Lyophilization in Food Processing: Freeze-Drying via Sublimation Explained

www.pmg.engineering Vol .02-Issue .14-April 2023 TECH-KNOWLEDGE The Official PMG Engineering Newsletter FOOD & BEVERAGE INDUSTRY ENGINEERING & DESIGN SCIENCE & TECHNOLOGY A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .14-April 2023 CONTENTS 1. WHITE PAPER A. HVAC B. Lyophilization 2. INDUSTRY BUZZ Latest Food Industry News Updates 3. WEEKS HIGHLIGHT A Look Into The Main Events Of The Week 2-5 6-7 8-9 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 10-12 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .14-April 2023 HVAC (HEATING, VENTILATION AND AIR-CONDITIONING) Introduction is a system Working spaces or indoor areas should provide thermal comfort along with high indoor quality air. HVAC stands for Heating and ventilation and air conditioning in whole to provide healthy and comfortable internal conditions by removing hot air. All of the effectiveness of HVAC depends on its design. Importantly it is designed for minimal use of non-renewable energy and less water pollutant emissions. HVAC systems are essential in a number of industries, and provide the atmosphere necessary for food to be kept fresh and to ripen so that it is safe to eat as well as flavorful, and is also known as climate control. Because certain types of plants prefer humidity levels of 50% or greater, in hot and dry environments quality HVAC systems, are vital for creating an environment where fragile fresh produce can flourish. Need for HVAC System Need for HVAC can be for following listed uses like 1.To improve air quality of the confined space for providing a comfortable working environment to the workers. 2.To regulate moisture in the processing area to minimize in environment hence preventing the microbial growth the growth of water activity improve process quality, by providing in the processing 3.To contaminant-free, filtered air room preventing any sort of contamination 4.To maintain constant temperature throughout the year as there can be wide fluctuation in temperature during various time period of year. To keep uniformity of comfort level HVAC can be used. Types of HVAC System 1. Heating and Air Conditioning Split System: A wall-mounted split system air conditioner consists of two parts; a wall-mounted indoor unit and an outdoor unit. The indoor unit blows cool air into the room, and the outdoor unit dissipates the heat from the cooled area. Refrigerants are used to cool or heat the air. 2. Hybrid Heat Split System: A hybrid heat system reacts to changing temperatures and automatically adjusts to the most efficient energy saving method available to heat or cool the space. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .14-April 2023 PLATE HEAT EXCHANGER 3. Duct Free Split Heating and Air Conditioning System: Ductless free split-system air-conditioners in potential have commercial buildings. applications numerous 4. Packaged Heating & Air Conditioning System: It has higher cooling or heating capacity and is usually able to cool an entire commercial building. The nominal capacities ranges from 3 tons to 15 tons. The conditioned air is transferred to the space to be conditioned through ducting which is in the ceiling and wall of the usually hidden building. The unit is placed outside the building, a special room in a building or even on top of a roof. Components and working 1. Thermostat- The thermostat is usually the most visible part of HVAC system. When the ambient temperature becomes too cold or too hot, the thermostat will trigger the heat exchanger or the evaporator coil-condensing unit combo to begin as per circulating warmed or requirement. cooled air 2. Furnace- The furnace is the key component of HVAC system. Its function is to heat supply air which is to be distributed to various rooms of building via the HVAC. This heating process is accomplished using one of four possible heat sources combustion (burning natural gas, oil, coal, or propane), electric resistance, heat pump, or solar energy collected on site. 3. Heat exchanger- The heat exchanger are inside furnace unit's housing. This component switches on when the furnace is activated by thermostat to produce warmer heat exchanger pulls in cool air, heats it, and circulates the resulting heated air via ducts and out through the vents. temperatures. The 4. Evaporator coil - It acts to cool the air when thermostat is set to lower temperatures. Located in a metal enclosure on the furnace's exterior, to the top or side, the evaporator coil works similarly to an automobile radiator to produce cool air, which is then circulated through the ductwork. is connected 5. Condensing unit- the It evaporator coil. This unit are filled with refrigerant gas. When the refrigerant has been cooled to a liquid by heat exchanger with the exterior