High Pressure Processing

Manufacturing Costs and Facility Design ConsiderationsFacility Design Considerations

for Commercial HPP Manufacturing

May 6, 2010y 6, 0 0

Introduction

Mike Billig – VP Marketing GridpathMike Billig VP Marketing, Gridpath Solutions Inc.Gridpath Solutions is the NA Partner ofGridpath Solutions is the NA Partner of NC Hyperbaric14 Y VP M k ti d S l14 Years as VP Marketing and Sales, AmeriQual Foods

USDA Contract Manufacturer3-NC Hyperbaric Wave 600 300L Machines

Agendag

Commercial Food ApplicationsppHPP Manufacturing OptionsFacility RequirementsFacility RequirementsSupport EquipmentPackaging Compatibility and the EffectsPackaging Compatibility and the Effects on Manufacturing Capacity and CostsOperational and EconomicOperational and Economic Considerations

Commercial applications in the world:

HPP commercial products

Meat products

• Destruction of pathogens : Listeria, Samonella, coliforms…• Shelf life increase• Stabilisation of preservative-free or low salt content productsp p

Country Year Products Spain 1998 Sliced cooked ham and “tapas” USA 2001 Sliced cooked products and proscuitto ham USA 2001 Poultry products USA 2002 Pre cooked chicken and beef stripsUSA 2002 Pre-cooked chicken and beef strips Spain 2002 Sliced cooked chicken, ham and turkey

products, Serrano cured ham Italy 2003 Proscuitto ham, salami & pancetta Germany 2004 Cured and smoked sliced and diced ham Japan 2004 N itrites- free bacon, sausages and sliced meat USA 2005 Ready- to-eat meat based productsSpain 2005 Cured meat products & Serrano ham Canada 2006 Cured meat products USA 2006 Whole roasted chicken USA 2006 Sliced cooked turkey and chicken Canada 2008 Sliced deli meatsCanada 2009 Sliced deli meats

HPP commercial products

S iti ti d h lf lif iVegetable products

• Sanitisation and shelf life increase.

• Preservation of colour, flavour and vitamins.• Reduction of PPO activity in avocado.Reduction of PPO activity in avocado.• Reduction of the starch retrogradation of the rice.

Country Year Products Japan 1990 Fruit jams and fruit and vegetable sauces Japan 1994 Pre-cooked & hypoallergenic riceJapan 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 productsMexico 2003 Avocado products Mexico 2003 Avocado products Canada 2003 Apple products : jam and sauce USA 2004 Tofu Spain 2005 RTE vegetable meals USA 2006 Tomato sauces Australia 2008 Fruit pures & coulis

Commercial HPP products

Juices and beveragesS iti ti d h lf lif i• Sanitisation and shelf life increase

• Destruction of pathogens microorganisms• Preservation of colour, flavour & vitamins

Country Year Product Japan 1991 Grapefruit juice Japan 1992 Mandarin juice F 1994 Ci j i

of freshly squeezed fruits

France 1994 Citrus juicesMexico 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 juicesy g jUSA 2002 Orange juice, lemonade and smoothies Czech Republic 2004 Broccoli & apple, beetroot, carrot juices Northern Ireland 2006 Smoothies Australia 2008 High quality juices

HPP Commercial Products

Shellfish and fish

• Shelf life increase• Opening seafood shell at 200 to 350 MPa• Easy shellfish meat extraction

S iti ti (i ti ti f Vib i )• Sanitization (inactivation of Vibrio)

Country Year Products USA 1999 Oysters USA 2001 Oysters USA 2001 OystersUSA 2001 OystersUSA 2001 Oysters USA 2003 Crab Canada 2004 Seafood Canada 2004 Lobsters N Z l d 2004 M l h ki f dN. Zealand 2004 Mussels shucking for medsItaly 2004 Desalted cod USA 2005 Lobsters Canada 2006 Seafood Japan 2007 Shellfish USA 2008 Crab

HPP Manufacturing Optionsg p

Contract ManufacturingContract ManufacturingAdvantages

Manage Capital Risksg pControl Operational CostsEliminate line capacity constraints and risksSh t ti t k tShorten time to marketAbility to analyze market performance while minimizing entry costsTake advantage of contract manufacturer’s processing expertise In House Production

HPP Manufacturing Optionsg p

Contract ManufacturingContract ManufacturingDisadvantages

Higher Manufacturing CostHigher Manufacturing CostLogistics ChallengesFreight CostsgLess Usable Shelf Life

