Cold Pasteurization technique

1. By :Mangal Dev Bariwal

5. Juices

6. ICE Tea variant

7. Pasteurisation Techniques
Conventional Pasteurization
• Pasteurization temp 950C/15 sec
• 25% of electricity*, 25% reduction
of carbon footprint*
Replacing By Cold Pasteurization
• HPP High pressure Processing
• ASEPTORAY UV Technique

8. The Challenge- Thermal Pasteurization
Microorganism in the Juice and Ice tea are normally
inactivated by pasteurization.
High Energy
Consumption
Minor effect on
Spores
(TAB)
Change
Preservation flavour, aroma , and natural taste
Protection of natural colour, nutrient value Antioxidants

9. TEMP PROFILE OF ICE TEA BEVERAGE
Process: 30~75℃→140℃(4S、10S、15S)→85~92℃→40℃→(10-20℃)return
Hot Fill pasteurisation process for industrialized still /Ice tea drinks 2012*

10. 117.7 billion gallons
Global annual consumption of industrialized still drinks 2012*
Most of it are pasteurized by heat, as it being done since 1864.
* Neves et al, The orange juice business, World consumption of fruit juices,
nectars, and still drinks 2012,p 119.

11. Thermal Pasteurization Alternatives
Ultra Filtration
• High energy consumption
• High cost
• Limited to clear liquids
Pulsed Electric Fields
• Requires an expensive aseptic filler.
• Does not work on spores.
• Still not widely available or accepted.
High Pressure Processing (HPP)
• Require highly cost equipment
• Require alignment of the entire process.

12. What is HPP?
Hiperbaric©2013
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13. Industrial HPP Equipment
Hiperbaric©2013
Hiperbaric.com

14. What is HPP?
Hiperbaric©2013
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15. What is HPP?
HPP
• Instantaneous transmission
• No pressure gradients
• Identical in every point
• Cold temperature
HEAT
• Slow transmission
• Temperature gradients
• Not uniform
• Temperature damages
organoleptic quality
Hiperbaric©2013
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16. HPP by Food Sector
HPP Global Production by 20124: + 700 000 000 Kg
Hiperbaric©2013
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17. HPP Products and Applications
Dairy, JUICE and ICE tea
• Shelf life extension
• Pathogen Destruction
• Functional, bioactive products
Hiperbaric©2013
Hiperbaric.com

18. HPP Products and Applications
VEGETABLE •Shelf life extension and increased safety• Maintenance of flavor and nutrition
BASED • Reduction of PPO in avocado products
• Reduction of starch retrogradation in rice.
Country Products
Japan Fruit jams and fruit and vegetable sauces
Japan Pre-cooked & hypoallergenic rice
USA Avocado products : guacamole, sauces
Italy Fruit jams
USA Avocado products
Mexico Avocado products
Mexico Avocado products
Mexico Avocado products
Canada Apple products : jam and sauce
USA Tofu
Spain RTE vegetable meals
USA Tomato sauces
Australia Fruit pures & coulis
Mexico Avocado products
Peru Avocado products
Chile Avocado products
Peru Avocado products
N. Zeland Avocado products
China Fruit jams
Mexico Avocado products
España Avocado products
Hiperbaric©2013 Hiperbaric.com

19. HPP Products and Applications
JUICES • Shelf life, safety, brand protection
• Respecting flavor and nutrition
• Premium, cold pressed, never heated
Country Product
France Citrus juices
Portugal Apple & citrus blended apple juice
Italy Fruit and vegetable juices
Czech Republic Broccoli & apple, beetroot, carrot juices
USA Juices and superfood smoothies
Spain Smoothies & juices
Australia Smoothies & juices
Northern Ireland Wheatgrass & Broccoli sprout juices
The Netherlands Smoothies & Juices
USA Citrus juices
Korea Juices and smoothies
Brazil Zumos
Italia Smoothies
UK Apple juices
USA Coconut water
Korea Citrus juices
Hiperbaric©2013
Hiperbaric.com

