GEA Convenience-Food Technologies Process Expo, Chicago IL, November 2011 Henrik Thrysoe Defrosting Technology.
Post on 17-Dec-2015
213 Views
Preview:
Transcript
GEA Convenience-Food Technologies
Process Expo, Chicago IL, November 2011
Henrik Thrysoe
Defrosting Technology
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA - Defrosting
A controlled process for fast thawing of meat by means of low
pressure steam and indirect heating to reduce defrosting time while
improving food safety, logistics, , shelf life and increasing yield.
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Defrosting Application Drivers
1) Food Safety
2) Raw material availability and on-time delivery performance
3) Costs savings
4) Yield gains
5) Environmental (sewage)
6) Consistency in raw material quality
7) Labor involvement
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Defrosting/Tempering Solutions in the Market
1) Defrosting in open vats with running water.• Long defrosting time.• Loss of meat juice (2 – 8% yield loss).• Food safety issues.• Drain / sewer issues.
2) Defrosting cabinets with hot air fans.• Long defrosting time.• Loss of meat juice (3 – 6 % yield loss).• Uneven defrosting temperatures.• Low guarantee of food safety.
3) Microwave tunnels with radio frequency waves.• Only suitable for tempering (max. -10 C).• Difficult to defrost uniformly (above 00 C) - product heat spots.• Loss of meat juice (yield loss).
4) Steam & Indirect heating defrosting.• Short, automatically controlled process.• High food safety and traceability.• Low cost of ownership (no yield loss, low operating costs).• High end product quality (bacteria killing process).
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Many Challenges with existing process
1) Defrosting rooms / cabinets with hot air fans.• Double handling • Spacers• Labor heavy• Pallet hot surface – cold centers• Protein drip on floor• Rewrapping to prevent meat falling on floor• Microbial issues• 48 hours to 72 hours process time
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrosting Process
Part 1: Steam Step
Part 1: Steam Step
Part 2: Tempering Step
Part 2: Tempering Step
Part 3: Massage Step
Part 3: Massage Step
Steam supply
Heating
Cooling
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Vacuum impact on steam temperature
212 º F 91 º F
= 1.00 bar = 0.05 bar(0 % vacuum) ( 95 % vacuum)
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Water at 100 oC / 212 o F contains 418 kJ/kg energy
Steam at 100 oC / 212 o F contains 2.675 kJ/kg energy
Steam at 33 oC contains 2.562 kJ/kg energy
Energy content of cold dry steam
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Safety Working Process Zone
65 mbar
50 mbar
37,5o C 98 F
33o C90 F
Product temperature development during processProduct temperature development during process
12,8o C 13,6o C
= Possible steam temperature variation
= Possible steam pressure variation
= Product temperature peaks during process
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
PLC based defrosting - Total Process Control
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Temperatures During Defrosting Process
The graphs show that the product surface temperatures not to exceed 55° F / 12,7°C during the defrosting process, which is well below temperatures where there may be a risk of heat (protein) denaturation and of starting bacterial growth (above 800 F/280C).
The entire process is under 50 mb vacuum (no / micro oxygen atmosphere)
End product temperature typically: 33°F / +0.5 C to 37°F / 2.7°C
Riblets defrosting
-5
0
5
10
15
20
25
30
35
40
45
50
1 2 3 4 5 6 7 8
Program steps
Te
mp
in F
are
nh
eit
Surface
Core
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrosting Range - Poultry
• Whole Chicken
• Chicken / Turkey Wings
• Chicken / Turkey Legs
• Chicken / Turkey Chunks
• Chicken / Turkey Drumsticks
• Chicken / Turkey Breast fillets
• Turkey Tenders **
** Turkey Tenders in > 5kg / 11 lb blocks is not applicable
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrosting Range - Pork
• Pork Loins
• Pork Bellies
• Pork Middles
• Pork Inside/outside and knuckle
• Pork Riblets
• Pork Flanks
• Pork Necks
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrosting Range - Beef
• Beef Knuckles
• Beef Hearts
• Beef Liver
• Beef Tongue
• Beef – Various cuts
• Beef Top Rounds
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Typical Defrosting Times
• Defrosting time is subject to block size, start temperature, accepted pick-up from steam and end-product specification.
Chicken fillet IQF: 4-5 hours.
Chicken /Turkey fillets in blocks: 6-8 hours.
Chicken / Turkey wings IQF: 4-5 hours.
