MATTU UNIVERSITY

DEPARTMENT OF CHEMICAL ENGINEERING

Principles of Food Processing Technology (ChEg5135)
Equipment design aspects of Sterilization
By: Getachew Legesse

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 Sterilization
By : Me
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 Sterilization
Is the complete destruction or elimination of all viable organisms in/on
a food product being sterilized

Destroys yeasts, molds, vegetative bacteria, and spore formers, and

 allows the food processor to store and distribute the products at
ambient temperatures, with extended shelf life

Consists of four distinct stages

First, the product must be heated to a temperature of 110°C–
125°C to ensure sterilization
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 Sterilization
Consists of four distinct stages

Second, the product requires a few minutes to equilibrate,

since the surface will be hotter than the central portion of
the container causing a temperature gradient

The equilibration stage allows reduction in the temperature

gradient
Third, the product must be held at this temperature for a certain
period
to ensure a predetermined sterilization value designated
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by Fo value
 Sterilization
Consists of four distinct stages
Finally, the product has to be cooled mainly to arrest further heat
treatment and avoid over cooking

The basic principles of sterilization technology as applied to food

processing are:

the processed product must be free from microorganisms capable

of
producing food-poisoning toxins and
those microorganisms that cause food spoilage during
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product shelf life, until it is consumed
 Sterilization
The basic principles of sterilization technology as applied to food
processing are

clostridium botulinum spores are capable of growing in low-acid

(pH >4.6) products during storage and
hence must be heat treated to the equivalent of at least
121.1°C for 3 min
the processing conditions should be applied to the slowest-heating
point referred to as “cold point
when the slowest heating part is sterilized, by exposing it to
the required time–temperature profile, the rest of the product
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will be sterilizedPowered By: Mr. Getachew Legesse 6
 Sterilization
Methods of Sterilization

The food sterilization methods are divided into two categories:

 sterilization by heating (thermal processing) and sterilization
without heating (nonthermal processing)

Thermal processing is widely practiced in spite of some problems such

as that the process of heating might
reduce nutrition or deteriorate the quality of foods and that it is
ineffective against certain types of bacteria

Thermal processing is further divided into two categories as

in-container sterilization (bulk canning) and aseptic sterilization
(processing)
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 Sterilization
Bulk Canning
Processing Equipment
The two aims of in-container sterilisation are to
inactivate micro-organisms or enzymes and
produce the required sensory and nutritional properties by adequate
cooking of the product

The length of time required to sterilise a food is influenced by the

Heat resistance of micro-organisms or enzymes likely to be present

in the food and their numbers , concentration or activity;
Heating conditions; pH of the food
 size and shape of the container
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Powered By: Mr. Getachew physical state of the food 11
 Sterilization
Bulk Canning
Processing Equipment
The food processing industry produces a wide range of products in a
variety of containers

Retorting systems can be subdivided in several ways

1. Methods of Processing the Containers

The two types of retorts are batch retorts and continuous retorts
In batch systems, the retort is filled with product, closed, and then put
through a processing cycle

In continuous retorting systems, containers are continuously fed into

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 Sterilization
Bulk Canning
2. Methods of Heating Medium

The heating medium used in retort are: steam, steam/air, water, direct
flame or fluidized bed

Batch Retorts

Arranged either vertically or horizontally and are used for canned

products that are
placed into baskets immediately after seaming and
are then placed inside the retort shell

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 A= steam,
B =water
C= draining
D= venting
E =air
F= safety valve
and a pressure
relief valve

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Fig: Vertical batch retort
Fig: Horizontal batch retort
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Fig: Horizontal batch retort
 Sterilization
Batch Retorts

The operating cycle for this type of retort involves

loading the sealed containers into the retort,
bringing the retort up to a temperature of around 100°C, and

then allowing steam to pass through the container into the

atmosphere for sufficient time so that all air in the retort and in
between the cans is removed (venting)
before the retort is finally brought up to the operating
pressure and processing temperature
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 Sterilization
Batch Retorts

At the end of the processing time, the steam is turned off, and a
mixture of cooling water and air is introduced into the retort to cool the
cans

The purpose of the air is

to maintain the pressure in the retort following the condensation
of the residual steam after the initial introduction of cooling water

If this pressure is not maintained,

the containers may deform due to the pressure imbalances
between the internal pressure in the cans and the retort
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 Sterilization
Batch Retorts

As the temperature drops, the pressure in the retort may be controlled
and gradually reduced until atmospheric pressure is reached and water
can be allowed to flow through the retort,
cooling the cans to a temperature of about 40°C before they are
removed from the retort