20. Industrial HPP for the Juice Industry
HPP Juice Brands
HPP:
Fruit juices
Smoothies
100
50
0
8 20
2008
100+
50+
Vegetable juices 2010
2012 2014 HPP Juice Brands
Hiperbaric©2013
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21. Case 1, Blueprint - the Cleanse, Detox category
Raw fruit & vegetal juices, cleanses
Hiperbaric©2013
Hiperbaric.com

22. Case 2, Evolution Fresh Starbucks - Cold Pressed Fruit
Evolution Fresh (USA)
4 x Hiperbaric 420 for juices
Hiperbaric.com

23. Case 3, Suja Juice - the Explosive Growth
Suja (USA)
Hiperbaric 420 for juices
Whole Foods
Supplier of the Year 2014
Hiperbaric.com

24. Case 4, The UK Cold Pressed Juice Market
Hiperbaric©2013
Hiperbaric.com

25. Case 5, the Coconut Water
Hiperbari
Hiperbaric.com

26. Recognisition and Legitimisation
Tumeric ALIVE
BEST FUNCTIONAL BEVERAGE
Harmless Harvest
PRODUCT OF THE YEAR
WTRMLN WTR
BEST JUICE Tio Gazpacho
BEST SMOOTHIE OR MEAL REPLACEMENT
WTRMLN WTR
BEST PACKAGING DESIGN
Hiperbaric©2013 Hiperbaric.com

27. AseptoRay System

28. T
I
e

29. So, what’s new ?
Standards UV system can not penetrate turbid liquids*
Milk : >8000 NTU
Turbid orange juice: 4000 NTU
Clear Apple: 1200 NTU
Water turbidity: 1 NTU
* Ultraviolet Light in Food Technology Principles and
Applications, Koutchma et al. 2009

30. Mechanism of Action
Utilizes optimal wavelength (254nm)
in varying exposures to deactivate
contaminants and pathogens while
preserving nutrients and organoleptic
properties
Transfers UV energy directly and
selectively to microbial DNA
Limits secondary effects on liquids

31. Applications and Markets
Juice Wine Water Milk Soy Liquid
Products Sugar
Whey

32. Juices

33. ICE Tea variant

34. The Market
$16 Billion market representing the 9.6
billion liter of juice is sold in the US
annually.
$ 8.8 Billion is 100%
fruit juice.
Per capita in the US this
numbers represent 52.5$
and 30.3 L per year.

35. Juice Pasteurization
Juices normally undergo two pasteurization processes
First pasteurization to become commercially sterile .
Second pasteurization, prior to filling to avoid
recontamination.
But ͙thermal treatments can not destroy spoilage spores.

36. Fruit Juice/ Ice tea Beverages RTS : Challenges and what is TAB?
TAB Is a general name for “Thermo Acidopihilic Bacteria”.
Although it is not a safety hazard, it’s presence in consumer products has
been widely reported to cause flavor spoilage problems.
33-35% of juice manufactures had TAB associated problems1,2,3.
TAB Spoilage
1. Engineering Aspects of Thermal Food Processing. Editor: Ricardo Simpson , 2009.
2. Walker M, Phillips CA (2008) Alicyclobacillus acidoterrestris: an increasing threat to the fruit juice industry? International Journal of
Food Science and Technology 43: 250-260. doi: 10.1111/j.1365-2621.2006.01427.x
3. oward I (2006) ACB Workshop October 2005-Review. European Quality Control System (EQCS) Workshop 2006. Available:

37. AseptoRay System
Pilot Results

38. Results: Overview
Liquid
Sugar
All Bacteria were eliminated.
5 log reduction HACCAP requirement was achieved in all
liquids.
No organoleptic change in tested liquids (Milk, Apple juice).
Milk Juice

39. Results : Liquid Sugar log reduction
Liquid
8.0
6.0
4.0
2.0
0.0
-2.0
-4.0
-6.0
E.coli
9
E.coli
12Bx 50 Bx
Series1
10
E.coli
Series2
Sugar
6.3
6.6
B. Atr.
Spores
70 Bx 50 Bx