air, the the condensing unit pumps evaporator coil to be evaporated into a gas. liquid the to to 6. Refrigerant lines- The refrigerant lines carry a refrigerant substance the condensing unit to vaporized in the form of a gas, and return it to the evaporator coil in liquid form. These "lines" are actually narrow from a durable heat- and cold- resistant metal such as copper or aluminum. tubes manufactured 7. Ductwork- Ductwork refers to the system of ducts that transports air warmed or cooled by the system to the various areas of building. They may flexible plastic, be manufactured polyurethane, fiberglass, or fabric. from steel, 8. Vents- These are rectangular outlets which transfer the heated or cooled air from the duct system into the individual rooms. Air Handling Units: Air handling unit is a device used to regulate and circulate air as part of a heating, ventilating, and air-conditioning (HVAC) system. An air handler is usually a large metal box containing a blower, heating or cooling elements, racks or chambers, sound attenuators, and dampers. Air handlers usually connect to a ductwork ventilation system that distributes the conditioned air through the building and returns it to the AHU. filter PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .14-April 2023 LYOPHILIZATION Introduction is reduced below Freezing is a unit operation in which temperature its freezing point of a food (removal of sensible & latent heat of fusion), and a proportion of the water undergoes a change in state to form ice-crystals. Immobilization of water to ice and the resulting concentration of dissolved solutes in unfrozen water lowers the water activity of the food. Lowering of temperature, lowers the microbial activity as well as suppresses the chemical reactions in the food. Generally, we find two type of freezing method, quick freezing and slow freezing. In slow freezing, food products are introduced to low temperature for relatively longer time duration and hence the ice crystal formed are of larger in size, which are sometimes not at all desirable depending on characteristic of food product. In quick freezing, relatively even lower temperature is used for food product but exposure time is less. Hence the ice crystal formed are of smaller size. Even though ice crystal formed during quick freezing small helps texture and other in preserving characteristic of product, sometimes it may cause to temperature shock to product. Choosing the method of freezing is hence of utmost importance. the Sometimes known as freeze drying, lyophilisation is a preservation technique extensively used in food industry for preserving food material and for prolonging shelf life. is in of food product technique a non-thermal Freeze drying preservation technique used for majorly heat sensitive food product. Freeze drying employs treatment controlled temperature to preserve the main characteristic of in case exposed to lost product that can be uncontrolled condition. Freeze drying can be highly effective for preservation of wide range of product including fruits, vegetables, meats, flavours, herbs, coffee etc. Temperature used in lyophilisation is between -50 to -80 deg. C and product can be kept as such, without any characteristic changes for several years in case of unopened condition and can last for at least few days after opening if stored in refrigerated condition. Lyophilization Technique lyophilization, temperature of product In is brought down to such a low temperature where the solid, liquid and vapour coexists, which is also known as triple point. In this process the initial liquid solution or suspension the pressure above the frozen state is reduced and the water removed by sublimation. Thus a liquid –to- vapor transition takes place. If, however, solid ice is maintained at a pressure below the triple point then on heating the ice will sublime and pass directly to water vapor without passing through the liquid phase. frozen, is READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .06-February 2023 in product 1. Freezing: Free water present is freezed to change its state from liquid to solid. Product is freezed below its triple point. Reason for bring down temperature to triple point is that it helps in the next step of the process. Freezing is the most important step of lyophilization and it is preferred to have larger crystals to easily sublime it. 2. Primary Drying: Second step involves lowering of pressure and providing enough heat to sublime the ice to vapour form. It gets easy due to the product existing in its triple point temperature. In this primary drying phase, about 95% of the water in the material is sublimated. In industrial level, this is most time taking process as slightly higher temperature can lead to deterioration of texture of product. Controlled pressure act as catalyst for sublimation. 