Cans are removed from the retort at this temperature since this allows
the surface of the cans to dry rapidly by
evaporation thereby reducing the risk of leaker spoilage
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 Sterilization
Water Processing Retorts
This system is mainly used for the processing of glass jars

Raining water techniques require the use of either an external steam

injection system or system outside the direct environment of the retort

In the heat exchanger,

the cold water feeding the system is combined with the recycled
heating medium and
raised to the temperature required in the retort before being
admitted to the sterilization chamber through a spray arrangement
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 Sterilization
Water Processing Retorts
The containers are arranged to allow good contact between the hot
water heating medium and
the product either using spacer bars or distribution plates

It is imperative that a good distribution of the water occurs,

as otherwise stratification may occur and certain containers will
receive inadequate heating process

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 Sterilization
Water Processing Retorts

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Fig. Water processing retorts
 Sterilization
Crateless Retort Systems
They are usually 2.5 m high and 2 m in diameter with four to five
times greater capacity than the conventional three-basket vertical retort

The crateless retort is filled with water, which acts as a cushion for
cans filled from an automatic conveyor
 After loading the cans a hydraulic lid is closed

Steam is admitted through the top opening and this forces the water
out of the retort through the bottom opening

The hot water can be recycled in another retort or in the next cycle
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 Sterilization
Crateless Retort Systems

After processing, cooling water is let in through the bottom and is

discharged through overflow

After the cooling cycle, the retort is drained off and the bottom door is
partially opened and
the cans fall onto a shaker screen and are conveyed by a
belt to the unscrambler

It is critical that the steam condensate be removed from the bottom of
the crateless
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 Sterilization
Continuous Crateless Retort Systems

Working Process
1. Loading: The retort is filled with cushion water. Cans are loaded into
the retort with high speed conveyor.
2. Inletting: The cushion water is replaced by steam.
3. Venting and sterilizing: The cans are cooked at the preset pressure
and temperature.
4. Cooling: After cooking, the retort is once more filled with water, and
pressure cooling, if necessary, is performed.
5. Discharging: The cans proceed along the conveyor to the unscrambler
to be oriented. All conveyor transfers take place underwater.
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Fig. Continuous hydrostatic steriliser

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 Sterilization
Fluidized Bed Sterilization

The fluidized bed retort is a cooker in which sand or ceramic pellets

are used as the heat transfer medium

The medium is kept hot and fluid by a flame underneath and an air
stream
The particles behave much like boiling liquid

Cans move through the bed, meeting the same resistance as they would
if the medium were a thick liquid
receiving some abrasive
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effect from the particles
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 Sterilization
Fluidized Bed Sterilization

The main advantage of the system is the control of uniform

temperature

The process is continuous and several sizes may be sterilized

simultaneously

The main disadvantages are the possibility of burning and

 discoloration of the can surface and damage of the can seals

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 Sterilization
Aseptic Processing

Exhibit the greatest quality improvement over conventional canning

when viscous low-acid products are processed

Many products can be commercially sterilized prior to packaging by

continuous processes so that their
organoleptic and nutritional quality is not significantly affected

Products such as puddings, sauces, dips, and pastes are currently

aseptically processed
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Aseptic Processing
Sterilization
Aseptic packaging of foods is a process that enables products,
sterilized in bulk,
to be filled and sealed into sterile containers, under aseptic
conditions
There are two reasons for its use:
 (a) to enable containers to be used that are unsuitable for in-
package sterilization and
(b) to take advantage of HTST sterilization process,
which is thermally efficient and generally give rise to
products superior in quality compared with those processed at
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lower temperatures for longer times
 Sterilization
Aseptic Processing
Application of the aseptic process involves

(a) sterilization of the product,

(b) sterilization of the packaging material, and
(c) maintenance of the sterility during the filling and sealing
operations

The advantages of aseptic packaging of food products are

provides a higher quality product
A wide variety of packaging materials of different sizes and shapes
can be used
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 Sterilization
Aseptic Processing
The advantages of aseptic packaging of food products are
There is minimum handling of the containers during the
sterilization process
 provides a high surface area for efficient heat transfer

Disadvantages of aseptic packaging of food products are

large capital investment,

applicability to limited range of products
requirement of a relative homogenicity of the fluid, and
a need for sophisticated
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 Sterilization
Aseptic Processing
Sterilization Systems
The production of a sterile product by continuous-flow sterilization
involves
(a) heating the product by passing it through a suitable heat
exchanger to raise it to operating temperature,
(b) passing the product through a holding section for a
predetermined time to effect sterilization, and
(c) cooling it to a temperature of 35°C or less prior to aseptic filling

