juming tang, ph.d. professor of food engineering department of biological systems engineering
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915 MHz Single Mode Microwave Technology for Food Safety - from development to commercialization Key elements: vision, team/competence, passion/persistence, delivery/resources . Juming Tang, Ph.D. Professor of Food Engineering Department of Biological Systems Engineering - PowerPoint PPT PresentationTRANSCRIPT
915 MHz Single Mode Microwave Technology for Food Safety - from development to
commercialization
Key elements: vision, team/competence, passion/persistence, delivery/resources
Juming Tang, Ph.D.Professor of Food Engineering
Department of Biological Systems EngineeringWashington State University, Pullman WA
Microwaveheating.wsu.edu
Challenges in Developing New Technologies
Conceptdevelopment
Pilot-plant testingEquipment
ProductMicrobial
Regulatory acceptanceScale-up &industrial
implementation
Lengthy canning processes (30-100 min at 121C) cause losses in texture, appearance
Two frequencies allocated by the US Federal Communications Commission (FCC) for industrial heating
applications
2,450+50 MHz (0.12 m) - domestic microwave ovens
- industrial heating systems
915+13 MHz (0.33 m)- industrial heating systems
5
WSU Microwave Consortium I (2001-2010)- initiated with support from US DoD Dual Use Science and Technology
(DUST) Program
Graphic Packaging
NFPA
Rexam
Kraft
Hormel FCINatick
WSUOBS
Masterfoods
Pilot-scale systems
Computer simulation & mock-up units
Process development
• Industrial implementation
915 MHz Single-Mode Microwave Sterilization Technology
Microbial studies
• Scaling-upRegulatory acceptance
Dr. Frank Liu, Project Engineer Computer simulation and experimental validation
Development of pilot-scale protocols
Dr.Frank Liu, Project engineer Engineering design and manufacturing
Measurement of food properties
29.5°C
91.6°C
40
60
80
AR01
WSU 2nd generation system - four single mode cavities, 40 kW max MW power, received FDA acceptance for first filing on Oct.
2009
Microwave assisted thermal processing system (MATS)
waveguidecavity
0 phase shift
Change of Shear Force in Pink Salmon Fillet Heated at 121˚C
30
50
70
90
110
130
150
170
0 20 40 60 80 100 120 140
Cooking time (min)
Shea
r for
ce (N
)
Chicken and dumplings in 8 oz pouches (Print-pack) processed
with WSU Microwave Sterilization System, produced for sensory studies at US Army
Natick Soldier Center
• Chicken and dumplings in 8 oz foil pouches by retort (control) for the sensory
studies
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On Oct. 7, 2009, we received first FDA approval
Visiting FDA Low Acid Food Team in DC, 2004
First FDA filing: mashed potato in 10 oz trays -2008
Engineers conducting heat distribution and heat penetration studies
NFPA strain 3679 (P.A.. 3679) as the surrogate.
D121C should be 3-4 times that of C. botulinum spores, so that we use smaller number of surrogate to validate 12 log reduction in C. botulinum spore populations
Microbial validation of food safetyTargeted microorganism – C. botulinum spores
Prepare samples for inoculated pack studies with PA 3679 spores
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On Oct. 7, 2009, we received first FDA approval
Second FDA filing: salmon fillets in sauce in 8 oz pouches - 2009
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Salmon filet, skinless and boneless
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8-oz Printpack pouch
Developing data to seek FDA approval for non-homogeneous foods
• Positioning Ellab sensor tip at the
location determined by heating pattern
Processing real food in MW system
• Data retrieval from Ellab temperature sensor
• Temperature profile overlay with MW system data
Inoculating PA 3679 spores to the cold spot in salmon fillets
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Incubation in Walk-in Incubator (~ 36°C)
• Positive pouches
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Process accepted on Dec. 15, 2010
Submitter: Kenneth Lum
PINK SALMON, SKINLESS AND BONELESS IN ALFREDO SAUCE
(processing method) MICROWAVE ASSISTED HEATING (finished pH) 6.3
(sterilizer) OTHER SEE COMMENTS; Microwave Assisted Prototype
(heating medium) WATER IMMERSION (process source)
Source Attached Document09/22/2010 -- LETTER
SCSI, subsidiary of Seafood Products Association, formerly NFPA NW Laboratory
Process Source -- MW Filing Rec 9-22-10SG.pdfNotes: Process Recommendation letter
(date filed) 12/15/2010
• Submitter: Kenneth Lum
Summary of Major Milestones• July, 01 Formed WSU Microwave Consortium I• July, 02 Developed first 915 MHz single mode pilot
system (10 kW)• Oct., 06 Received US patent for 915 MHz single
mode microwave sterilization system design • Aug.,07 Developed a second generation
system – semi-continuous system (40 kW)• Oct., 09 Received FDA acceptance for MW
sterilization of mashed potato in 10 oz trays• Nov. 10 Formed MW Consortium II, focusing on
commercialization• Dec. 10 Received FDA acceptance for MW
sterilization of salmon fillets in sauce in 8 oz pouches
• 2011 Filed petition to USDA FSIS for processing foods containing >2% egg, poultry and meats
WSU licensed exclusive rights for commercialization of this technology to Food Safety Chain (FSC) corporation (Maple Valley, WA). Formed MW Consortium II (Nov. 11, 2010).
Commercialization
WSU• Education• Research
• Computer simulation models• Processing filing protocols
Structure of WSU MW Consortium II
Food Chain Safety, Co.• Engineering design• Industrial systems• Supports/servicing
AmeriQual• 1st industrial system• Plant tests support
• Market testing
MW Consortium II11 Companies &SPA
WSU MW Consortium II sub-teams
1. Regulatory (preparing data and filing documents to FDA and USDA FSIS, guiding engineering team in system design)
2. Engineering (industrial system design, technology implementation)
3. Product development (formulations and processes for best products -unique to the technology)
4. Education and training (short-courses and hands-on training for industrial personnel)
5. Packaging (new packaging development, regulatory concerns)
Example: activities of product development sub-team at WSU
Packaging sub-team update at a concern meeting in Evansville, IN, May 2011
Industrial members in a microwave sterilization short course
Thank You
Microwaveheating.wsu.edu