Upload
nguyenanh
View
282
Download
8
Embed Size (px)
Citation preview
2 BÜhler pasteurization and sterilization solutions
Safety for your food.Bühler pasteurization and sterilization systems.
For foods with a low moisture content, Bühler provides
a number of sophisticated solutions for effective pas-
teurization and sterilization – tailored to the processing
of cocoa, nuts and seeds. The technologies are char-
acterized by ease of use, reproducible results and high
effectiveness.
Both effective and gentle processes are needed to meet
increasingly stringent legal provisions and to guarantee
not only the safety but also the quality of food for the end
consumers. The targeted inactivation of microorganisms
is a must for ensuring the safety of end products and
their shelf life.
You can meet this responsibility with the pasteurization
and sterilization solutions from Bühler and secure the
safety, quality and success that your products deserve.
natural inactivation of germs using steam
The heat resistance of pathogenic germs strongly in-
creases as water activity decreases, so in dry foodstuffs,
the use of steam significantly improves inactivation. In
addition, steam is a natural medium, so your products
are not subjected to chemicals or radiation.
one of the most sensitive issues for the food industry is the bacterial contamination of end products.
serious illness in consumers or a severe loss of brand image are risks that can be avoided by utilizing the
steam pasteurization or sterilization solutions from Bühler.
tem
per
atur
e [°
C]
100 °C
sterilization process
pasteurization process
Parasiten
Moulds & Yeasts
e. Coli
Salmonella
time
Termophile spore forming microorganisms
Figure 1: Different heat resistances of microorganisms require modified time/temperature processes for inactivation.
BÜhler pasteurization and sterilization solutions 3
advantages for the customer:
– Individual solution: the right pasteurization or sterilization for every requirement and application
– Safe solution: Bühler batch systems with modern online process capture guarantee reproducible results
– Complete solution: extensive product support from planning, design, installation and startup through to
validation of the process (ProValid)
– Comprehensive service: Technical and technological support and comprehensive advice
Bühler solution Barth CCp Barth nr-Cep Barth debactM
product Nuts, peanuts Nuts, peanuts –
Cocoa beans – Cocoa beans
Spices, herbs, seeds, grains Seeds –
process Pasteurization or sterilization process with steam
Pasteurization with steam and then roasting
Sterilization process with steam
process control Control of steam temperature using pressure
Steam injection at atmospheric pressure into the roasting chamber
Steam injection at very high pres-sure (hTST process)
inactivation objective Vacuum process: Vegetative, pathogenic microorga-nisms, such as salmonella
Over-pressure process:Including thermophile spore formers
Vegetative, pathogenic microorga-nisms, such as salmonella
Vegetative, pathogenic microorga-nisms but also thermophile spore formers
Capacity 100 to 20,000 kg/h 100 to 2,000 kg/h 1.000 to 4,000 kg/h
Characteristic high flexibility through batch process and wide temperature range(75 to 120 °C)
roasting and pasteurization in one system
reduction of TPC to < 5,000 cfu/g in 100 seconds cycle time
proValid validation Possible Possible Possible
4 BÜhler pasteurization and sterilization solutions
Barth CCP – Controlled Condensation Process. Pasteurization solution for diverse applications.
With the Barth CCp controlled pasteurization pro-
cess, Bühler offers a gentle processing solution
for all kinds of nuts, cocoa beans, oil seeds, spices
and other dry foodstuffs.
Barth CCp – forward-looking technology
Many sensitive products must be processed at tempera-
tures below 100 °C to maintain their unique properties.
