved mass transfer • Enhanced textural properties • Shortening of drying procedure • Decreased costs • Lower energy consumption
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONICALLY AIDED DRYING Ultrasonic propagation could cause numerous series of alternative compressions and expansions, like pressing and releasing of a sponge (sponge effect).
The mechanical forces created are higher than surface tension which withold the moisture inside the capillaries of the fruit creating microscopic channels which may ease moisture removal.
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
• Environmental aspects
• Clean technology • No moving parts • Shortening drying time • 40% of saved energy • Improved food Quality • Low noise • No waste material • No waste water
ULTRASONICALLY AIDED DRYING
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Apple sample before and after ultrasonic treatment
ULTRASONICALLY AIDED DRYING
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
• Texture results
Elasticity
Work
Hardness
ULTRASONICALLY AIDED DRYING
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
• Conclusions – SO FAR!!! • Ultrasonic pre-treatment of apple pieces before drying enables shorter time of drying • Increase of ultrasonic intensity additionally lead to more time shortening of drying • Removal of higher amounts of water from ultrasonically treated samples is enabled for the shorter duration of drying • Amplitude of 50% indicates as adequate with achieved results for ultrasonic pre-treatment of apple pieces – HARDNESS + • Under maximum of ultrasonic amplitude treatment and after drying of such pre-treated samples to large hardness of the samples occurred whereby those parameters of pre-treatment were not suitable • Improved elasticity – ELASTICITY - • More time for chewing – WORK +
ULTRASONICALLY AIDED DRYING
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONICALLY AIDED HOMOGENISATION
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Milk homogenisation
• Hypothesis
• Size reduce of fat globules • Improvesd homogenisation • Improved stability • Prolonged shelf life • Energy savings
• Material
• Cow, goat and soy milk • PhD thesis – Tomislav Bosiljkov (Cow milk)
ULTRASONICALLY AIDED HOMOGENISATION
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONICALLY AIDED HOMOGENISATION
METHOD 1
A – 30, 60, 90
t (5; 7.5; 10)
Cycle – 1
d – 10 mm
V – 400 mL
Im.depth – 3 cm
METHOD 2 A – 30, 60, 90 t (5; 7.5; 10) Cycle – 1 d – 7 mm V – 400 mL Im.depth – 3
cm
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Descriptive
statistics
Mode Median Mean value
Variance Maximum
1.7 2.35 2.80 2.11 8.9
ULTRASONICALLY AIDED HOMOGENISATION
Inhomogenised milk
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
A = 90 %; t = 10 min; d (probe) = 7 mm A = 90 %; t = 10 min; d (probe) = 10 mm
ULTRASONICALLY AIDED HOMOGENISATION
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONICALLY AIDED HOMOGENISATION
A = 90 %; t = 10 min; d (probe) = 7 mm A = 90 %; t = 10 min; d (probe) = 10 mm
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONICALLY AIDED HOMOGENISATION
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONICALLY AIDED HOMOGENISATION
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
• CONCLUSIONS – Results were analyzed and compared
– The best results were obtained with treatment time of 10 min for both US devices
– Sonotrode diameter had significant influence due to dispersion of cavitaional “cloud” i.e. – intesities
– Decreased time of treatment with increase of US amplitude – increased intensities
– Less energy consumption compared with conventional homog.
– No moving parts – cheaper amortization
– More uniform particle size distribution of fat globules – prolonged shelf life
– Milk, Ketchup, Dressing, Juices, Sauces, Mayonaise
Milk homogenisation
ULTRASONICALLY AIDED HOMOGENISATION
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASOUND ASSISTED EXTRACTION OF BIOACTIVE COMPOUNDS
Mechanical effect of US:
• Disruption of cell walls of the plant • Enable easier release of cell compounds • Better solvent admission to cell compounds • Improved mass transfer • Energy savings
• Material
• Sage • PhD thesis – Maja Dent
ULTRASOUND ASSISTED EXTRACTION OF BIOACTIVE COMPOUNDS
• PROCESS OPTIMIZATION
• Ultrasound
– Frequency
– Acoustic power
– Cycle
– Amplitude
• EXTRACTION
– Treatment time
– Temperature
– SOLVENT
– Particle size
– pH
• SOLVENT
– Selelective for targeted compounds
– Severe extraction capacity
– not be reactive with other plant compounds
– Inoffensive for the people and equipment
– Completely volatile
– Economical (low price)
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASOUND ASSISTED EXTRACTION OF BIOACTIVE COMPOUNDS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Total phenols - SAGE
Conventional extraction - 60°C
Extraction time 30 min
Solvent 30% Ethanol 30% Acethone Water
TP (mg GAE/ g
dry sage)
62.78 54.96 51.7
ULTRASOUND ASSISTED EXTRACTION OF BIOACTIVE COMPOUNDS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Total phenols – Sage
ULTRASONIC EXTRACTION A-100% C-1
SOLVENT 30% Ethanol
Sonotrode 7 mm 22 mm
Extraction time
(min)
8 10 11 12 8 10 11 12
TP (mg GAE/ g
dry sage)
63.56 66.23 74.84 75.87 78.30 79.93 91.09 75.22
ULTRASOUND ASSISTED EXTRACTION OF BIOACTIVE COMPOUNDS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ULTRASONIC EXTRACTION A-100% C-1
SONOTRODE 22 mm
EXTRACTION T.