3. Secondary Drying: Then comes secondary drying, which primarily focus on the removing of unfrozen water. The temperature is raised higher than in the primary drying phase, and the pressure to encourage is also in in desorption. Before packages, it is treated with inert gas to break the formed vacuum. For food product, nitrogen gas is used. this stage sealing the product lowered Industrial Requirement: A lyophilization plant consists of: 1.Drying chamber having temperature controlling plates 2. Capacitor to collect the water coming out of the product in the drying chamber 3. Cooling system 4. Vacuum system to reduce the pressure in the room 5. Capacitor for the drying process. The food product is firstly freezed to its freezing point, even liquid product is freezed below their freezing point. Then they are placed in the drying chamber where temperature of the chamber is set according to the product to be freezed and is always below 0 Deg. C. Applied vacuum facilitates ice evaporation which again lower the temperature of the product which are compensated by heating the product a bit by means of heating plate. The vapour evaporated is again freezed and during the process, freed water is drained. PROS the hydrolysis chemical temperatures, Due low to decomposition, is particularly minimized. There is no concentration of solution prior to drying. Hence, salts do not concentrate and denature proteins, as occurs with other drying methods. Again the basic importance or need for lyophilisation is due to decrease in weight and bulk of the product which helps in handling of bulk material during storage or transportation. Shelf life of product increases by reducing the microbial attack and self-metabolic activity. CONS Even Lyophilization have their own limitation as it yields a very hygroscopic product and makes it difficult to maintain the required storage condition at every step. It is also very time taking process and the processing plant very complicated making it very expensive and can be used of higher quality product. Though it beneficial for heat sensitive product but again it can be used for certain types of products only. Chance of deterioration of fatty tissue by rancidity is the major drawback to the sensory values. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ Practus: India's food and beverage industry offers immense opportunities. The market for food display cabinets is expected to reach $41.4 billion by 2031. According to Practus, the nation's food and beverage business is a broad and dynamic market that offers several potentials for innovation and to satisfy shifting customer expectations. Moreover, given rising consumer desire for healthy and sustainable food options, there has never been a better time to investigate the potential in this sector. the "Consumers are becoming more environmentally and health-conscious, focusing more on functional meals that offer advantages over essential nutrition. Also, more households are hopping on the bandwagon of traditional millets and old recipes. This year, millets like jowar and bajra are widely utilized in rotis, khichdi, cookies, muffins, and crackers, "Bhavik Desai, the head of client international management solutions for India at the consulting firm Practus, made the observation. Allied Market Research released a new report named "Food Display Cabinet Market." Market analysts forecast that the food display cabinet market, valued at $18.5 billion in 2021, would increase at a CAGR of 8.4% from 2022 to 2031 to reach $41.4 billion. To sell, hot, cold, and frozen meals and beverages are stored and shown in food display cabinets. Via cabinet holes, transparent doors, lids, or panels typically closed to access the contents; these cabinets let users see the things being stored while stepping into the cold. A chamber that allows you immediate access to all of the contents. A food display cabinet is a catering tool used to store and show food. They are employed to maintain food at the ideal temperature. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Prince Charming is IBC's first beer in the traditional Graff style. To deliver a healthier future, DSM quantifies its impact. Independence Brewing Company, The Trenton Group's India's top craft beer brewery, has added a new item to its delectable menu A mouthwatering malt and fresh apple mixture called Graf is fermented to create this speciality ale, which is then aged IBC was the first to with strawberries. introduce the Graf alcoholic beverage style. Importantly, Charming. dubbed Prince This lightly carbonated beer has a somewhat sweet aftertaste and oozes with the flavor of juicy strawberries and caramel. It comes in three volumes of 250 ml, 500 ml, and 1 liter, with an ABV percentage of 4.8 and an IBU percentage of 0. Also, it has a faint pink tint that tantalizes the taste senses into wanting more. It is a flavorful, fruity beer best savored on a hot summer day. It is the ideal addition to the sweltering summer heat. 