Chicken / Turkey wings in blocks: 6-8 hours.
Turkey thighs/breasts in blocks: 7-8 hours.
Pork or beef in blocks: 6-9 hours.
• The defrosting time is calculated on basis of max. Filling degree of tumbler (36-38% = about 8,300 lbs / 3,800 kg batch in ScanMidi10).
• The above-mentioned capacities exclude loading and unloading.
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Chicken / Turkey Defrosting with Consistent Results
Relevancy:No damage to product / meat fibers
Yield 103%
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrosting Results
Pork Shank after defrosting Out of the Tumbler
3% steam added
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrosting with Consistent Results
Pork Insides and Outsides – 3% added steam – Yield = 103
No Damage !No Meat dust !
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Beef Skirts for Fajita
No damage to meat
structure
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Turkey Thigh Defrosting
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Pork bellies for Bacon
Defrosting high fat products (45% - 55%)
• Product: pork bellies,IQF frozen,
• Result• Process time: 6 1/2 hours• Steam addition: 3%• Start temperature: -6,8 °C
End temperature: +4 °C
• Product evaluation:Good, no fat smear on surface
CFS TemperingDefroster Room(left) (right)
End products
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Block sizes for defrosting
Chicken Breast2 kg blocks
300 x 250 x 50 mm
Chicken Breast20 kg blocks
540 x 350 x 50 mm
Turkey Breast10 kg blocks
540 x 340 x 50 mm
Pork Riblets10 kg blocks
470 x 280 x 100 mm
Turkey Breast15 kg blocks
550 x 350 x 80 mm
Chicken Inner Wings15 kg blocks
500 x 350 x 100 mm
Turkey Breast - US18 kg blocks
470 x 460 x 100 mm
Deboned Turkey Legs19 kg blocks
490 x 320 x 130 mm
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Block size range:
2 – 35 kg
Block sizes for defrosting
Pork Loins20 kg blocks
550 x 350 x 100 mm
Beef cuts (1-10 kg)25 kg blocks
580 x 370 x 130 mm
Pork Silverside25 kg blocks
540 x 340 x 150 mm
Pork Ham Cuts27 kg blocks
580 x 380 x 140 mm
Pork Necks31-35 kg blocks
560 x 340 x 220 mm(average)
Raw materialfor sliced ham35 kg blocks
560 x 360 x 220 mm
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrost Installation
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrost Installation GEA Defrost Installation
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrost In Production
Turkey Breast
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Simple Block Feeding / Deboxing
Deboxing and
Frozen block feeding
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Multi Purpose Functionality
Tumbling during the
day - Defrosting during the
night !!
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Defrosting Sanitation / Food Safety
Total visibility to food zone – No hidden corners or sharp edges !
Relevancy:Easy USDA inspection
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Beef Pork TurkeyWeekly Requirement 100,000 100,000 100,000Fresh WIP Costs $/lbFrozen WIP Costs $/lb $2.60 $2.20 $1.50Difference
Fresh Meat Shrink (Yield %)Current Defrost Yield 94.00% 95.00% 95.00%CFS Defrost Yield 96.50% 100.00% 100.00%Difference 2.50% 5.00% 5.00%
Yielded Costs $/lb (Fresh Meat)Yielded Costs $/lb (Current Defrosted) $2.766 $2.316 $1.579Yielded Costs $/lb (CFS Defrosted) $2.694 $2.200 $1.500Difference $0.072 $0.116 $0.079
Batch Size (lb) 8,000 8,000 8,000Days/Week 5 5 5Batches/Week 13 13 13Weekly/Volume 104,000 104,000 104,000Weeks/Year 50 50 50Annual Volume (lb) 5,200,000 5,200,000 5,200,000Total Annual Volume (lb) 15,600,000
Annual Savings - Relative to Fresh MeatAnnual Savings - Relative to Current Defrost$372,616 $602,105 $410,526Current Defrosting Cost - $0.035/lb $182,000 $182,000 $182,000
Cost of Ownership ($92,674) ($92,674) ($92,674)Interest - 8.2% ($66,693) ($66,693) ($66,693)Net Savings $395,248 $624,738 $433,159Total Net Savings $1,453,145Capital Costs $2,440,000ROI 59.6%Payback (years) 1.68
Relative to: Existing Air Defrosting
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Beef Pork TurkeyWeekly Requirement 100,000 100,000 100,000Fresh WIP Costs $/lb $2.90 $2.40 $1.75Frozen WIP Costs $/lb $2.60 $2.20 $1.55Difference $0.30 $0.20 $0.20
Fresh Meat Shrink (Yield %) 99.50% 99.50% 99.50%CFS Defrost Yield 96.50% 100.00% 100.00%Difference 3.00% 0.50% 0.50%
Yielded Costs $/lb (Fresh Meat) $2.915 $2.412 $1.759Yielded Costs $/lb (Current Defrosted)Yielded Costs $/lb (CFS Defrosted) $2.694 $2.200 $1.550Difference $0.220 $0.212 $0.209
Batch Size (lb) 8,000 8,000 8,000Days/Week 5 5 5Batches/Week 13 13 13Weekly/Volume 104,000 104,000 104,000Weeks/Year 50 50 50Annual Volume (lb) 5,200,000 5,200,000 5,200,000Total Annual Volume (lb) 15,600,000
Annual Savings - Relative to Fresh Meat $1,145,416 $1,102,714 $1,085,729
Cost of Ownership ($92,674) ($92,674) ($92,674)Interest - 8.2% ($66,693) ($66,693) ($66,693)Net Savings $986,049 $943,346 $926,361Total Net Savings $2,855,755Capital Costs $2,440,000ROI 117.0%Payback (years) 0.85
Relative to: Fresh Meat
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Independent Lab Quality Analysis
• ”Silliker BV” Institute for Food Safety & Quality Solutionwas asked to test, fresh material versus defrosted material
• Samples of Chicken Breast were performed according to the form: ”Routine Product Evaluation” from The National Food Laboratory
• Products were evaluated on:Chemical, Microbial and Sensoryaccording to the 5-point scale
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Chemical Results
SAMPLE FRESH DEFROSTED
Fat 1.7% 1.5%
Salt 0.83% 0.77%
Moisture 71.5% 71.6%
Protein 25.0% 25.5%
The chemical compounds meet specifications, no difference between the fresh or defrosted meat.
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Sensory Results
Sample Initial After Hold
3 hours (65C)
Initial After Hold
3 hours (65C)
Initial After Hold
Sweet 1 1 1 1 1 0
Salty 5 5 4.5 4.5 4.5 5
Sour 0 0 0 0 0 0
Bitter 0 0 0 0 0 0
Fresh Meat Defrosted Meat Specifications
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Microbial Results
SAMPLE FRESH DEFROSTED
Total Plate Count/g
(max. 25,000)
240 360
Total Coliforms/g
(max. 100)
<10 <10
The microbial compounds meet specifications – no difference between the two tests.
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Product Attribute Summary
Microbial.
• Microbe numbers constant or reduced relative to frozen.
• Safer than water defrosting.
Color/appearance:
• No difference.
Aroma:
• No difference.
Flavor:
• No difference.
Texture:
• Only small difference – Defrosted meat lightly more tender compared to fresh meat.
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Sensorial Results - Conclusion
The Sensory evaluation shows only differences where all aspects meet
specifications, also after hold on 65°C
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Microbiological results from defrosted Riblets.
Comparing frozen vs. Defrosted surface samples.
CFS defrosting process is a safe bacteriological process that CFS defrosting process is a safe bacteriological process that contributed to a bacterial reduction in the order of up to log 2 .contributed to a bacterial reduction in the order of up to log 2 .
Bacterial Reduction During CFS Defrosting
0
50,000
100,000
150,000
200,000
250,000
300,000
350,000
400,000
Surface,Frozen
Surface,Defrosted
Bac
teri
a P
er G
ram
Microbial Investigation 1
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Microbial Investigation 2
Microbiological results from defrosted Pork Muscles. Comparing surface microbes on CFS vs. air defrosted pork.
CFS defrosting process is a safe bacteriological process that CFS defrosting process is a safe bacteriological process that compares favourably to air defrosted meat.compares favourably to air defrosted meat.
Surface Microbes After Defrosting
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000
CFS CFS Air Defrost
CF
U's
CFS
CFS
Air Defrost
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Microbial development – Test
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
Microbial development = Zero
GEA Convenience-Food TechnologiesHenrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100
GEA Convenience-Food Technologies - Microbial Safety Statement
Validation on microbial safety at customers and by local authorities has shown that GEA defrosting process is considered safe and even better compared to existing approved defrosting processes.
CFS process has no microbial growth !!!
top related