It is therefore important for the required pasteurization to
be carried out at reduced pressure to keep the evapo-
ration temperature and moisture condensation low dur-
ing the process. On the other hand, a certain product
surface moisture is important to achieve the desired log
reduction of salmonella. In the Barth CCP system, this
technologically demanding challenge is met by a pres-
sure-controlled process and the pre-heating of the prod-
uct to a temperature just below the system‘s evaporation
temperature.
effective and flexible process
Controlled steam germ removal using the Barth CCP
reactor is based on a pressure-controlled batch principle.
advantages for the customer:
– Pressure-controlled batch process provides
flexible process temperatures in the range from
75 to 120 °C at any residence time
– Controllable change in product moisture
– Patented and TerP-approved process
Barth CCP 50
BÜhler pasteurization and sterilization solutions 5
All important parameters such as pressure, time and
temperature can be set individually to suit the spe-
cific product being treated. An optimal result is always
achieved, thanks to the numerous variation options within
a very wide range.
Guaranteed 5-log reduction
The Barth CCP process shows a reduction of more than
five logs in the bacterial count for Enterococcus faecium,
a surrogate for salmonella. During the treatment, the
process temperature is controlled via the pressure or the
vacuum.
A reduction in the pressure causes a drop in the evapo-
ration and condensation temperature and thus a reduc-
tion in the process temperature. Consequently, the inac-
tivation rate can be controlled by changing the pressure
conditions and the residence time in the pressure vessel
and the product is gently pasteurized.
As the process can also be operated at over-pressure
conditions and at temperatures of more than 100 °C, it
is also able to inactivate thermophilic microorganisms.
Barth CCP can therefore be used for dry foodstuffs
where there is a requirement for an extremely low total
plate count (TPC) level, such as for cocoa beans or
spices.
excellent product quality
After CCP pasteurization, products such as almonds or
pepper show no significant changes in terms of appear-
ance, taste, texture or color, therefore no skin loosening
and no significant changes in the volatile oil fraction.
Furthermore, the moisture content can be controlled and
adjusted.
terp approved
In 2008, an application was made to the Technical expert
review Panel (TerP) of the Almond Board of California
(ABC, Modesto, CA) to validate the pasteurization pro-
cess for a five-log reduction of Salmonella SE PT 30 in
almonds. After examining all the necessary information,
TerP approved the validation in April 2008.
the system at a glance
3
6
2
5
4
71
3
6
2
5
4
7
Conditioning system
Weighing hopper
Barth CCp vessel
Vacuum pump
steam injection
discharge hopper
Cooling system
Machine type Batch size [l]
Cycle time[min]
example of throughput for 300 kg/m³ bulk density[kg/h]
example of throughputfor 600 kg/m³ bulk density[kg/h]
Barth CCp 250 250 10 to 15 300 to 450 600 to 900
Barth CCp 500 500 10 to 15 600 to 900 1,200 to 1,800
Barth CCp 1000 1,000 15 to 20 900 to 1,200 1,800 to 2,400
Barth CCp 3000 3,000 15 to 20 2,700 to 3,600 5,400 to 7,200
Barth CCp 7000 7,000 15 to 20 6,300 to 8,400 12,600 to 16,800
1
6 BÜhler pasteurization and sterilization solutions
Barth NR-CEP – roasting and pasteurization. Premium roasting quality for nuts and seeds.
at which nuts oxidize can be reduced by a factor of 2.5
when compared to conventional roasting processes.
pasteurization independent of the degree of roast
The patented roasting and pasteurization technology
achieves a better than five-log inactivation of pathogenic
microorganisms such as salmonella. The Barth Nr-CeP
system complies with the latest standards for modern
pasteurization technologies and can be adjusted for
many needs and requirements.
premium roasting results and a long shelf life
The Barth Nr-CeP nut roaster allows a huge variety of
parameters to be carried out. In batch operation, any
combination of roasting time and temperature is possible.
The partly fluidized roasting ensures that energy is
distributed evenly between each individual nut, thus
making a homogeneous and optimal aroma and taste
possible for the entire batch. Consequently, processing
will be equally effective, irrespective of whether hazel-
nuts, almonds, peanuts, macadamias, pecans, cashews,
pumpkin seeds or sunflower seeds are being roasted.
