steristep ® germ reduction for low moisture products (spices, herbs, dehydrated vegetables, seeds,...

STERISTEP®

Germ reduction for low moisture products

(spices, herbs, dehydrated vegetables, seeds, nuts…)

Process owned and worldwide patented by FCD

1.

2.

3.

4.

How was born STERISTEP® ?

CONTENTS

Process control

Process description

Products treated

5. Sum-up of the advantages

Overview of existing technologies

IMTECH NAPASOLHOSOKAWA

1st generation:

Advantages:Sterilization ensuredParameters controlledcan treat powders and big particles sizecan treat small lots

Limitations:Equipment , labor and maintenance costs (moving parts, filters, CleaningBatch system

Continuous Autoclave system

VENTILEX

Advantages :Vibration: no damage to particlesEasy scale up as thickness of bed is regular, increasing capacity is increasing width.Can treat powders of big formsCan achieve sterilization.Perfect for a customer treating only one product like pepper (lot of sporulated forms)

Autoclave technology

TEMA

Sterilizer and pasteurizer

Fluid bed technology

Limitations:No small lotsCleaning time is 50% of production time.Quantity of steam: roughly 10 times more than other technologies in continuous. So fragile products like thyme, sage or rosemary don't have any more essential oil at the outletHygroscopic products like pistachios get very wet

REVTECH

2nd Generation: Pasteurizing system

Advantages: Transport by vibration, no damage to particlesProduct is heated by contact with tube, 10 times less steam than Ventillex or TemaCan achieve pasteurization (not sterilization).

Limitations: Minimum of quantity is 250 KG, no small lotsCannot treat powders (due to rheologic effect)Cannot treat too big particles like cinnamon sticksCan only feed the tube to 1/3Impossible to guarantee the inside is cleanLong cleaning time (8 hours for 2 people to clean the line)Poor bacteriological results when the sizes of particles have a big range: vibrations make segregations, fines go down, big particles go up, there’s no mixing in the tube so steam cannot treat the bottom products.

3rd generation: Safesteril pasteurization system (joule effect)

ETIA

Advantages: Can treat powders heat by contact, less steam is injected.product is heated by contact with tube, 10 times less steam than Ventillex or Temacan achieve pasteurization ( not sterilization).

Limitations: Transport by screw, risk of damage the particles when big especially in the bypass sectionMinimum of quantity is 250 KG, no small lotscannot treat too big particles like cinnamon stickscan only feed the auger to 1/3 long time to clean 8 hours for 2 people to clean the line

1. How was born STERISTEP®?

Elodie Janson & Nicolas Braun Die Traumfabrik Dubai

1. How was born STERISTEP® ?

What are the key properties to have good process ?►Possibility to treat large/sensible particles ? YES Vibrations used

►Possibility to treat powders ? YES Vibrations used

►Possibility to treat small lots ? YES No minimum feeding grade required

►Homogeneity of the treatment ? YES Steps ensure the mixing

►Easy, quick and accessible cleaning ? YES <3hrs for a 3,300lbs/h unit

►Low energy cost ? YES <90 kWh/ton

►Low maintenance cost ? YES < $1000/year

►TERP validated process ? YES 6log reduction of E. Faecium

For the first time ever, a steam pasteurization equipment was designed in order to meet a need, rather than adapting from an existing technology

2. Process description

2. Process descriptionGeneral view of the process

COOLING UNIT ”CS”

CHILLER / AIR DRYER HOPPER & DOSING

DECONTAMINATING UNIT ”DS”

STEAM BOILER

2. Process descriptionHopper and dosing system

► Hopper► Level probes indicate the remaining level of product► Possibility to control an automatic feeding system

OPTION : hopper can be placed on a weighing system (indicates the flow of product treated in kg/h)

► Vibrating dosing system ► Vibration = no risk of breakage► Continuous and regular flow► Height (thickness) of the product is controlled for a

homogeneous treatment► Easily accessible for cleaning and inspection

2. Process descriptionDS : Decontamination System (1/5)

Conveying method

►“Staircase” design in stainless steel►9 steps►2 vibrating engines►Particles move from one step to another – from top to bottom►Fine powders (2 microns) or whole products (chili pods, breakable herbs)

smooth and continuous mixing of the particlesregular exposure to steam

homogeneous treatment and final product

Heating surfa

ce

Heatingsurface

Hea

ting s

urf

ace


HEAT and STEAM : two sources of energy for more flexibility and effectiveness

Direct heat►Particles heated by contact with a heated stainless steel surface

►Heat comes from simple electrical resistances= low energy consumption

►4 sides heated = condensation avoided= high heating surface/m2

= fast rise of product temperature= short residence time= preserves the organoleptic

properties of the product


Steam (100 – 120°C / 220°F – 275°F) : necessary for decontamination

Injected with nozzles at the bottom of each step :To slightly condense on the product To increase the heat conductivityTo control the moisture of the product during

the treatmentsteam injection with nozzles is

controlled

2. Process descriptionHeat and Steam Balance

• Heat and steam can be adjusted for a greater flexibility.