(min)
11
SOLVENT 30% ETHANOL 30% ACETHONE WATER
TP (mg GAE/ g dry
sage)
91.09 69.95 57.54
Conventional extraction - 60°C
Extraction time 30 min
Solvent 30% Ethanol 30% Acethone Water
TP (mg GAE/ g
dry sage)
62.78 54.96 51.7
ULTRASOUND ASSISTED EXTRACTION OF BIOACTIVE COMPOUNDS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Advantages of ultrasonic extraction v.s. classic extraction: INCREASED YIELD Enhanced extraction rate Extraction conducted under lower temperatures - enhance
extraction of heat sensitive components. Enhancement of extraction processes where solvents
cannot be used (juice concentrate processing) Potential opportunity for aqueous extraction or use of
alternative solvents by improving their performance Less creation and release of heat Ecologically more acceptable method – sustainable food
innovation Commercially viable and scaleable
ULTRASOUND ASSISTED EXTRACTION OF BIOACTIVE COMPOUNDS
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Comparision and advantages over traditional food
processing
-
Shorter processing of foods - Low increase of temperature - Energy savings - Improved food quality - Decresed amount of emulsifiers - Increased yield - Improved texture and structure - Ecologically more acceptable method sustainable food innovation - No toxic waste
ULTRASOUND PROCESSING OF FOODS: Drying, homogenization and extraction in foods assisted by
ultrasound
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
DEFOAMING
ultrasound technology for use in the food and beverage industry
the foam issues present in the majority of beverage filling lines
easy to install, safe and cost-effective method of removing foam
by removing the need for chilling or slower line speeds there are productivity improvements
for carbonated soft drinks , non-carbonated juices, teas, dairy drinks, sparkling wine, carbonated alcoholic pre-mixes or beer
the solution can be applied all sizes of can, bottle and pouch containers on aseptic or hot fill lines.
it is not expensive to operate and it doesn’t affect the quality or taste of the product
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
SPRAY DRYING OF PROTEINS- reduction of viscosity
Ultrasound technology can modify the fluid dynamics of the protein concentrate stream feeding the spray dryer, allowing for higher concentration and percentage dry solids into the dryer.
It uses efficient, high-energy sound waves to deliver one or more of the following mechanisms:
Remove entrained air and oxygen bubbles Open up the compaction layers of the proteins Temporarily reduce viscosity Create a temporary change in the protein molecule alignment What are the benefits? In addition to reducing energy consumption, the ultrasound technology: increases output by 10% reduces overall fixed and variable cost reduces filling losses and waste treatment costs reduces chilling requirements reduces capital costs and increases profits provides payback in under one year
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
THE ULTRASOUNDS CLEANING PROCESS
designed specifically for each application to optimize performance and total cleanness.
different temperature, frequency and chemical combinations are used. Determination of the best process parameters for each problem (dirt, grease or coal dust adhered to the surface of the object)
Temperature: Temperature increases (80-90ºC) in liquids augment steam pressure
and facilitate the presence of bubbles (Cavitation). This results in increased cleaning power.
Frequency: It determines the size of the bubbles generated during Cavitation. High dirt levels require lower frequency levels, with higher power. High frequency levels are used for finishing operations or to clean delicate components (Optics).
Chemicals: Each application requires a certain chemical and concentration level based on factors such a working temperature, type of dirt, cleaning time and material.
Ultrasound waves optimize the effects of the cleaning agents, thus reducing the level of chemicals needed.
A suitable combination of the above named parameters significantly reduces cleaning time, which is the fourth parameter of the Ultrasounds Cleaning Process.
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Ultrasounds cleaning systems are based on high-frequency sound waves transmitted through a cleaning liquid. The component to be cleaned is submerged into the cleaning liquid. The treatment lasts between 10 and 45 minutes and does not require the presence of any laborer.
The result is a micro-brushing effect on the objects. Since the air bubbles are smaller than 1µm, they get into any openings, regardless of their size. Therefore, ultrasound cleaning is the most suitable cleaning system for highly complex components of any material (alloys, steel, alluminium, copper, bronze, titanium, certain plastic types etc
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
SCALE UP SEMI
INDUSTRY (SMES)
INDUSTRIAL
LAB SCALE RESEARCH
LABORATORY FOR UNIT OPERATIONS R & D CENTRE FOR ULTRASOUND APPLICATIONS IN FOOD TECHNOLOGY &
BIOTECHNOLOGY
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
IMPACT OF ULTRASOUND ON PROCESS EFFICIENCY IN FOOD INDUSTRY
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
ACKNOWLEDGMENT
Dr. Nada Knežević
Dr. Davorka Gajari
Society of Chemists and Technologists of Koprivnica
Podravka Food Company
THANK YOU FOR YOUR ATTENTION
IMPACT OF ULTRASOUND ON PROCESS EFFICIENCY IN FOOD INDUSTRY
TRENDS IN FOOD INDUSTRY – Koprivnica, Croatia, September 5th, 2014.
Mladen Brnčić Faculty of Food Technology and Biotechnology
Zagreb Croatia