hpp cooked meat promatec food ventures nc hyperbaric

www.nchyperbaric.com

Promatec Food Ventures: De presentatie Sliced and Processed Meat SPM & Ready Meals 2009


High Pressure Processing:Principles, technical and microbiological

considerations of an emerging technology

NC Hyperbaric


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


� 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


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


SUCCESSFUL EXAMPLES ALL OVER THE WORLD

HIGH PRESSURE PROCESSING


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


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


� 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.


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


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)


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


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(%

)


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


EFFECT OF HIGH PRESSURE PROCESSING ON RAW MEAT

-Colour changes-Textural changes-Due to modifications in the 3D structure of raw proteins


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)


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)


HIGH PRESSURE EFFECTS ON MICROORGANISMS

Effects on bacterium spores


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


COMMERCIAL APPLICATIONSHIGH PRESSURE PROCESSING


• 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



USA 2003 Sliced onions

Canada 2003 Apple products : jam and sauce

USA 2004 Tofu

Spain 2005 RTE vegetable meals

USA 2006 Tomato sauces


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


• 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


FOCUS ON MEAT PRODUCTSHPP commercial products


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 ?


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 …


Safety


0

5

10Colour

Sliced

Adhesiveness

Crunchy

Elasticity

Tenderness

Juicy

Fibrous

Non processed

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


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


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


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


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


• 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)


ESPUÑA (Spain)


CAMPOFRIO (Spain)

Starting point: securing export products


CAMPOFRIO (Spain)

Major current productions: new product propositions


EXPORT MARKETS


VISMARA - GRUPO FERRARINI (Italia)

Prosciutto ham & cured products


ABRAHAM (Germany)German proscuitto ham exported to USA


NATURAL PRODUCTS


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


HORMEL (USA)

http://www.hormelnatural.com/


KRAFT – OSCAR MAYER (USA)

• HPP ham, turkey, chicken

• Natural, minimally processed, no artificial ingredients…


ITOHAM (Japan)for nitrite free meat products


PERDUE FARMS (USA)

• HPP poultry strips

• MAP in a resealable bag

• No preservatives


KAYEM FOODS (USA)

NATURAL CHICKEN SAUSAGES


FOSTER FARMS

(USA)


TYSON (USA)

RTE Natural Oven Roasted Chicken:Whole birds, breasts, drumsticks, thighs…


FRESHERIZED FOODS (AVOMEX)

(USA)Ready-to-eat meat meals


MAPLE LEAF (Canada)for RTE meat based meals with rice, pasta, vegetables


OUR EQUIPMENTWave 6000 range

� Specially designed for the food industry

� Safe, ergonomic, reliable

� Clean and evironmentallyfriendly


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


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


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


THANK YOU FOR YOUR ATTENTION

FRANCISCO PURROY, DVMTechnical Sales Manager

+34 [email protected]

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: [email protected]: www.promatecfoodventures.com

hpp cooked meat promatec food ventures nc hyperbaric

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