- a major non-profit food research institution and the best partner for food industry in Taiwan Technology, Service and Partnership (Founded 1967) Main Campus in Hsinchu Chiayi Site located at Chiayi industry Innovation and Research Center, MOEA (Inaugurated in 2011) Major Research Field: Food machinery Food Packaging (Inaugurated in 2005) Southern Taiwan Service Center Major Research Field: Food process engineering Pilot plant for functional drinks Health foods commercialization Tainan Site located at Southern Taiwan Innovation and Research Park, MOEA
Outline 1. Innovation in Thermal Processing A. Ohmic heating B. Microwave assisted fry-drying C. Microwave assisted hot air drying 2. Innovation in Aseptic Packaging Systems A. Validation of aseptic systems B. Design of aseptic filler for vial C. Development of container and cap sterilization 3
Innovation in Thermal Processing Ohmic Heating Microwave Heating Microwave Assisted Fry-Drying System Frying Drying Microwave Assisted Hot Air Drying System Product Development Process & System Development
The basic principle of electrical resistance heating (Ohmic heating) is to make the food part of an electric circuit through which current flows. Heat generation occurs within the medium due to its inherent electrical resistance. As heat is generated rather than transferred, there is no theoretical limit on the temperature which can be reached. AC Power Supply electrical lead Insulating Layer Electrode Foodstuff Electrode Container Yang et al., Methods and equipment for Ohmic heating, TW 483738.
Problems in Early Development of Ohmic Heating Electrolysis and product contamination Use of unsuitable electrode material Difficulty in ensuring good contact between electrodes and products of complex surface geometry Arcing and scorching of the electrodes Absence of crust texture which may be required for foods such as meat or bread
The Practice of Ohmic Heating(1/2) For safety operation, the system was designed with a maximum current density of 4,000 Am -2 and with an applied field strength value in the region of 18.3Vcm -1. The process is more energy efficient than microwave heating, because nearly all of the electrical energy goes into the food as heat. Whereas microwave heating requires no physical contact, however, ohmic heating requires electrodes in good contact with the food.
The Practice of Ohmic Heating(2/2) Research at FIRDI had developed a method of heating semi-solid foods, e.g. rice cakes or minced fish gel, with ohmic heating where the food material remain paste-like during heating process to maintain good contact with electrodes. The process when applied 110V or 220V alternative current (60Hz) to the food material (0.6kg) will generate heat to raise temperature of 50 o C within 4 min., while compared to conventional steam cooking a time of 60 minutes is required.
Ohmic Heating Technology Milestone of System Development 2009 Liu et al., Application of Ohmic heating for thermal coagulation of food heating, TW M379335. Victor Hildebrand, Electric conduction cooking package, US 5055312 A. Chan et al., Equipment of thermal coagulation of food heating, TW 479467. 2001 2012 1987 1999 1980 APV Baker Yang et al., Methods and equipment for Ohmic heating, TW 483738.
Ohmic Heating Technology Patents Granted Methods and equipment for Ohmic heating Country Patent type Patent number Taiwan TW 153775 Japan Invention JP 3194733 China ZL 99119735.6 Application of Ohmic heating for thermal coagulation of food heating Country Patent type Patent number Taiwan TW M379335 Japan JP 3158648 Utility Model ZL 2009 2 China 0218513.4 Equipment of thermal coagulation of food heating Country Patent type Patent number Taiwan TW 187690 Utility Model China ZL 01232463.9 Application of the container of Ohmic heating and its cooking apparatus Country Patent type Patent number Taiwan TW M432374 China Utility Model ZL2012200885 35.5
Development of Recipes (1) The Traditional Taiwanese food The new concept of rice cakes steamed radish cake The steamed radish cake is a common snack food in Taiwan, and it represents a symbol of good luck so that. It takes much more time to cook in tradition; however, the new technology can shorten processing time effectively. Steamed rice paste with Kimchi Steamed Rice cake with Cantonese curing meat It offers new cooking experiences applied with mixed rice paste and various sauces combined with different food ingredient to develop new products and to reduce cooking time.
Development of Recipes (2) The Western cuisine The Terrine Garlic spicy chicken risotto Vegetarian Terrine Chicken Terrine Risotto choose natural garlic and onion mixed with cream sauce and cheese. It only takes 6 minutes to heat and to generate the effects of gratin by the addition of butter and cheese in the formulation without using of oven. Vegetarian terrine and chicken terrine are easy to make and has a rich nutrients. It adapts to be as appetizers or as a side-dish.
Development of Recipes (3) Desserts The recipe development of ohmic heating cuisine Cheese cake The making of aromatic cheese cake will need 50 minutes traditionally, and the time can be shortened to 8 minutes with the application of ohmic heating. To date, 5 series of 30 cuisine have developed. Designed different formula and procedures for household cooking, food service and catering. Can Help to establish unique recipes for any application.