The heat exchange process is limited to liquids containing small

particles
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 Sterilization
Aseptic Processing
Sterilization Systems
For sterilization of large pieces, special equipment is required

The key components of the aseptic systems are the

timing or metering pump,
product heater,
holding tube,
cooler, and back-pressure valve
The type of aseptic processing equipment selected is dependent on the

 pH, the viscosity or consistency of the product, and

on whether it containsPowered
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particulate and their size
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 Sterilization
Steam Injection Sterilization

This is the most rapid method of heating the product and facilitating
the attainment of sterilization temperature within seconds

Steam injection injects steam into the product to be treated and steam
infusion adds the product to the steam

The steam must be high-quality culinary steam and not contain any
off-flavors that could change the taste of the product
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 Sterilization
Steam Injection Sterilization

 Steam at 965 kPa into a pre-heated liquid product in fine bubbles by a

steam injector & rapidly heats product to 150ºC

After a suitable holding period (e.g. 2.5 s) product is flash cooled in a

vacuum chamber to 70ºC;
condensed steam & volatiles in product are removed

Moisture content of product returns to approximately the same level

as raw material
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Steam Injection Sterilization
Advantages:
one of the fastest methods of heating & cooling; suitable for more
heat-sensitive foods
volatile removal is an advantage with some foods (e.g. milk).
Limitations:
only suitable for low-viscosity products
relatively poor control over processing conditions
requirement for potable steam, more expensive to produce than
normal processing steam
regeneration of energy is less than indirect systems
flexibility
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 Infusion Sterilization
A steam infusion chamber typically has multiple nozzles through
which the product is distributed and enters a steam atmosphere in a
number of jets without
hitting the wall of the vessel until it reaches the bottom cone

Combined with the rapid method of cooling by injection of the hot

product into a vacuum chamber and
 evaporation of an equivalent amount of water, a very high quality
product is obtained

The method is combined usually with heating and cooling in heat

exchangers
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Legesse 41
 Infusion Sterilization
Food is sprayed in a free-falling film into highpressure (450 kPa)
potable steam in a pressurised vessel

Heated to 142–146ºC in 0.3 s, held for 3 s in a holding tube before

flash cooling in a vacuum chamber to 65–70ºC

Heat from the flash cooling is used to pre-heat the feed material.

Advantages
over injection methods
liquid does not contact hotter surfaces & burningon is reduced.

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 Infusion Sterilization
Advantages

almost instantaneous heating of food to the temperature of steam

& very rapid cooling
high retention of sensory characteristics & nutritional properties

greater control over processing conditions than steam injection

lower risk of localised overheating of product
suitable for higher viscosity foods compared to steam injection

disadvantages
– blockage of the spray nozzles
– separation
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 Sterilization
Processing Equipment
Tubular Aseptic Sterilizer

Is an indirect heating/cooling method that uses stainless-steel coiled or

straight tubular heat exchangers

The tubing diameter is relatively small compared to product flow

As a result, extremely high-flow velocities within the tubing maximize

turbulence
 High turbulence induces rapid heat transfer

The tubing diameter is suited

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By: Mr. product
Legesse flow and viscosity 44
 Sterilization
Processing Equipment
Tubular Aseptic Sterilizer

Tubes are fabricated into coils or bundles, and placed along with
special media baffles into stainless-steel jackets

 Hot water, steam, or cold water pass through these jackets to heat or
cool the product flowing within the tubes

A series of horizontal tubular heat exchangers and a vertical holder

tube heat hold the product
to the required sterilizing
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 Sterilization
Processing Equipment
Tubular Aseptic Sterilizer

This system provides high heat transfer rates and a scrubbing action
that reduces “burn off” or
fouling in the tubes, resulting in a very short processing time

This helps to preserve the natural flavor of the product

The system has considerable flexibility in the range of products they

can handle and
the
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temperature range Powered
at which a specific product can be processed
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 sterilisation
Effect on foods Colour
In meats the
red oxymyoglobin pigment is converted to brown
metmyoglobin, and
purplish myoglobin is converted to red–brown
myohaemichromogen
Maillard browning and caramelisation also contribute to the colour of
sterilised meats
In fruits and vegetables, chlorophyll is converted to pheophytin,
 carotenoids are isomerised from 5, 6-epoxides to less intensely
coloured 5, 8-epoxides, and anthocyanins are degraded to brown
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pigments
 sterilisation
Effect on foods
Flavour and aroma

In fruits and vegetables, changes are due to complex reactions which
involve the degradation, recombination and volatilisation of
aldehydes, ketones, sugars, lactones, amino acids and organic
acids