The two-step roasting process developed and patented
by Bühler largely preserves the microstructure of the nuts
and thus achieves an unparalleled shelf life: the speed
advantages for the customer:
– Pasteurization efficiency independent of degree
of roast
– Optimum aroma and extended shelf life of
roasted products
– Saves energy and space through pasteurization
and roasting being combined in one system
– Patented and TerP-approved process
Barth Nr-CeP 3000
the Barth nr-Cep system allows granular prod-
ucts to be pasteurized during the roasting process.
Here pasteurization is independent of the degree
of roast so that even debacterization without roast-
ing is possible.
BÜhler pasteurization and sterilization solutions 7
safe and reproducible results
Safe pasteurization and high product quality are achieved
through controlled condensation of saturated steam on
the product surface. This is achieved by directing steam
into the roasting chamber for a defined period of time,
after a warming phase.
reproducible inactivation of pathogenic microorganisms
such as salmonella is achieved thanks to the good con-
trol and traceability during batch operation.
log-reduktion of Enterococcus faecium
(surrogate of Salmonella SE PT 30)
pasteurization time [min]
Trial 1 Trial 2 Trial 3
Target 5-log reduction
108
107
106
105
104
103
102
101
100
10-1Ger
m c
oun
t [c
fu/g
]
0 62 84 10
Components of a two-step roasting and pasteurization process
Machine type Batch size at 500kg/m³ bulk density [kg]
example of throughput with roasting process [kg/h]
example of throughput without roasting process [kg/h]
Barth nr-Cep 1250 50 100 150 to 200
Barth nr-Cep 2000 250 500 750 to 1,000
Barth nr-Cep 3000 500 1,000 1,500 to 2,000
1. Weighing hopper2. roasting zone3. Cooling zone4. Product discharge5. Supply air fan6. hot air generator7. Saturated steam injection8. exhaust air fan, roasting zone9. exhaust air cyclone,
roasting zone10. Fresh air fan11. exhaust air fan, cooling zone12. exhaust air cyclone, cooling
zone
6
9
2
1
105
7
4
11
8
3
12
8 BÜhler pasteurization and sterilization solutions
Barth Debac™ – debacterizing system for cocoa. reduction in the germ count with flavor protection.
With the Barth debactM system, Bühler provides
a tried-and-tested process for reducing the germ
count to below the detection limit. this very gentle
treatment leaves the kernel, and therefore the co-
coa flavor, unchanged.
no compromises and safe germ reduction
The temperatures that occur during cocoa and chocolate
production are not sufficient to inactivate pathogenic mi-
croorganisms such as salmonella. These germs are pro-
tected by their low moisture activity and high fat content.
The DebacTM principle is an effective method of quickly
eliminating pathogenic and even thermophilic vegeta-
tive germs and their spores to below the detection limit.
Minimal treatment times are made possible thanks to the
unique combination of high pressure (up to 5 bar) and the
associated high temperature, and a film of moisture on
the bean’s surface.
advantages for the customer:
– Consistent, efficient germ count reduction to
below the detection limit
– No effect on the taste and moisture content of
the cocoa kernel, as the shell provides protection
– “Puffing effect”: improved shell separation and
fewer fines in the nibs
– easy secondary drying, as the moisture on the
surface evaporates as a result of the cocoa
beans’ intrinsic energyBarth DebacTM 1
BÜhler pasteurization and sterilization solutions 9
Barth Debac™ – debacterizing system for cocoa. reduction in the germ count with flavor protection.
The process control system of the Barth Debac™ system
provides seamless monitoring, control and documenta-
tion and thus reproducible results.
taste-neutral debac™ method
Thanks to the barrier function of the cocoa shells with
regard to temperature and moisture, the Debac™ method
is absolutely taste-neutral when it comes to the end
product. Chemical analyses show there is no increase in
the pyrazine content, which would point to undesirable
effects during the roasting process, and there is also no
rise in the water content of the cocoa nibs.
A small volume per batch and the relatively high pressure
of the steam of up to 5 bar allow highly effective debac-
terization within a very short time. Depending on the
product, this allows the Barth Debac™ debacterization
system to achieve a throughput of 4 t/h.
progression of steam pressure in the reactor
1 32
5 5
4 66 1 32
1 process cycle (in continuous operation)
Machine type throughput [kg/h]
Batch-size [kg]
reactor diameter [mm]
system height[mm]
Barth debactM 1 1,000 30 665 2,760
Barth debactM 2 3,000 85 880 3,420
Barth debactM 3 4,000 120 1,000 3,980
1 Filling the reactorFlushing with steampressure build-upreleasing pressureFilling the dosing hopperdischarging the reactor
3
2
5
4
6
Filling the
dosing hopperFilling
the reactorFlushing
with steampressure build-up
releasing pressure
discharging
10 BÜhler pasteurization and sterilization solutions
Services from Bühler. Practice-based pilot plant and laboratory trials.
In the Bühler pilot plant in Freiberg, all the debacterizing
methods offered by Bühler can be tested, evaluated and
optimized.
experienced process engineers carry out pilot trials
and test series with the customer prior to a decision on
whether to buy. These trials provide an insight into the
required dimensioning of the potential plant.
The available pilot plant enables trials to be carried out
on a small industrial scale to optimize products or pro-
cesses. Qualified food and processing engineers draw on
their expertise in the field to advise customers. The Büh-
ler central laboratory in Uzwil is the ideal point of contact
for demanding analysis tasks and also offers services
such as consulting, training and method development.
as a leading technology partner in the food industry, Bühler enables customers to test the performance
of its steam pasteurization or sterilization plants in advance. professional trials and analyses enable cus-
tomers to accurately evaluate the different methods and their results regarding the reduction of germs
and other impurities. these trials form the basis for selecting the optimum plant to meet customer re-
quirements and process the customer‘s products.
advantages for the customer:
– State-of-the-art pilot plant for customer trials
– Product and process optimization
– Many years of experience in the field of cocoa and
nut processing
– Support from qualified food and processing engi-
neers
– Interdisciplinary exchange with other areas of
Bühler‘s expertise and with educational establish-
ments
BÜhler pasteurization and sterilization solutions 11
ProValid: Validation service from Bühler.Comprehensive service from a single source.
the aim of Bühler‘s validation service is to provide
documented proof that a pasteurization or ster-
ilization process meets the previously specified
acceptance criteria in practical use.
Compared to sampling, validation offers greater reliabil-
ity that a process achieves the required log reduction in a
proven manner and in compliance with the defined con-
ditions. The process conditions are documented and can
be used as proof for audits, for example.
Validating a process
With ProValid Basic and ProValid Premium, Bühler offers
two validation packages with different service scopes.
Both validation packages include a process validation
based on microbiological indicators, for which non-pa-
tho genic comparison microorganisms, known as surro-
gates, are used. The advantage over measuring physi-
cal parameters is that the degree of inactivation can be
determined directly. The validation then focuses on the
critical process parameters that achieve the required log
reduction.
lo
g 1
0 re
du
cti
on
elements of the validation
proValidBasic
proValidpremium
Consulting
Initial check: Check on whether the system can be validated in principle • •
Definition of the requirements and creation of a validation plan • •
Definition of the surrogate as microbiological indicator • •
Check on premises and process steps – •
initial tests
Initial validation trials: Worst-case tests to define validation parameters – •
Comparative analysis of the pathogenic germ with a surrogate in the laboratory – •
Validation
Acceptance evaluation/IQ: check on equipment installation – •
Function evaluation/OQ: functional check of equipment under conditions at place of installation
– •
Inoculation of the product sample with the previously defined surrogate and evaluation of this • •
Performance check/PQ: check on performance based on microbiological indicators • •
documentation
Validation report • •
• = Included in package, – = Not included
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
6
5
4
3
2
1
0
Figure 2: Inactivation rates per product sample
Bühler Barth GmbH
Daimlerstr. 6
D-71691 Freiberg am Neckar, Germany
T +49 7141 705-0
F +49 7141 705-100
www.buhlergroup.com/cocoa-and-nuts