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
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® ?
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 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
2. Process descriptionDS : Decontamination System (2/5)
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
2. Process descriptionDS : Decontamination System (3/5)
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
2. Process descriptionDS : Decontamination System (4/5)
Some of the products treated
Mushrooms Pistachios Cinnamon sticks
Rice flour
2. Process descriptionDS : Decontamination System (5/5)
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
2. Process descriptionConfiguration adjusted to your building layout
DS 1 CS 1
Incoming product Incoming product Area Area
Separation wall““clean” area clean” area
2. Process descriptionConfiguration adjusted to your building layout
DS 1
CS 1
Separation Wall (Recommended)
““clean” area clean” area
Bypass
2. Process descriptionExample of configurations
STERISTEP 75
6,600 lbs/h unit for almonds & pistachios
2. Process descriptionExample of configurations
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)
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 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
4. Products treatedOther products
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
4. Products treatedOther products
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
4. Products treatedOther products
PEPPERMINT LEAVES
SAGE
RAW TEST 1
TPC 390 000 2 100
Enterobacteriaceae 1 200 <10
Yeast <10 <10
Molds <40 <10
RAW TEST 1
TPC 460 000 140
Enterobacteriaceae 29 000 <10
Yeast <100 <10
Molds 18 000 <10
4. Products treatedOther products
PISTACHIOS
RAW TEST 1
TPC 320 000 <40
Enterobacteriaceae 210 <10
Yeast <10 <10
Molds <40 <40
RAW TEST 2
TPC 530 000 <10
Enterobacteriaceae 80 <10
Yeast <10 <10
Molds 2 400 <40
WALNUTS
4. Products treatedOther products
ALMONDS
RAW TEST 2
TPC 330 000 120
Enterobacteriaceae 70 <10
Yeast <10 <10
Molds 59 000 <10
4. Products treatedOther products
CINNAMON POWDER CHILI POWDER
RAW TEST 1
TPC 840 000 380
Enterobacteriaceae 27 000 <10
Yeast 260 <10
Molds <10 <10
RAW TEST 1
TPC 660 000 46 000
Enterobacteriaceae 2 100 <10
Yeast <10 <10
Molds 150 <10
4. Products treatedOther products
BLUE POPPY SEEDS
RAW TEST 1
TPC 570 000 1 800
Enterobacteriaceae 3 600 <10
Yeast <10 <10
Molds <10 <10
RAW TEST 1
TPC 27 000 000 26 000
Enterobacteriaceae 1 600 <10
Yeast <10 <10
Molds 7 500 <10
WHITE PEPPER
4. Products treatedOther products
CORIANDER SEEDS
RAW TEST 2
TPC 2 200 000 850
Enterobacteriaceae 1 400 <10
Yeast <10 <10
Molds 100 000 <10
RAW TEST 1
TPC 3 800 000 10 000
Enterobacteriaceae 160 <10
Yeast <10 <10
Molds <10 <10
GINGER SLICES
4. Products treatedOther products
TURMERIC POWDER
RAW TEST 2
TPC 3 000 000 9 300
Enterobacteriaceae 160 000 <10
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. 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…