In milk the development of a cooked flavour is due to

denaturation of whey proteins to form hydrogen sulphide and
 the formation of lactones and methyl ketones from lipids

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 Effect on foods
Texture or viscosity
In canned meats, changes in texture are caused by coagulation and a
loss of water holding capacity of proteins,
which produces shrinkage and stiffening of muscle tissues

Softening is caused by hydrolysis of collagen, solubilisation of the

resulting gelatin, and melting and dispersion of fats through the product

In fruits and vegetables, softening is caused by

hydrolysis of pectic materials,
gelatinisation of starches and
partial solubilisation of hemicelluloses, combined with a loss of
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cell turgor
 sterilisation
Effect on foods
Nutritional value

Canning not affect carbohydrates and lipids

Proteins are coagulated and, in canned meats, losses of amino acids are
10–20%

Vitamin losses are mostly confined to thiamin (50–75%) and

pantothenic acid (20–35%)

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Effect11/2/2024 Powered By: Mr. Getachew Legesse
of Heat Processing on Major Nutritional Components 53
Equipment design aspects of evaporators and concentrators
Evaporators:
 Heat transfer efficiency: Design should prioritize efficient heat transfer
between the heating medium and the liquid being evaporated.
 This can be achieved through proper selection and configuration of heat
exchangers.
 Vapor separation: Equipment design should include effective vapor separation
mechanisms to separate the evaporated vapor from the concentrated liquid.
 Energy optimization: Equipment should be designed to minimize energy
consumption by incorporating features such as multiple-effect evaporators or
mechanical vapor recompression.
 Maintenance and cleaning: Evaporators should be designed to facilitate easy
maintenance and cleaning to prevent fouling and ensure optimal performance.

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 Concentrators
 Evaporation principles: Concentrator design should be based on the principles
of evaporation, focusing on efficient heat transfer and vapor separation.
 Product handling: Equipment should handle viscous or concentrated products
effectively, ensuring smooth flow and preventing product degradation or
fouling.
 Energy efficiency: Design should aim to minimize energy consumption through
heat recovery systems, insulation, and optimization of operating parameters.
 Control and automation: Concentrators should incorporate advanced control
systems and automation to ensure precise control of process parameters and
enhance operational efficiency.
 These equipment design aspects are essential for achieving optimal performance,
energy efficiency, product quality, and safety in pasteurizers, sterilizers, evaporators,
and concentrators used in food processing applications.
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Introduction
Drying(Dehydration)
 Removal of relatively small amounts of water as vapor by air

 Removal of water from process material and other substances

 Removal of other organic liquids from solids

 Evaporation–removal of large amounts of water

 Usually the final processing step before packaging-as a

preservation technique especially for food

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 The removal of moisture, which is actually dehydration or drying,
prevents the growth and reproduction of microorganisms causing decay
and minimizes many of the moisture mediated deterioration reactions.
 Further, removal of moisture brings about substantial reduction in weight
and volume, thus minimizing packing, storage and transportation costs
and enable storability of the product under ambient temperatures.

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 Drying can be defined as the application of heat under controlled conditions to remove

the majority of the water normally present in a food by evaporation.

 The main purpose of dehydration is to extend the shelf life of foods by a reduction in

water activity (aw).

 This will inhibit microbial growth, however the processing temperature will not

normally be sufficient to cause inactivation, thus care will needed to be taken with the

product on subsequent rehydration.

 Drying does cause deterioration in the eating quality and nutritive value of the food.

 The role of the food engineer is to design a plant that will minimize such detrimental

effects while obtaining efficient drying rates. Typical foods that are important

commercially include; sugar, coffee, milk, potato, flour, beans, pulses, grains, nuts,

breakfast cereals, tea and spices.

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 Mechanism of Drying
 Drying as a mechanism, you will realize, involves the removal of free moisture from
the surface and also moisture from the interior of the material.
 How does this mechanism work? When hot air is blown over a wet food, heat is
transferred to the surface, and the latent heat of vaporisation causes water to
evaporate.
 Water vapour diffuses through a boundary film of air and is carried away by the
moving air.
 This creates a region of lower water vapour pressure at the surface of the food, and a
water vapour pressure gradient is established from the moist interior of the food to
the dry air.
 This gradient provides the driving force for the removal of water from the food.
 So you have seen that dehydration involves the application of heat to vapourise
water and some means of removing water vapour after its separation from the food.
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 Drying Techniques and Methods
 Several types of dryers and drying methods, each better suited for a
particular situation, are commercially used to remove moisture from a wide
variety of food products including fruit and vegetables.

 While sun drying of fruit crops is still practiced for certain fruit such as
prunes, figs, apricots, grapes and dates, atmospheric dehydration processes
are used for apples, prunes, and several vegetables.