Prototype of Domestic Ohmic Cooker Ohmic
Design plus Technology Ohmic Heating Microwave Heating Industrial Dechnology Electrode AC Power Supply electrical lead Insulating Layer Foodstuff Container Electrode Industrial Catering IDEA Catering Reddot Domestic Recipe Development Domestic 15
Microwave assisted frying mechanisms: microwave could interact with molecules directly and generate heat inside while frying more uniform and faster frying Features: Crispy and juicy fried foods in any size 1. Improve frying efficiency of 2.5 times the deep-frying. 2. Reduced 30% to 50% of the frying time. 3. More than 30% savings of oil furnace. 4. Uniform and high quality frying, e.g. 1 ~ 100 fried chicken are the same quality. 5. No more need to defrost frozen, fried with the machine directly within the meat tender and juicy in any size. 16
Microwave Assisted Deep-Frying System Fast Heating Reduce 60-75% of frying time, increase 20-30% of yield Healthy Reduce 50% of oil uptake. Delicious Product remain juicy but with crispy crust texture Energy Saving Reduce 30% of electric power as compared to conventional frying. 17
Dough Mixing Compound Pressing Steam Cooking Noodle Formation Fry Drying or Hot-air Drying Cooling Rolling Molding Packaging 18
Process to Be Improved Frying-Dry Instant Noodles Shortcomings: Oil uptake during frying Oil cost dependent Target to reduce oil uptake from 24% down to 17%. Non-Fry Instant Noodles Shortcomings: take long time (c.a. 90 min.) to dry noodles from 40% down to below 10% of moisture content Uneven drying Target to shorten drying time within 30 min. 19
Magnetron Microwave distributor Circulator Pilot Scale Continuous Microwave-assisted Fryer Circular frame Chock plane Waveguide Power supply & Controller Slot Waveguide and Multimode Cavity Type Microwave Assisted Fryer Capacity (pics/hr.) 2,700 Conveyor Stainless steel Temperature Uniformity (± o C) 5 Drying Mold Round noodles Repressive Apparatus recycle Heating Source Natural gas, electricity Heating Efficiency (%) 80 Microwave Power Output 1 ~ 4kW Microwave Leakage Values Frying Time (sec) 50 ~ 90 (mw/cm 2 ) 320
Process of Microwave-assisted Hot-air Dryer Combined Conventional Fryer for Instant Noodles Microwave-assisted Hot-air Dryer Microwave-assisted Hot-air Dryer + Conventional Fryer Conventional Fryer Pre-dried by Microwave Assisted Hot-air Dryer Microwave Power Ratio: 1.3-1.4 W/g Hot-Air Temperature: 90 o C for 5.5min Final Fry-Drying Oil Temperature: 155-165 o C Frying Time: 60 80 sec. RESULT Oil uptake: 17% 21
Design of Microwave Assisted Hot-air Dryer for Non-Fry Instant Noodles Hot air Drying Section 90m Feeding Section Out Section Steam Heat exchanger Section Microwave assisted hot air section 18m Hot air Drying Section 90m Microwave assisted hot air section 18m 22
Design of Standing Wave Heating Cavity and Hot-air Module Hot air input Microwave input Hot air input Microwave input Material Feeding 23
The Assembly of Microwave Assisted Hot-air Dryer 20kW, 915 MHz Microwave Input 20kW, 915MHz Microwave Input 20kW, 915MHz Microwave Input Product Direction Re-circulated Reflective Microwave 24
The Assembly of Microwave Assisted Hot-air Dryer for Commercial Trial Microwave Power: 3 x 20kW, 915MHz Capacity: 6,500 pc/hr. Drying Time: 30 min. 25
Aseptic Processing & Packaging UHT Process Container Sterilization Sterility Validation Hygienic Design & Validation Design & Validation of Container Sterilization Design of Filling Valve Sterility Validation of Aseptic Systems Product Development Process & System Development
Aseptic processing pilot plant @ CIIC Provide total solutions and near commercial technologies to the industry. Provide processors to test formulation and process during new product development. Small batch production for market test. Testing new process machinery. Validation of Storage stability Evaluation of Thermal Degradation Formulation, Mixing, Blending Sterilization Process Aseptic Packaging Evaluation of Deaeroation Dispersion, Emulsion Stability 27
Layout of Aseptic Particulate Processing and Combibloc Test Filling Platform EB LAB Particulate beverage processing and filling area UHT sterilizer Deaerating tank -20 Freezer 4 Refrigerator Homogenizer Aseptic surge tank Filling and packing area CIP Unit Water treatment area Formulation and quality control room Semi-product blending area Package material storage area
Process authority of thermal process evaluation in Taiwan and US FDA. Target products Low-acid canned foods Aseptic packaged products Scheduled Process System Validation U.S. FDA/FCE-SID Filing and register service Challenge test of Aseptic Safety FDA LACF 2541C 29 Validation of Aseptic
Nutraceutical drinks Nutrition Formula Acid or low-acid drinks Nutraceutical Drinks Acidify products Store at room temp. Maintain nutritional quality of product Acid products UHT Aseptic filling Low-acid products Hot filling Preservative addition Autoclaved 30
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Study of Food Container Sterilization Technology Container Sterilization Mechanism Design Deoxidize Cap Develop & Verify technologies Critical Parts Design Validation Technology Hygienic Design Microbiological Validation 1. Design and Development of Pulsed-light Sterilization 2. Develop Sterilization Process Parameters 3. Reduce the use of sterilizing agents 4. Development of Pulsedlight Activated Deoxidize Cap 32
Light Intensity (J/cm 2 ) Photomas Zone Lamp Zone Effective Zone 440 mm 31 mm Design of Cap Sterilization Testing Platform Irradiation Distance 40mm Light Intensity Distribution Photomask Pulsed-Light Lamp Quartz Cap 14 Pcs. Photo mask Forward direction +70 mm 0 mm Cap Rail -70 mm Irradiation Distance (mm) Cap Rail 33
Combined Hydrogen Peroxide and Pulsed-light Container and Cap Sterilization System Hydrogen- Peroxide 25% Heating Atomizer Air Second Heating Air Container & Cap In Hydrogen- Peroxide Sterilization Hot Air Drying Pulsed-light Container & Cap Out 34
Hydrogen Peroxide Atomizer Validation of Hydrogen Peroxide and Pulsed-light Cap Sterilization Mechanical Design Assembly Light Intensity Distribution Before After Atomized Hydrogen Peroxide light spectrum Distribution 35
e-beam Sterilizer for Container 36
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