Technology for Food Safety from development to commercialization Key elements vision teamcompetence passionpersistence deliveryresources Juming Tang PhD Professor of Food Engineering ID: 581875
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915 MHz Single Mode Microwave Technology for Food Safety - from development to commercializationKey elements: vision, team/competence, passion/persistence, delivery/resources
Juming Tang, Ph.D.
Professor of Food Engineering
Department of Biological Systems Engineering
Washington State University, Pullman WA
Microwaveheating.wsu.eduSlide2
Challenges in Developing New TechnologiesConceptdevelopmentPilot-plant testingEquipmentProductMicrobial
Regulatory acceptance
Scale-up &
industrial
implementationSlide3
Lengthy canning processes (30-100 min at 121C) cause losses in texture, appearanceSlide4
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
Slide5
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
FCI
Natick
WSU
OBS
MasterfoodsSlide6
Pilot-scale systemsComputer simulation & mock-up units
Process development
Industrial implementation
915 MHz Single-Mode Microwave Sterilization Technology
Microbial studies
Scaling-up
Regulatory acceptanceSlide7
Dr. Frank Liu, Project EngineerComputer simulation and experimental validationDevelopment of pilot-scale protocols
Dr.Frank Liu, Project engineer
Engineering design and manufacturing
Measurement of food propertiesSlide8
WSU 2nd generation system - four single mode cavities, 40 kW max MW power, received FDA acceptance for first filing on Oct. 2009Slide9
Microwave assisted thermal processing system (MATS)Slide10
waveguide
cavity
0 phase shiftSlide11
Change of Shear Force in Pink Salmon Fillet Heated at 121˚C Slide12
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 studiesSlide13
13On Oct. 7, 2009, we received first FDA approval
Visiting FDA Low Acid Food Team in DC, 2004Slide14
First FDA filing: mashed potato in 10 oz trays -2008Slide15
Engineers conducting heat distribution and heat penetration studiesSlide16
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 populationsMicrobial validation of food safetyTargeted microorganism – C. botulinum sporesSlide17
Prepare samples for inoculated pack studies with PA 3679 sporesSlide18
18On Oct. 7, 2009, we received first FDA approvalSlide19
Second FDA filing: salmon fillets in sauce in 8 oz pouches - 2009Slide20
20Salmon filet, skinless and bonelessSlide21
218-oz Printpack pouchSlide22
Developing data to seek FDA approval for non-homogeneous foods Positioning Ellab sensor tip at the location determined by heating patternProcessing real food in MW system
Data retrieval from Ellab temperature sensor
Temperature profile overlay with MW system dataSlide23
Inoculating PA 3679 spores to the cold spot in salmon fillets Slide24
24Incubation in Walk-in Incubator (~ 36°C)Positive pouchesSlide25Slide26
26Process accepted on Dec. 15, 2010Submitter: 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 Document
09/22/2010 -- LETTER
SCSI, subsidiary of Seafood Products Association, formerly NFPA NW Laboratory
Process Source --
MW Filing Rec 9-22-10SG.pdf
Notes: Process Recommendation letter
(date filed)
12/15/2010
Submitter:
Kenneth LumSlide27
Summary of Major MilestonesJuly, 01 Formed WSU Microwave Consortium IJuly, 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 traysNov. 10 Formed MW Consortium II, focusing on commercializationDec. 10 Received FDA acceptance for MW sterilization of salmon fillets in sauce in 8 oz pouches2011 Filed petition to USDA FSIS for processing foods containing >2% egg, poultry and meats
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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).
CommercializationSlide29
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 systemPlant tests support
Market testing
MW Consortium II
11 Companies &SPASlide30
WSU MW Consortium II sub-teamsRegulatory (preparing data and filing documents to FDA and USDA FSIS, guiding engineering team in system design)Engineering (industrial system design, technology implementation)Product development (formulations and processes for best products -unique to the technology)Education and training (short-courses and hands-on training for industrial personnel)Packaging (new packaging development, regulatory concerns)Slide31
Example: activities of product development sub-team at WSUSlide32
Packaging sub-team update at a concern meeting in Evansville, IN, May 2011 Slide33
Industrial members in a microwave sterilization short courseSlide34
Thank You
Microwaveheating.wsu.edu