►Heat conduction ►Heat convection

Plate temperature Steam quantity

For herbs :

For pepper :

►Plates ►Steam


Some of the products treated

Mushrooms Pistachios Cinnamon sticks

Rice flour


No minimal quantity required

►Possibility to treat small lots (5 – 10 kg)

►… and still have big capacities (20 – 40 tons)

►… on the same equipment !

2. Process descriptionBypass section (optional)

Isolates the “warm” area (decontamination) and “cold” area(cooling)►If product has not reached sufficient temperature or residence time, it is ruled out.

Separates the treated and non-treated products ►No disruption of the decontamination cycle

Run trapdoor can be adjusted with control parameters

cooling unit

Decontamination unit

bypass

2. Process descriptionCS : Cooling System

Product

inlet

cold water circulating

Product outlet at

room temperatur

e

2. Process descriptionCS : Cooling System

Importance of the cooler : to stabilize the product and to pack it without risk of recontamination

►Vibrating plate cooled by water (cross-current)►Filtered, cold and dry air injected at the input = to avoid condensation of the steam►Product reaches a room temperature (20-30°C)►No more bacterial development

2. Process descriptionAnnexes

STERISTEP® requires 3 fluids for the decontamination

►Steam generator : “culinary” steam produced for thedecontamination unit (5% of the flow of treated product at 6 bars)

► Air dehumidifier : injection of filtered, cold and dried air at the input of the cooler to remove the moisture of the steam remaining within the hot product

►Water chiller : cold water (5-12°C) is circulating in the double jacket

of the cooler. Closed loop (no water consumption)

2. Process descriptionMaintenance and Online support

Low maintenance and spare parts►Main maintenance : change the fan filters

Online support : control cabinet connected to the Internet with a modem►Online troubleshooting►Software update►Assistance for the production

2. Process descriptionCleaning

The key of success for a flexible production►Designed for a quick cleaning►Complete accessibility : no “hidden” area►All parts can be visually controlled►Dry cleaning : vacuum►Wet cleaning : water and bactericides / washing soda

“Water fall” design

Water goes to one collecting point

2. Process descriptionSTERISTEP models

4 models from 550lbs/h to 2,640lbs/h are available

►STERISTEP 25►STERISTEP 50►STERISTEP 75

►STERISTEP 100

Units can be doubled for more capacity !

2. Process descriptionConfiguration adjusted to your building layout

““clean” area clean” area

Incoming product Incoming product Area Area

DS 1

CS 1

Separation wall


DS 1 CS 1

Incoming product Incoming product Area Area

Separation wall““clean” area clean” area


DS 1

CS 1

Separation Wall (Recommended)

““clean” area clean” area

Bypass

2. Process descriptionExample of configurations

STERISTEP 50

1,100 lbs/h unit for herbs & spices


STERISTEP 75

6,600 lbs/h unit for almonds & pistachios


DOUBLE STERISTEP 75

2x 1,700 lbs/h unit for herbs & spices

2. Process descriptionVideo of the process

Here is the link to a video showing the process :

Video Link

(or type “FCD SAS” in Youtube/Dailymotion)

http://www.youtube.com/watch?v=tUrOSnH8zPU

3. Process control

3. Process controlControl cabinet, PLC and supervision

Control of the process ►Motors, temperature probes, level probes, steam and air exhaust, control of the annexes..

