Tech-Knowledge April 2023 Issue 16

www.pmg.engineering Vol .02-Issue .16-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 Retort Packaging Vol .02-Issue .16-April 2023 CONTENTS 1. WHITE PAPER A. Retort technology B. Retort Packaging 2. INDUSTRY BUZZ Latest Food Industry News Updates 3. WEEKS HIGHLIGHT A Look Into The Main Events Of The Week 2-6 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 .16-April 2023 RETORTING TECHNILOGY Introduction Retorting is one of the major technique used for the thermal processing of food products which are packed either in semi rigid flexible laminates or in metal or alloy cans. Retort Technology provides the advantage of processing the food and packaging together which makes the filled product more commercial stable. This technique is used for commercialization of traditional or ethnic dishes which are important due to their delicacy and are high in demand. It can be defined as the heating of low acid food prone to microbiological spoilage in hermetically sealed container to extend shelf life. Operating Principle responsible The major objective of this thermal processing is to destroy microorganisms and to deactivate the enzymatic activity which are for shortage of shelf life and changing of physical and chemical properties of food. Retort consists of basket in which packaged food is kept. Then these the sterilizing food products are exposed temperature (121 Deg. C) mainly by the application of steam and high pressure (15 psi). Compressed air and water are used for sterilizing and cooling for the food products respectively. Principally, it involves seven steps to a) Preparing the Retorts: Cleaning by washing and steaming for a short time, checking the thermometer, pressure gauge, recorder, inlet, outlet valves etc. before loading the cans b) Loading: Cans are Jumble stacked for better steam circulation However, this reduces the retort capacity by about 25% and care should be taken to avoid denting. c) Venting: Removal of air from the retort before process timing begins. d) Come-up-time: This is the time required to bring up the retort to processing temperature after steam is turned on. Most important thing is to see that all air is driven out through vents before processing starts. The vent should be closed when process time starts. f) Blowing Down: Stopping steam supply and opening the vents. The retort pressure should be ‘zero’. Too quick blowing gradually brought to down may result in buckling of cans. Open the retort only after pressure reaches zero. g) Unloading: Unload the cans and cool outside promptly. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .16-April 2023 PLATE HEAT EXCHANGER Components of Retort 1. Steam inlet: It is a valve-controlled pipe of suitable size and the opening through which steam is admitted to the retort. 2. Steam Spreader: It is a pipe with perforations for uniform distribution of steam inside the retort. Perforated steam spreaders shall be maintained to ensure that they are not blocked during operation. 3. Safety Valve: It is set to open, when the working pressure has exceeded the safety limit pressure of the retort. 4. Vent: These are large valve, openings controlled by gate, plug cock, or other adequate valves used for the elimination of air during the venting period 5. Bleeder: It is a small opening used to remove air entering the retort with the steam and to provide circulation of steam in the retort and shall be open during the entire process, including the come-up time. 6. Drain Valve: It is an opening used to remove the condensed or cooled steam (water). A non- clogging, water tight drain valve shall be used; screens shall be installed over all drain openings. 7. Pressure gauge: is used to maintain correct processing the temperature to show the pressure inside the retort at all times. corresponding pressure to 8. Thermometers: To maintain correct processing temperature and to show the temperature inside the retort during heat processing. 9. Rails: In case of horizontal retorts only, used for pushing the trolley. 10. Water inlet and spreader: It is used for spraying cold water on the can for cooling after heat process is over. 11. Crates, baskets and devices: To hold the cans. Types of Retort It 1.Batch Retort: It can be either horizontal type or vertical type. The retort has a lid or door with good fastening. for temperature, pressure and safety devices. They can also be of circular or rectangular cross section. In batch systems, the retort is filled with product, closed and then put through a processing cycle. necessary controls has is continuous 2. Continuous sterilizer: There intermittent product container handling and agitation. The retort system is constructed of a series of cylindrical vessels called shells (typically 1.5 m diameter). To maintain pressure in the shells, containers enter and exit through self- inlet and discharge valves. Product sealing agitation increases rate of heat penetration, allows use of higher processing temperature (up to 138°C), and improves product uniformity and quality. in still recent advancements Retort processing relies on aggressive application and penetration of heat throughout foods, process engineering coupled with evolution of packaging technology have allowed for overall improvement of the technology. Retort processing presents the advantage of increased shelf life with less loss of nutrients due to which it can be applied to process ready-to-eat meals, marinades, vegetable curries, soups and rice. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .16-April 2023 RETORT PACKAGING Introduction Food packaging has become heart of modern food industry, which helps to store food and beverages in hygienic manner. Packaging is enclosure of products, items or packages in a wrapped pouch, bag, box, cup, tray, can, tube, bottle or other container contributing achieve functions such as /or preservation, containment, protection and communications and utility or performance. Ready-to-eat food products have dominated packaged food Industry. Ready to eat foods (RTE) in metal are container or flexible pouches that only need to be cut open and heated before being served. RTE food includes wide range of ethnic food products viz. vegetarian / delectable desserts. / non-vegetarian, basic foods, enclosed convenience food Retorting or In-bottle Sterilization is one of the major technique used for the thermal processing of convenient foods which are packed either in semi rigid flexible laminates or in metal or alloy cans. Packaging before heat treatment providing the advantage of both processing the food and packaging together, making filled product more involves commercially heating of food products prone to microbiological spoilage in hermetically sealed container to extend shelf life for commercialization of traditional or ethnic dishes, which are important due to their delicacy and are of high demand. stable. This technique from product techniques differ to Processing product and from package to package, hence, retort designs and operating procedures vary. Traditionally, metal cans were used for retort processing however, over the years we have seen wide usage of pouches, plastic pots and trays, allowing more convenience, better product quality through reduced processing time, reduction in costs for food manufacturers and better surface to for provide consumers. intended marketing information The materials of packaging must be inert, heat sealable, dimensionally stable and heat resistant (usually 115°C–125°C). They should have low oxygen and water-vapour permeability and be physically strong to resist penetration by the foodstuff contained and abuse during handling and storage. Efficiency Determining Factor is not a good 1.Type of container – Glass conductor of heat. Therefore, product in a glass jar takes more time to heat compared to equivalent size/shape metal can. 2.Size and shape of the container – A large container will take longer to heat than a small container, hence size of container matters. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION READ MORE.... Vol .02-Issue .06-February 2023 temperature 3. Retort retort temperate will result in more rapid heating but also may lead to more over-processing of product near the package. – A higher 4. Agitation- Agitation of the containers will increase the heating rate by mixing the contents of the container, especially with viscous or semi-solid foods. End over end agitation is better than axial agitation. 3. Type of product – Different products conduct heat more or less easily and have different heat capacities. Some products are more viscous than others are which can have a particularly significant effect in agitating retorts. 4. Headspace – insufficient headspace can also affect the rate of heating, especially in an agitating retort. Field of Applications the need 1. Traditional Retort Cans: The market for canned food products continues to grow which is driven by its high mechanical strength, for convenience, appealing recyclable properties of the cans, thermal stability, resistance to pressure and excellent barrier properties, increase in shelf life and food safety. Generally, tinplate (Consists low-carbon, mild steel sheet or strip, 0.50–0.15 mm thick, coated on both sides with a layer of tin) and for metal container and aluminium are used closure construction for food and drink products. Both are low-cost materials and nontoxic, having adequate strength and are capable of being work hardened. Cans are used for safe preservation of low acidic food such as meat, seafood, poultry, dairy products etc. They have high mechanical strength but major disadvantage associated with them is that they take more time to transfer heat as compared to retort pouch. relatively 2. