RapidPak Technology

Flash PasteurizationFlash Pasteurization

PackagingSolutions

FlashRv 07-08

Flash Pasteurization

Flash module

Project: Integrate a steam surface pasteurization (Flash) chamber

Flash module

Project: Integrate a steam surface pasteurization (Flash) chamber into a hotdog packaging machine

Provides an effective kill step immediately prior to package sealing:p y p p g g• Destroys bacteria, such as Listeria monocytogenes on product surface• No negative effect on quality• Easily integrates into existing plant layout

PackagingSolutions

FlashRv 07-08

y g g p y

Co-Development Project

From research to commercialization…

• Thermal processing• Pasteurization

• Packaging machine design• Bio-safety Class II Laboratory

• Original concept, research, and patents• Research facilities and prototypes (ERRC)• Process engineering,

PackagingSolutions

FlashRv 07-08

Process engineering,

Defining the Problem• Shortcoming of Current Hotdog System

Manufacture Cook Chill-Peel-Convey-Collate-Load Seal Package

Kill Potentialcontamination

• Add a final Flash kill stepCook Chilling to Packaging Flash pasteurization Seal

Kill Post-lethality killHigh risk zone

Flash Concept: Surface pasteurize at the last possible moment before packaging

PackagingSolutions

FlashRv 07-08

Machine Configuration

Film Travel Direction

DischargeTop film Bottom film

g

Cut Seal LoadFlash Heat Treatment

Form Fill Preheat Film

Flash cycle time = 1.5 to 2.0 seconds

Treatment Film

yMachine cycle rate = 3 seconds / index

PackagingSolutions

FlashRv 07-08

Flash Pasteurization HeadSteam Inlets

Flash Head

Exhaust Flash Head Exhaust Flash Head

Steam Injection -- Flash ModuleProduct

• Inject pressurized steam• Maximum contact on most difficult area – ends • 1 5 second cycle kills 2 to 3 logs of Lm

PackagingSolutions

FlashRv 07-08

1.5 second cycle kills 2 to 3 logs of Lm

Flash Pasteurization Head

Steam Inlet

St

Flash Equipment – Top View

SteamOutlet

PackagingSolutions

FlashRv 07-08

Development – Historical to CurrentFlash Delivers:• Food Safety Protection

– > 2.0 log reduction signal and double layer0 og educ o s g a a d doub e aye– < 1.0 log growth at refrigerated temperatures– > 2.0 log reduction of spoilage bacteria, resulting in increased shelf life,

on average of 20% to 30% increase– Alternative 1 when combined with antimicrobials

• Product– No significant difference on basic tastes between flash and non-flashed product

No significant difference on aromatics between flash and non flashed product– No significant difference on aromatics between flash and non-flashed product– No significant difference on aftertastes between flash and non-flashed product– No increase in measurable purge

• MachineMachine– Use ordinary film / no increase in leakers– No loss of cycle rate– Minimal utility usage (250 lbs/hr steam, 2 gpm water)

PackagingSolutions

FlashRv 07-08

Development - Results

• All results confirmed in-house and by independent Deibel Labs• Full-scale signal and double-layer machines• Can use live Listeria to validate

Pathogen Testing LabPathogen Testing Lab

PackagingSolutions

FlashRv 07-08

Actual Lab Results – Single LayerNumber SAMPLE CFU Dilution

1 Control 1 4 6 6.602062 Control 2 5 6 6 698972 Control 2 5 6 6.698973 Control 3 24 5 6.3802114 Sample 1 5 3 3.698975 Sample 2 4 3 3 602065 Sample 2 4 3 3.602066 Sample 3 1 3 3.00000

Log Kill Log Kill 3.1

56789

10

g

012345

1 2 3 4 5 6 7 8 9 10 11 12 13 14Control Flashed Product

PackagingSolutions

FlashRv 07-08

Storage Studies – Double Layer

* Inhibit Growth Over Refrigerated Shelf Life

10Log Growth -0.5Initial Log Kill 2.26 9 Weeks Refrigerated Storage

Samples Taken Weekly

6789

10

12345

01 2 3 4 5 6 7 8 9 10 11 12 13 14Control Week 1 Week 2 Week 3 Week 4 Week 6 Week 9

PackagingSolutions

FlashRv 07-08

Results to Date

Flash Pasteurization Process

Results Summary

Hot DogsLog reduction of Listeria monocytogenes

(inoculation = 106)Single Layer 2 0 3 028 mm, 6 hot dogs / pack 2.0 – 3.0

Double Layer23 mm, 8 hot dogs / pack 2.0 – 3.0

Triple Layer22mm, 12 hot dogs / pack

2.0 - 3.0

PackagingSolutions

FlashRv 07-08

Flash with Antimicrobial Injector

Antimicrobial Antimicrobial Injectors

• Flash and antimicrobials work together to increase log killFlash and antimicrobials work together to increase log kill• Surface apply steam and antimicrobials • Cost savings – pull antimicrobials out of the product• One control system to control Flash and antimicrobial (log data)

PackagingSolutions

FlashRv 07-08

One control system to control Flash and antimicrobial (log data)

Double-Layer Flash Machine

PackagingSolutions

FlashRv 07-08

Single-Layer Machine

PackagingSolutions

FlashRv 07-08

RapidPak Technology

Flash PasteurizationFlash Pasteurization

PackagingSolutions

FlashRv 07-08

END