 Continuous processes as tunnel, belt trough, fluidised bed and foam-mat

drying are mainly used for vegetables.

 Spray drying is suitable for fruit juice concentrates and vacuum dehydration
processes are useful for low moisture / high sugar fruits.

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 Drying Methods

 Batch–material is inserted into the drying equipment and drying proceeds for a

given period of time

 Continuous–material is continuously added to the dryer and dried material

continuously removed

 Drying is categorized according to physical conditions used to remove water

 Direct contact with heated air at the atmospheric pressure-water vapor

removed by air

 Vacuum drying–heated indirectly by contact with a metal wall or by radiation

 Freeze drying–water is sublimed from frozen material……Why??

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 Equipment of Drying

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 Dryers play a crucial role in the food processing industry by removing moisture from
various food products to enhance their shelf life and maintain quality.
 Here are some key design parameters for tray dryers, spray dryers, and fluidized bed
dryers:
Tray Dryer:
 Tray design: The trays should be designed to allow proper air circulation and
uniform heat distribution.
 They should have sufficient spacing between them to facilitate efficient drying.
 Airflow: The design should ensure adequate airflow within the dryer to promote
effective moisture removal.
 This can be achieved through the use of fans or blowers.
 Temperature control: Tray dryers should have temperature control mechanisms to
maintain the desired drying temperature throughout the drying process.
 Ventilation: Proper ventilation systems should be incorporated to remove evaporated
moisture from the drying chamber.
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Spray Dryer:
 Atomization: The design should include atomization systems that
efficiently convert the liquid feed into fine droplets for rapid evaporation.
This can be achieved through various atomization methods, such as
pressure nozzles or rotary atomizers.
 Airflow and drying chamber design: The drying chamber should be
designed to facilitate the efficient movement of hot air and droplets,
ensuring maximum contact and evaporation.
 Temperature control: Spray dryers should have precise temperature control
mechanisms to maintain optimal drying conditions and prevent product
degradation.
 Powder collection: Efficient powder collection systems, such as cyclones or
bag filters, should be incorporated to separate the dried product from the
exhaust air.
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Fluidized Bed Dryer:
 Bed design: The bed should be designed to ensure uniform distribution of
particles and efficient contact with the drying air.
 It should facilitate fluidization and prevent particle agglomeration.
 Air distribution: The dryer should have a well-designed air distribution system
to evenly distribute the drying air across the fluidized bed, ensuring efficient
moisture removal.
 Temperature control: Fluidized bed dryers should have temperature control
mechanisms to maintain the desired drying temperature throughout the
process.
 Product discharge: The design should allow for easy and efficient discharge of
the dried product from the fluidized bed.

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  In addition to these design parameters, considerations such as
insulation, material selection, safety features, and control
systems are important for all types of dryers to optimize
performance, energy efficiency, and product quality.

 It is essential to tailor the dryer design to the specific

characteristics and requirements of the food product being
dried to achieve the desired drying results

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 Identify a different types of dryers
 Freeze Drying: The Techniques of freeze-drying have been developed
over the past half-century for the purpose of preserving certain
biological materials, which are costly to produce, and which are highly
unstable.

 Perhaps its most notable successes have been in the preservation of

human plasma for transfusion purposes and in the preservation of the
early samples of penicillin during the war.

 Today it has numerous applications in the pharmaceutical industry, but

it falls far short of requirements for the food industry.

.
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 The cost of the process is also still too high to make it a practical proportion for
many of the cheaper foods. In this method of removal of water the product is
frozen and the temperature maintained below the triple point of the constituent
aqueous solutions so that the water vapour can be sublimed from the frozen
state.
 There is, therefore, a direct transfer from solid to vapour without the ice melting
and passing through the liquid phase.
 The process is carried out under high vacuum to provide a high vapour diffusion
potential and is accelerated by supplying heat in some convenient form, either
radiant, conductive or from microwaves.
 It is generally considered that as a means of dehydration.
 It produces a dried product of the highest quality and therefore is potentially an
extremely attractive method
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 Spray drying
 Spray Drying: Spray drying is a unique drying process since it involves
both particle formation and drying.

 It is most suitable for drying of liquid foods such as milk, fruit juices etc

 Spray drying involves the atomisation of feed into a spray, and contact
between spray and drying medium resulting in moisture evaporation.

 The drying of the spray continues until the desired moisture content in
the dried particles is achieved, and the product is recovered from the air.

 There are various types of spray dryers such as two stage dryers, three
stage dryers, multi stage dryers and compact spray dryers. Etc. other
type of dryers
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 Thank you

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