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION The first audited results of Royal DSM's efforts in addressing pressing societal and environmental concerns related to The world's food production and consumption processes are made clear. Are revealed. Royal DSM is a worldwide, purpose-led science-based corporation. The initial results offer a standard that will be used to gauge progress between now and 2030 as the corporation works to guarantee that nutritious food is easily accessible and livelihoods within planetary inexpensive. And healthy boundaries. This is the first full year since the company announced a series of ambitious, measurable, long-term food system commitments. Two new Good Flippin' Burgers outlets open in Mumbai. Two new locations for Good Flippin' Burgers have been opened in Mumbai's Thane Wagle Estate and Mira Road. With the opening of these recent locations, the burger chain will also try to attract new customers from the outer reaches of the city. Customers can order trademark meals from the Thane Wagle Estate store online and deliver them to their door. This is a curbside pickup. With this location, they hope to meet the needs of consumers who prefer to eat in the convenience of their homes or workplaces. On the other hand, the Mira Road location is a hybrid restaurant with various dining options, including dine-in, takeaway, and delivery services. This restaurant is the ideal place to have a delicious dinner with friends or family in the relaxing outside atmosphere, and it has outdoor seating for about 12. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION N O N - T E C H N I C A L C O N T E N T WEEKS HIGHLIGHT 1-7 APRIL BLINDNESS PREVENTION WEEK Prevention of Blindness Week is observed on the 1st week of April - 1st to 7th of April to alert and awaken the society towards various factors which cause blindness. 4 APRIL HAPPY MAHAVIR JAYANTI Mahavir Jayanti is one of the most significant festivals among the Jain community celebrated with splendour in India and across the world. The festival commemorates the birth of Lord Mahavira. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION L I R P A PMG N O N - T E C H N I C A L C O N T E N T 6 APRIL INTERNATIONAL DAY OF SPORTS The International Day of Sport for Development and Peace, which takes place annually on 6 April, presents an opportunity to recognize the positive role in communities and in people's lives across the globe. sport and physical activity play 6 APRIL HANUMAN JAYNTI Hindus celebrate the birth of the deity Hanuman, during the Hanuman Jayanti festival. Hanuman is known for his unwavering devotion and is thought to be a devoted follower of Rama, an avatar of Vishnu. He regard as a representation of power and vitality, and on this occasion, he is honored for these qualities. Each Indian state has a different way of celebrating Hanuman Jayanti depending on the time of year and local customs. in high is held DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION L I R P A PMG T E C H N I C A L C O N T E N T DID YOU KNOW? Fact 1 Pineapples are fruit that are neither pine nor apple. Pineapples are actually a type of bromeliad. The pineapple got its name from a combination of the Spanish "pina" (named after a pine cone) and the English "apple" (so named because of its sweet taste). Fact 2 Tomato ketchup was once sold as a medicine, claiming to cure ailments such as diarrhoea, indigestion, and jaundice. Dr. John Cook Bennett, an American physician, is said to have proposed the idea in 1834 and later sold the recipe in the form of 'tomato pills'. L I R P A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Fact 3 According to the company, each jar of Nutella contains approximately 50 hazelnuts. In a large tank, the cocoa powder is combined with the hazelnuts, sugar, vanillin, and skim milk until it forms a paste-like spread. T E C H N I C A L C O N T E N T Fact 4 A fresh, ripe whole cranberry will bounce if dropped. Berries that are old or damaged will not bounce. This ability to bounce at the sorting mill allows berries to pass the quality test. This property determines which berries are sold as bagged berries and which berries are juiced. L I R P A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T Fact 5 The density (mass/unit volume), of limes causes them to sink while lemons float. If an object is less dense than the liquid it is placed in, it will float; if it is denser than the liquid, it will sink. Because limes are slightly denser than lemons, they sink while lemons float. L I R P A PMG DESIGN+BUILD FOOD FACTORIES. 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