Emerging Technologies Showcase - e3tnw.orge3tnw.org/Portals/0/E3TFiles/E3T MATS Presentation...

E3TE3T EnergyEfficiencyEmerging Technologies

Microwave Assisted ThermalSterilization - MATS™

Emerging Technologies ShowcaseJanuary 21, 2015

Bill Wilson, P.E.

Washington State University Extension EnergyProgram

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Introduction

What we are going to discuss:New process technology for post-packagingprocessing (sterilization) of low-acid/high-moisturefood products resulting in long-term, ambientcondition, shelf-stable, food products preservation


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BPA TI Project Funding Acknowledgement

http://www.bpa.gov/Doing%20Business/TechnologyInnovation/TIPProjectBriefs/2014-TIP-261.pdf

http://www.bpa.gov/Doing Business/TechnologyInnovation/TIPProjectBriefs/2014-TIP-261.pdf


Microwave Assisted Thermal Sterilization (MATS™)

• Developed by Dr. Juming Tang’s Microwave Group at WashingtonState University, Pullman Campus – affiliated with the Department ofBiological Systems Engineering

• Adaptation of 915 MHz frequency microwave energy for internalheating of food products in their hermetically sealed storagecontainers to sterilization temperatures

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• Process for deactivation of microorganisms and their spores.Internal temperatures in excess of 212oF required (generally 250 –265oF), with adequate “holding” time once temperature is reached

• We are all very familiar with conventional post –packagedsterilization technologies as food processors, domestic foodpreservationists, or consumers

• Examples of products created using conventional technologies andtarget categories for MATS™ technology follow ….

What is Post-Packaging Sterilization?

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Examples of Post-Packaged Sterilized Products


How is Post Packaging Thermal Sterilization Achieved?

• Imparting thermal energy to heat container andcontents to sterilization temperature

• For flexible or semi-rigid non-metallic containersin particular must be done in pressurizedatmosphere environment to avoid product watercontent vaporization

• Most frequently, pressurized atmosphere is steam(15 psig sat. steam ~247oF), or hot water atsterilization temperature maintained at 20 psig orgreater pressure


Attributes of MATS™ vs. Conventional Technologies

• Benefits Significant reduction in thermal processing time (1/4 to 1/10 of conventional

processing time) Greatly improved product visual and sensory appeal - particularly prepared meals

containing delicate ingredients Improved nutrient retention Inherently capable of adaptation to continuous-type sequential processing system

design Shelf-stable end-products eliminate refrigeration requirements for processing,

warehousing, transportation, retail sales storage/presentation Initial indication of a reduction in processing energy intensity (gross combined

process energy consumption/unit mass of product) – usually stated as Btu’s per lb.of product

• Drawbacks Processing energy cost/production unit increase due to electrical vs. thermal

energy utilization (particularly for natural gas)


Conventional Sterilization Methods

• Conventional Technologies

Steam heated retorts (also called “autoclaves”)

Water immersion retorts

Steam water spray retorts

• All types –

Batch operation (most typical)

Continuous operation (rare)

Disadvantages Warm-up losses Vent & bleeder losses Product thermal mass Long come-up & cook

time Long product cooling

time

Batch-Type Retorts – “Still” Steam


Batch-Type Retorts – Water Immersion(with Water Recovery Vessel)

Disadvantages Warm-up losses Long come-up & cook time Long product cooling time


Batch-Type Retorts – (Steam Water Spray)

Disadvantages Warm-up losses Electrical & Compressed

Air Consumption

Advantages No Steam Venting Loss No Continuous Bleeder Loss Minimal Water Volume Heat-up

WSU MATS™ 40 kW Pilot Line


WSU MATS™ Semi-Continuous 40 kW Pilot Line

View: Preheating Section (lower) MicrowaveSection (Upper)

20 KW 915 MHz MicrowaveGenerators

Summary of WSU MATS™ Major Milestones

July 2001 Formed WSU Microwave Consortium I

July 2001 Developed first 915 MHz single mode pilot system (10 kW)

Oct. 2006 Received US patent for 915 MHz single mode microwavesterilization system design

Aug. 2007 Developed a second generation system semi-continuoussystem (40 kW)

Oct. 2009 Received FDA acceptance for MW sterilization of mashedpotato in 10 oz. trays

Nov. 2010 Formed MW Consortium II, focusing on commercialization

Nov. 2010Food Chain Safety (Maple, Valley, WA) is granted license forexclusive rights for commercialization of MATS™Technology [Now 915 Labs]

Dec. 2010 Received FDA acceptance for MWsterilization of salmon fillets in sauce in 8 oz. pouches

Mar. 2012 Received non-objection letters from USDA FSIS


Retort Processes Energy ConsumptionComparisons

• Like many Energy ConsumptionComparisons – “It Depends” Currently batch or continuous

operation?

Product temperature increase required

Equipment capacity utilization anddensity of product pack

Initial projection of Microwave comparedwith batch processing indicatesfavorable energy intensity and overallenergy efficiency metrics

EnergyIntensity??

Commercial Assessment Outcome Summary

7.110.4

32.5

0

5

10

15

20

25

30

35

Still Steam Immersion w/ WaterRecovery

Steam Water Spray

Lb/F

t3

Lb. Product/Ft3 Usable Retort Volume(As Measured/Estimated) Product/Volume

Ratio

864

1,293

300 260

0

200

400

600

800

1,000

1,200

1,400

Still Steam Immersion w/Water Recovery

Steam WaterSpray

ContinuousRotary Retort

(cans)

Ener

gy In

tens

ity, B

tu/l

b Pr

oduc

t

Energy Intensity(As Measured/Estimated)

Energy Intensity


Commercial Assessment Outcome Summary

651

1293

658

260

0

200

400

600

800

1,000

1,200

1,400

Still Steam Immersion w/Water Recovery

Steam WaterSpray

ContinuousRotary Retort

(cans)

Ener

gy In

tens

ity, B

tu/l

b Pr

oduc

tEnergy Intensity

Normalized for Pack Density & Temp. RiseEnergy Intensity


Input Energy Distribution

29.0% 18%

56.2%79.2%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Still SteamHorizontal

WaterImmersion

Steam WaterSpray

ContinuousRotary

Retort (cans)

Input Energy Distribution(As Measured/Estimated)

Electrical

Product & ContainerSensible Heat:Surface Losses

Preheating

Bleeder Losses

Vent Losses

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WSU Microwave Group: www.microwaveheating.wsu.edu

Food Chain Safety/915 Labs: www.fcsmats.com

Bill Wilson: [email protected](360) 956-2041

For Additional Information:

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http://www.microwaveheating.wsu.edu/

http://www.fcsmats.com/

mailto:[email protected]


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