HPP Manufacturing Optionsg p

In House ManufacturingIn House ManufacturingAdvantages

Lower HPP Processing CostsgNo Logistics ChallengesNo Freight CostsM i U bl Sh lf LifMaximum Usable Shelf Life

For Customers and ConsumersFor Internal Production Efficiencies

Contract Processing OpportunitiesProprietary Technology

HPP Manufacturing Optionsg p

In House ManufacturingIn House ManufacturingDisadvantages

Capital Investment RequiredCapital Investment RequiredEquipmentBuilding

Longer Initial Time to MarketNew Technology

Facility Requirementsy q

Processing Room DesignProcessing Room Design Inside Existing FacilityIn New FacilityyRoom EnvironmentCeiling Height Requirements Line Design and floor S R i tSpace RequirementsFloor Requirements

Line Design and Floor Space RequirementsLine Design and Floor Space RequirementsHPP Equipment Placement

Facility Requirementsy q

Line Design and Floor Space RequirementsLine Design and Floor Space Requirements Support Equipment

Infeed systemsUnloading systemsProduct drying Pack Off Stationsac O Stat o s

HPP Intensifier PlacementFloor level OverheadSeparate room

Equipment Implementation

Example of Wave 6000/420

Equipment Implementation

Dual Line System with Support Equipment

Facility Requirementsy q

Product controlProduct controlProcess Flow

Separation of Processed and UnprocessedSeparation of Processed and Unprocessed product

DocumentationProduct Taken to Processing LineProcess DocumentationPost Process Tracking

High Pressure Processing Industrial Equipment

Throughput from 250 kg/hour

135 L

300 L

55 L

300 L T d300 L Tandem

Wave 6000/420Up to 2.5 tons / hour:

Wave 6000/420

Infeed Conveyory

Carrier Unloader

Drying Systemy g y

Package Compatibilityg p y

V fl hVacuum or gas flush.Semi-rigid trays.Efficiency varies, efficacy does not.

Package/Process Functionalityg y

15% CompressibilityGeometry/MemoryFilm ContactLabel Application

Packaging Effect on Economicsg g

Package design and loading efficienciesPackage design and loading efficienciesCycle Times

G fl hGas flushLoad densityProduct hold time at pressure

Typical Modificationsyp

Gas reduction.Shallow drawShallow draw.Geometry change.Label ApplicationLabel Application.Label Material changechange.

Loading Efficiencyg y

Product carriers cut to suit application.Utilization of space impacts throughput.Infeed SystemsGas takes up space.Gas is more compressible.

Cycle Timey

Operational/Economic Considerations

Equipment decisionsq pHPP equipment

Horizontal for speed and process controlEquipment uptimeq p p

Number of IntensifiersIntensifier LocationSupport Equipment IntegrationSupport Equipment Integration

Production schedulingLabor RatesUtility CostSpare Parts cost

Operational Considerationsp

Production Line SchedulingProduction Line SchedulingLine Manning

One Person Loading CarriersOne Person Loading CarriersOne Person Operating Machine and Documenting the Process.One Person Unloading Carriers

Support groupsWarehouse

Take Product HPP LineTake Processed Product to WarehouseTake Processed Product to Warehouse

Operational Considerationsp

Support groupsSupport groupsQuality control

In Process and Post Process Product Evaluation

MaintenanceMaintain Machine Uptime

Change High Pressure TubingChange High Pressure TubingChange Intensifier SealsMaintenance Cost $4.00 to $4.50 Per Cycle

SanitationSanitationDaily to WeeklyBased on Failure Frequency

Economic Considerations

Fixed OH AllocationFixed OH AllocationCycle Times/Package DesignTotal cost to HPP products $0 03/lbTotal cost to HPP products $0.03/lb -$0.04/lb plus fixed overhead allocation

Equipment cost amortized over 7 yrsEquipment cost amortized over 7 yrsLabor – production and maintenanceUtilitiesUtilitiesInstallation costsFacilities modification

Case Studyy

With Proper Planning EquipmentWith Proper Planning, Equipment Installation is EfficientTwo NC Hyperbaric Wave 6000 300LTwo NC Hyperbaric Wave 6000 300L Installed and Operational in 7 daysP d ti C d D 10Production Commenced on Day 10

Ran Continuously 24/7 for 5 monthsEquipment Uptime Over 95%

High Pressure Processing

Thank You

Michael Billig (812) 490-1241