40. Water
Water log reduction
6
Water
5
4
3
4.5
5.0
2
1
0
E.coli
-1
-2
Yeasts B. Atr. Spores
Before After
4.5
2.3
AAT Spores

41. Apple Juice /Fruit Punched Ice tea
7
6
5
4
3
2
1
0
-1
-2
-3
-4
Clear Apple log reduction
4.8
5.6
AAT Spores Bacillus atrophaeus
spores
Before After
Juice
8.9
E.coli

42. Orange Juice
Juice
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
-1.0
-2.0
Clear Orange log reduction
6.2
3.3
AAT Spores E.coli Bacillus atrophaeus
spores
Before After
Turbid Orange log reduction
6.0
5.0
4.0
3.0
5.7
2.0
1.0 1.7
0.0
AAT Spores
Before After
5.2
E.coli

43. Energy consumption
In Conjunction To Pasteurization
• Reducing the pasteurization temp
from 950C/15 sec to 730C/15 sec
• 25% of electricity*, 25% reduction
of carbon footprint*
Replacing Pasteurization
• 4 times less than pasteurization
* Juice pasteurization - Can we do better?, Tetra Pack white paper, Nov 2014

44. Comparison to other cold pasteurization systems
Pasteurization cost per liter
0.35
$0.0800
$0.0700
$0.0600
0.0500
0.0109
0.0043
0.0003
AseptoRay Pulsed Electric High Pressure Pasteurization Pasteurization
Field (PEF) Processing (hot filling) (Cold Filling)
(HPP)
$0.0500
$0.0400
$0.0300
$0.0200
$0.0100
$-

45. Energy Saving
Assumptions:
5000 L/Hr.
Pasteurization temp= 950C
1 kWh heat = 1.8 kg steam, 1 kg
steam = 0.07$
Regeneration: 85% (cold filling)

46. Business Model
Two alternative business models:
Go-to-market Strategy
Pay Per Use
Partnership model
Pay Per
Use allowing system
leasing, and pay per
liter of product.
Capital +service model
Capital +
Service
Buying capital equipment,
and service agreement for
UV lamps and maintenance.

47. System Advantages
Capability to inactivate Thermophilic Acidophilic Bacteria (TAB)
Reduces production and energy costs
Prolongs shelf life
Retains natural ingredients and taste

48. IP
The company filed a patent in Israel #230375
• Patent application priority date 8.1.14
• Second application will be applied in coming months.
IP Protected at USA,EU, China etc.
Applied for PCT at 9.1.15,

49. • Organic Sugar Cane Sugar no pesticide and no fertilizers and
organic manure used for farming
• Brown sugar From Molasses sugar contains Minerals and rich in
flavors
• Honey Purest and filtered is basically combination of fructose
and Glucose and water
• Use of natural Sweetener stevia
• Use of fruit sugar, Apple syrup
•
Another very Important Increasing trend in Ice tea

50. MANGL DEV BARIWAL
FOUNDER,PROCAESS DESIGN INC
Business Partner
Mobile: +91 8000892200
email: mdb.jkmbevregaes@gmail.com

51. Formulation and Ingredients

52. We provide Engineering Solutions and Project consultancy and feasibility study
Beverages recipe development and formulation
Beverages Sample Preparation
Ingredient Sourcing
Contract Packaging and Manufacturing Management
Food & Beverage Plant Project Management
Brewery Plant Design and Construction Management
Micro brewery, pub brewery
Dairy plants and Milk based Beverages Plant

53. Our services include:
Design calculation, Process/ Utility Equipment sizing
Beverages Process Tanks Design
Plant design and Equipment Design
Process Controls and Automations support
Procurement support for Plant and Machineries
Installation and Commissioning Support

54. Beverages Plant construction Management
Pressure Vessels of different capacities.
CE Marked Vessels and Filter Housings.
Skids with Pump and Piping Components.
Clean room Piping Projects as built and tested.
Process and Storage Vessels.
MANUFACTURING OF: