flavor and nutrition stability in aseptic beverage processing

ASEPTIC LIQUID REFRESHMENTS –FLAVOR AND NUTRITION STABILITY ASEPTI – PACK 2010, CHICAGO.

Sports drinks Energy drinksFortified drinks Teas and Coffee

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Respect for the nature of the product

Reduction of “stressful” processes for the product (high exposure to temperature) that modify (sensory) color, taste and destroy nutrients and active principles.

SELL MORE – SELL BETTER

In reality, the fundamental factor that convinces most beverage companies that Aseptic is the right technology for their business is the (sustainable) commercial advantage deriving from a generally improved product. Aseptic technology as a matter of fact, offers the possibility of extending and controlling with precision the characteristics of the product that adds benefit and value to the consumer.

Inside Aseptic, GEA - Procomac

REPRESENTATIVE PRODUCT TYPES Fruits, Vegetables or

Dairy Milk Yogurt / Buttermilk Soy based 100 %Juices Concentrates Flavored Fortified

With Particulates Drinks

Engineering characteristics

Low or High Viscosity

Newtonian or Non – Newtonian

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LAW DEMANDS – CONSUMER WANTS

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Regulatory Requirement

Log reduction – MicroCanning / Retort

Product / container / cap

Hot fill Product >> Container and

Cap

Aseptic>>>

Sterile “hardest” particle

Consumer Requirement

Sensory Flavor Aroma

Nutrition Vitamins Essential Amino

acids Essential lipids

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MATHEMATICAL MODELING – EXECUTIVE OVERVIEW …………………………...for no human inquiry can be called science unless it pursues its path through mathematical exposition and demonstration,..........................................................Leonardo da Vinci

…………………....interaction between matter and energy is the ultimate reality………………………....???

E = m c2 >>> Conservation of mass/ energy > Material and Energy balance Initial condition / boundary condition

Word model: Apple, Ripe, Green, Three Green apple > ripe green apple > Three ripe green apples

I have three ripe green apples, I have three ripe green apples? I have three green ripe apples, I have three ripe green apples !

Symbolic model – can you spot one? If m is changed to m/2, E >> E/2

What green is to apples, m and c are to E!A “representation”

CONCEPT TO

COMMERCIALIZATION

8

ASEPTIC PROCESS -

Thaw

Blend

Heat

Cool

FillHold

PROCESS MODELING 101-

Mass and Energy are conserved

Material and Energy balance over element

Extend to system boundary > BC

Should be true from beginning > IC to End of time ? ……….......> infinity

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Ashok Dhruv, LLC - ashok_dhruv@comcast.net

COMPREHENSIVE APPLICATION OF - CHEMISTRY, FOOD SCIENCE, PRODUCT AND PROCESS DEVELOPMENT

Application of Basic Heat & Momentum transfer principles with Kinetics: Microbial, Enzymatic, Bio-Chemistry Mathematical models, IT Tools

Results in Objective Measures of Safety, Sensory, Shelf life, Nutrition Yield, Capacity, Quality

Capital and Global Cost Optimization

15

Water and energy

conservation in food processingJuly 2007

Cooling water spray

Heat transfer rate = q

“q” = U * A * (T - t) =

T

t

A

M G C PGT G

= m W C PW t W

Bottle of Gatorade

HOW A BOTTLE : Heats or COOLS

WHY DO YOU LOOSE FLAVOR OR NUTRITION?

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WHY DO YOU LOOSE FLAVOR OR NUTRITION?

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Physical / ChemicalProcess

Equipment

MathematicalConstitutive Eqn.

Ini. & Boundary cond.

Physical laws

Laws of Math

ProductBy-productsWaste streams

Raw materials Utilities Labor

Physical propertiesOperating conditionsAssumptions

Microbial log cycle reductionEnzyme deactivation. amountObjective sensory quality

Physical form

Mathematical form

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tc x0 y0 z0 p q r

Axp

Ayq

Azr

Bx tc p By tc q Bz tc r Cx x0 p Cy y0 q Cz z0 r

Tf tc x0 y0 z0 ta Ti ta tc x0 y0 z0 460 R

T Avg t fwall T fi t fwall e

4 U cal D min

d2 f C Pf

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0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 530

50

70

90

110

130

150

170

190

210Time to heat fruit piece in puree

Time of heating, minutes

Tem

pera

ture

, de

g F 130

175

T f tc 0 0 0 R1

T f tcx

in

y

in

z

in

R

1

TAvgF tc R1

3 5

tc

GENERIC APPROACH

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Ashok Dhruv, LLC

- ashok_dhruv@comcast.net

Viscosity model for Pear puree based on data from Dr.Steffe's book, page 370.

