Mike Billig

High Pressure Processing
Manufacturing Costs and
Facility Design Considerations
for Commercial HPP Manufacturing
May
y 6, 2010
0 0
Introduction
z
Mike Billig – VP Marketing
Marketing, Gridpath
Solutions Inc.
z Gridpath Solutions is the NA Partner of
NC Hyperbaric
z 14 Y
Years as VP M
Marketing
k ti and
dS
Sales,
l
AmeriQual Foods
USDA Contract Manufacturer
z 3-NC Hyperbaric Wave 600 300L Machines
z
Agenda
g
z
Commercial Food Applications
pp
z HPP Manufacturing Options
z Facility Requirements
z Support Equipment
z Packaging Compatibility and the Effects
on Manufacturing Capacity and Costs
z Operational and Economic
Considerations
Commercial applications in the world:
HPP commercial products
Meat products
•
•
•
Destruction of pathogens : Listeria, Samonella, coliforms…
Shelf life increase
Stabilisation of p
preservative-free or low salt content p
products
Country
Spa in
USA
USA
USA
Spa in
Yea r
1998
2001
2001
2002
2002
Ita ly
Germa ny
Ja pa n
USA
Spa in
Ca na da
USA
USA
Ca na da
Ca na da
2003
2004
2004
2005
2005
2006
2006
2006
2008
2009
Products
Sliced cooked ha m a nd “ta pa s”
Sliced cooked products a nd proscuitto ha m
Poultry products
Pre cooked chicken a nd beef strips
PreSliced cooked chicken, ha m a nd turkey
products, Serra no cured ha m
Proscuitto ha m, sa la mi & pa ncetta
Cured a nd smoked sliced a nd diced ha m
N itrites- free ba con, sa usa ges a nd sliced mea t
Rea dy- to- ea t mea t ba sed products
Cured mea t products & Serra no ha m
Cured mea t products
Whole roa sted chicken
Sliced cooked turkey a nd chicken
Sliced deli mea ts
Sliced deli mea ts
HPP commercial products
Vegetable products
•
S iti ti and
Sanitisation
d shelf
h lf lif
life increase.
i
•
Preservation of colour, flavour and vitamins.
•
Reduction of PPO activity in avocado.
Reduction of the starch retrogradation of the rice.
•
Country
Japan
Japan
USA
Italy
USA
Mexico
Mexico
Mexico
Canada
USA
Spain
USA
Australia
Yea r
1990
1994
1997
2001
2002
2003
2003
2003
2003
2004
2005
2006
2008
Products
Fruit jams and fruit and vegetable sauces
Pre-cooked & hypoallergenic rice
Avocado products : guacamole, sauces
Fruit jams
Avocado products
Avocado products
Avocado products
Avocado products
Apple products : jam and sauce
Tofu
RTE vegetable meals
Tomato sauces
Fruit pures & coulis
Commercial HPP products
Juices and beverages
•
•
•
Sanitisation
S
iti ti and
d shelf
h lf lif
life increase
i
Destruction of pathogens microorganisms
Preservation of colour, flavour & vitamins
of freshly squeezed fruits
Country
Japan
Japan
F
France
Mexico
Lebanon
USA
Portugal
Italy
y
USA
Czech Republic
Northern Ireland
Australia
Year
1991
1992
1994
2000
2001
2001
2001
2001
2002
2004
2006
2008
Product
Grapefruit juice
Mandarin juice
Ci
Citrus
jjuices
i
Citrus juices and smoothies
Fruit juices
Apple juice
Apple & citrus blended apple juice
Fruit and vegetable
g
juices
j
O range juice, lemonade and smoothies
Broccoli & apple, beetroot, carrot juices
Smoothies
High quality juices
HPP Commercial Products
Shellfish and fish
•
•
•
•
Shelf life increase
Opening seafood shell at 200 to 350 MPa
Easy shellfish meat extraction
S iti ti (inactivation
Sanitization
(i
ti ti off Vibrio)
Vib i )
Country
USA
USA
USA
USA
USA
Canada
Canada
N Z
N.