Recipe function►Parameters saved and programmable

Control panelview►Possibility to send automatically the data per email at the end of a production

Connected to Internet for E-assistance

3. Process controlTraceability software

Saves the “history” of the process►Temperature, alarms… are recorded

Safe recording►A new file is generated for each recording►Access by login and password for each

operator / administrator

Multiple input data for each recording ►Customer name and folder, batch numbers,order numbers, formula data…

Recall function►To review a past production’s data►Export in Excel format

4. Products treated

4. Products treatedApplication

Pasteurization►Inactivation of pathogens : E. Coli, salmonella, reduction of yeast, molds and other coliforms

Sterilization►Up to 5 logs reduction of the Total Plate Count (TPC) *►Inactivation of pathogens : E. Coli, salmonella, reduction of yeast, molds and coliforms

* FCD does not guarantee any effect on heat resistant forms such as spores, bacilli that might not be eliminated by treatment.

4. Products treatedFamily of products : NO LIMIT OF SIZE

Spices Herbs & Tea cuts

Seeds & Nuts

Dehydrated vegetables

Dehydrated fruits

… and more !

4. Products treatedOther products

MUSHROOMS

RAW TEST 1 TEST 2 TEST 3

TPC 750 000 11 000 1 000 1 000

Enterobacteriaceae 41 000 350 10 10

Yeast 120 000 10 10 10

Molds 600 10 10 10


PARSLEY GARLIC SLICES

RAW TEST 1

TPC 1 600 000

1 000

Enterobacteriaceae 27 000 <10

Yeast <10 <10

Molds 280 <10

RAW TEST 1

TPC 540 000 710

Enterobacteriaceae

<10 <10

Yeast <10 <10

Molds <10 <10


CHILI PODS

RAW TEST 1

TPC 320 000 <100

Enterobacteriaceae <10 <10

Yeast > 30 000 <10

Molds > 30 000 <10

RAW TEST 1

TPC 410 000 120

Enterobacteriaceae 110 <10

Yeast 1 200 <10

Molds 7 300 <10

CINNAMON STICKS


PEPPERMINT LEAVES

SAGE

RAW TEST 1

TPC 390 000 2 100


Yeast <10 <10

Molds <40 <10

RAW TEST 1

TPC 460 000 140


Yeast <100 <10

Molds 18 000 <10


PISTACHIOS

RAW TEST 1

TPC 320 000 <40


Yeast <10 <10

Molds <40 <40

RAW TEST 2

TPC 530 000 <10


Yeast <10 <10

Molds 2 400 <40

WALNUTS


ALMONDS

RAW TEST 2

TPC 330 000 120


Yeast <10 <10

Molds 59 000 <10


CINNAMON POWDER CHILI POWDER

RAW TEST 1

TPC 840 000 380


Yeast 260 <10

Molds <10 <10

RAW TEST 1

TPC 660 000 46 000


Yeast <10 <10

Molds 150 <10


BLUE POPPY SEEDS

RAW TEST 1

TPC 570 000 1 800


Yeast <10 <10

Molds <10 <10

RAW TEST 1

TPC 27 000 000 26 000


Yeast <10 <10

Molds 7 500 <10

WHITE PEPPER


CORIANDER SEEDS

RAW TEST 2

TPC 2 200 000 850


Yeast <10 <10

Molds 100 000 <10

RAW TEST 1

TPC 3 800 000 10 000


Yeast <10 <10

Molds <10 <10

GINGER SLICES


TURMERIC POWDER

RAW TEST 2

TPC 3 000 000 9 300


Yeast <10 <10

Molds 6 600 <40

RAW TEST 2

TPC 750 000 23 000

Enterobacteriaceae <10 <10

Yeast <10 <10

Molds <10 <40

FENNEL SWEET WHOLE

5. Summary of the main advantages

5. Sum-up of the advantages

-‘Conti-batch’: possibility to treat small lots (<10kg) even though system is continuous

-Vibrations are used to convey the product= possibility to treat all sizes of product (30cm

cinnamon sticks…)= no breakage of sensible products (tea, leafs…)

= possibility to treat powders

-Quick cleaning and product changeover (<3hrs for the complete line)

-Low electrical consumption (= 90 kWh/ton)

-Low maintenance (< 1,000€/year)

-Validated process – complete pasteurization guaranteed

-1-5 TPC log reduction guaranteed

6. Other equipments proposed

NEW CONTINUOUS ROASTING/DRYING PROCESS !!

for dried fruits, cocoa, coffee…

ZA sycala cahors sud enteste 2 46230 Fontanes - FRANCE

[email protected]

steristep ® germ reduction for low moisture products (spices, herbs, dehydrated vegetables, seeds,...

Documents

particles product

big particles size

sizes of particles

largesensible particles

line slide

small lots limitations

powders of big forms

small lots cleaning