nm1

3 Estimate from data @ 26.6 C or 80 F

T :Temperature in degrees Fm: Moisture content in %km T m( ) e( )

6.243.118 10

3T 460

11.357 1 m( )

Pa s

nm

PPTm T m km T m( ) nm 1

PPTm 80 m6

s

18.422poise

VELOCITY PROFILE INSIDE A (HOLD) TUBE

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RESIDENCE TIME IN THE (HOLD) TUBE

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LogRedClB 1.044 10 4LogRedClB log e 10( ) LncitocfClB

CitoCfClB 1.00024CitoCfClB eLncitocfClB

LncitocfClB 2.403 10 4LncitocfClB0

min

KClB

d min

KClB 7( ) 3.534 10 3 min 1KClB K0ClB e

EClB

Rgas TAvg ( ) 460 R

TAvg 8( ) 196.762RExp 101.745ExpEClB

Rgas TAvg 15( ) 460 R

EClB

Rgas3.73 104 KEClB 3.73 104 Rgas KK0ClB 2 1040 s 1

Calculation of Microbial kill :

FTPast 37.228sFTPast0

min

10

TAvg ( ) TRef

z

d min

4.359minz 10 RTRef 180 R

Calculation of extent of Pasteurization :

HTST, UHT, ESL OR ASEPTIC PROCESSING – FLAVOR AND NUTRITION IMPACTS

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Flavor and Aroma

Volatile or Non ?To keep or reject?Sources

Comes from F & V

Added in formulation

Generated in process

Nutrition

VitaminsMineralsEssential Amino

AcidsProteins

Essential LipidsFats and Oils

LOSS OF VOLATILES: RELATIVE VOLATILITY AND PASTEURIZATION TEMPERATURE 0

4/1

2/2

3

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RELATIVE VOLATILITY OF AROMA COMPOUNDS IN FRUITS AND VEGETABLES

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APPLICATION: LOSS OF FRUIT VOLATILES IN FLASH COOLING

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COOKED FLAVOR AND GUAVA BEVERAGE

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, For a guava beverage the treatment time required for a sensory panel to detect change in cooked flavor was 119 seconds at 90 C, 184 s at 87.5 C and 248 s at 85 C. (JFS, 70, 2005, S149 – S-152).

Process Temperature, C Time, seconds Cooked flavor detection time, seconds

Conventional 63 1,800 0.333 HTST 72 15 0.0073 Cooked Guava Flavor 85 248 Cooked Guava Flavor 87.5 184 UT - Pasteurization 90 .5 0.00119136 Cooked Guava Flavor 90 119 UT - Pasteurization 100 .0.01 0.000066 UHT - Sterilization 138 2 0.2664

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What is the impact on my Nutrition? Let us see what happens to Thiamine, Vitamin B1.The following are equivalent “pasteurization” processes for milk.

Process Temperature, C Time, seconds Thiamin loss, % Nutrient loss reduction, %

Conventional 63 1,800 0.333 0 HTST 72 15 0.0073 97 UT - Pasteurization 90 .5 0.00136 99.6 UT - Pasteurization 100 .0.01 0.000066 99.98 UHT - Sterilization 138 2 0.2664 20

> 90 % reduction in Nutrient loss, does it matter at these low loss values?

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0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10

10

20

30

40

50

60

70Temp, Firmness and PG Conc. of peaches

Time, minutes

Tem

p F,

Firm

ness

, N, P

G C

once

ntar

tion

70

0

T MW ( )

R

Firm ( )

PG ( ) 100

10

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0 1 2 3 4 50

20

40

60

80

100

120

140

160

180

200Peroxidase activity drop in heat period

Time in heating MC tube, minutes

Act

ivit

y ra

tio,

; A

vg T

emp

deg

F

200

00

Ratio POD ( )

%

T Avg ( )

R

50

min

HOT FILL VS ASEPTIC PROCESS – BEVERAGES

HOT FILL VS ASEPTIC PROCESS – BEVERAGES

Ashok Dhruv, LLC - ashok_dhruv@comcast.net

VALUE GENERATION - INCREASED REVENUES - GROWTH Elasticity of demand

Price, AdvertisingCompetition

Product features and benefitsSensory perceptions - Product Appeal

Nutrition - Satiating, HealthShelf life - Convenience

Satisfy Consumer

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