Zealand
l d
Italy
USA
Canada
Japan
USA
Year
1999
2001
2001
2001
2003
2004
2004
2004
2004
2005
2006
2007
2008
Products
O ysters
O ysters
O ysters
O ysters
Crab
Seafood
Lobsters
M
Mussels
l shucking
h ki for
f meds
d
Desalted cod
Lobsters
Seafood
Shellfish
Crab
HPP Manufacturing
g Options
p
z
Contract Manufacturing
z
Advantages
Manage
g Capital
p
Risks
z Control Operational Costs
z Eliminate line capacity constraints and risks
z Shorten
Sh t time
ti
tto market
k t
z Ability to analyze market performance while
minimizing entry costs
z Take advantage of contract manufacturer’s
processing expertise In House Production
z
HPP Manufacturing
g Options
p
z
Contract Manufacturing
z
Disadvantages
Higher Manufacturing Cost
z Logistics Challenges
z Freight
g Costs
z Less Usable Shelf Life
z
HPP Manufacturing
g Options
p
z
In House Manufacturing
z
Advantages
Lower HPP Processing
g Costs
z No Logistics Challenges
z No Freight Costs
z Maximum
M i
Usable
U bl Sh
Shelf
lf Lif
Life
z
z
z
For Customers and Consumers
For Internal Production Efficiencies
Contract Processing Opportunities
z Proprietary Technology
z
HPP Manufacturing
g Options
p
z
In House Manufacturing
z
Disadvantages
z
Capital Investment Required
z
z
Equipment
Building
Longer Initial Time to Market
z New Technology
z
Facilityy Requirements
q
z
Processing Room Design
z
z
z
z
z
z
Inside Existing Facility
In New Facilityy
Room Environment
Ceiling Height Requirements Line Design and floor
S
Space
R
Requirements
i
t
Floor Requirements
Line Design and Floor Space Requirements
z
HPP Equipment Placement
Facilityy Requirements
q
z
Line Design and Floor Space Requirements
z
Support Equipment
z
z
z
z
z
Infeed systems
Unloading systems
Product drying
Pack
ac Off
O Stations
Stat o s
HPP Intensifier Placement
z
z
z
Floor level
Overhead
Separate room
Equipment Implementation
Example of Wave 6000/420
Equipment Implementation
Dual Line System with Support Equipment
Facilityy Requirements
q
z
Product control
z
Process Flow
z
z
Separation of Processed and Unprocessed
product
Documentation
Product Taken to Processing Line
z Process Documentation
z Post Process Tracking
z
High Pressure Processing Industrial Equipment
Throughput from 250 kg/hour
300 L
55 L
135 L
300 L T
Tandem
d
¾Up to 2.5 tons / hour:
Wave 6000/420
Infeed Conveyor
y
Carrier Unloader
Drying
y g System
y
Package
g Compatibility
p
y
z
z
z
Vacuum or gas fl
V
flush.
h
Semi-rigid trays.
Efficiency varies,
efficacy does not.
Package/Process
g
Functionality
y
z
z
z
z
15% Compressibility
Geometry/Memory
Film Contact
Label Application
Packaging
g g Effect on Economics
z
Package design and loading efficiencies
z Cycle Times
Gas flush
G
fl h
z Load density
z Product hold time at pressure
z
Typical
yp
Modifications
z
z
z
z
z
Gas reduction.
Shallow draw
draw.
Geometry change.
Label Application
Application.
Label Material
change.
change
Loading
g Efficiency
y
z
z
z
z
z
Product carriers cut
to suit application.
Utilization of space
impacts throughput.
Infeed Systems
Gas takes up space.
Gas is more
compressible.
Cycle
y
Time
Operational/Economic Considerations
z
Equipment
q p
decisions
z
HPP equipment
z
z
z
z
z
z
z
z
z
Horizontal for speed and process control
Equipment
q p
uptime
p
Number of Intensifiers
Intensifier Location
Support Equipment Integration
Production scheduling
Labor Rates
Utility Cost
Spare Parts cost
Operational
p
Considerations
z
z
Production Line Scheduling
Line Manning
z
z
z
z
One Person Loading Carriers
One Person Operating Machine and Documenting
the Process.
One Person Unloading Carriers
Support groups
z
Warehouse
z
z
Take Product HPP Line
Take Processed Product to Warehouse
Operational
p
Considerations
z
Support groups
z
Quality control
z
z
In Process and Post Process Product Evaluation
Maintenance
z
Maintain Machine Uptime
z
z
z
z
Change High Pressure Tubing
Change Intensifier Seals
Maintenance Cost $4.00 to $4.50 Per Cycle
Sanitation
z
z
Daily to Weekly
Based on Failure Frequency
Economic Considerations
z
Fixed OH Allocation
z Cycle Times/Package Design
z Total cost to HPP products $0
$0.03/lb
03/lb $0.04/lb plus fixed overhead allocation
Equipment cost amortized over 7 yrs
z Labor – production and maintenance
z Utilities
z Installation costs
z Facilities modification
z
Case Study
y
z
With Proper Planning
Planning, Equipment
Installation is Efficient
z Two NC Hyperbaric Wave 6000 300L
Installed and Operational in 7 days
z Production
P d ti C
Commenced
d on D
Day 10
Ran Continuously 24/7 for 5 months
z Equipment Uptime Over 95%
z
High Pressure Processing
Thank You
Michael Billig (812) 490-1241