R & D Systems for Food Processing

R & D Systems for Food Processing

R&D food processing

R&D food processing

 

   Ellab R & D system is designed to develop the retort processing technology based on the  type of products (rice, gravy, meat, fruits, vegetables, soups etc), type of packing material (cans, pouches, bottles, trays etc) and type of retorts (steam type, steam/air, water immersion, water cascading, rotary, shaking retort etc). 
 The picture A & B show similar RTE Food processed under two different types of retort processing conditions.
Which one do you want to make ?
Why to overcook and lose the good qualities of the Food ? 
Get the Maximum Out of it by optimizing the retort processing. 

Ready to Eat Foods processed seperately

Ready to Eat Foods processed seperately

 

The aim of the processor should be to optimize the processing, achieve the sterilization effect within shortest time without affecting the required qualities of the food. He should find methods to avoid over exposure of the products to the high temperature and longer duration of time. The processed products should be equal to or better than its fresh equivalence in all respects including the color, taste, texture, vitamin and nutritional values etc.    
ELLAB EVal Flex R & D system helps you to gather the following information 

Product 

1. Fo value of the products – make sure that the products are sterilized properly during the processing 

2. Cook Value  (Co value) of the products – make sure that the products are cooked properly during the processing 

3. Cooking Damage during the pre processing

4. Pressure developed by the products during processing5. Come up time, Holding  Time, Sterilization Time, Cooling Time, Total Process Time etc.  

Retort 

1. Heat Distribution data inside the retort  – to estimate the cold spots inside the retort

2. Heat Penetration data inside the retort – to estimate the time and temperature to achieve the required sterilization effect to all the processed products located at the cold spots.

3. Pressure profile inside the retort

 Packing Materials ( Retort Pouches)

 1.  The expansion / deformation / deflection / stretching occurring on the pouches during the retort  processing which helps the processor to establish the required over pressure profile for each type of products.

 2. The pressure developed inside the sealed pouches and pressure developed inside the retort. This data will be very helpful to define the pre-processing procedure as well as over pressure controls.  

 

How to Produce Shelf Stable Retort Processed Foods with safety, high quality and shelf life and Protect the Flexible Pouches from damage during retort processing?

We offer Ellab EVal Flex System Package which includes the modules for monitoring the Food Sterilization values ( Fo values), Cook Values ( Co values), Pressure Inside the Retort, Pressure developed by the products inside the sealed pouches, Deflection or deformation or stretching occurring on the pouches during processing etc.

The System has three modules

 1. Temperature Module : 

Thermocouple Probes

Thermocouple Probes

This module is used to establish the correct retort process technology based on the Sterilization values (Fo value) and Cook Value ( Co value).

Here you can define the required time / temperature profile, required Fo values, Co values, come up time, holding time, sterilization time, cooling time etc and process procedure for maintaining proper sterilization to the products.

2. Pressure Module :     

Preseaure measurement inside sealed containers

Preseaure measurement inside sealed containers

                  This module helps the processor to estimate the pressure developed in side the retort and pressure developed by the products inside the sealed pouches. The pressure developed by each type of product can be estimated separately which helps the processor to develop pre-processing techniques to minimize the development of the gases during the processing.

  3. Deflection Module :  

    

 

Deflection / Deformation / stretching monitoring system

Deflection / Deformation / stretching monitoring system

  The Deflection Module online monitors very accurately the expansion / deformation / deflection / stretching  occurring (ballooning effect) on the sample pouches during the retort processing.

The processor should find out the amount of expansion occurring on each type of products during retort processing. This should be done separately for each type of products and each type of pouches ( aluminium foiled and microwavable separately). The processor can establish the safe expansion limit of each type of containers.

 If the containers expand beyond the limit, then there could be bursting of pouches, weakening of the seal area or losing of the barrier properties. So it is very important to establish the expansion limits of each types of products processed in each type of containers. The over pressure should be applied based on this expansion limits.

 

 

Ellab R & D System Software

Ellab R & D System Software

The above graph from Ellab Eval Flex System shows the Time, Temperature, Pressure and Deflection Profiles of a product packed in retort pouch processed in steam / air retort.

The black color graph shows the Retort Temperature, Green Color shows the Product’s core temperature, the Red color shows the pressure inside the retort (over pressure) and the Blue color shows the deformation / stretching of the sample pouch during processing.

From the graph, it is shown that the sample pouch started to stretch / expand only when the product temperature reached 120 deg C. Then there was a sudden stretching up of the pouches. This was due to the fact that the products inside the pouches generated additional gas or the moisture might have been converted into steam which might have generated extra pressure.  So proper over pressure should be applied at that time and make the stretching within the limits to save the pouches.During the processing, do not allow the pouches to expand more than the required limits. If it expands more than the limits, then either pouches burst, or the seals will be loosed or the barrier properties will be damaged and in turn affects the shelf life and fails in the market.

From the above study, the processor gets the valuable data about the characteristics of the product including the following :

1  Required Food Sterilization value for the products to make the products sterilize properly

2  Required Cook value for the products to make proper cooking.

3   Pressure developed by the products during retort processing

4  Over Pressure inside the retort

5  Stretching occurring on the pouches during the retort processing. 

The above mentioned data are very important to define the specific process technology and process procedure for each and every type of products. Once it is defined and established, then it can be transferred into the production floor and then operator should follow the same process whenever they process similar products.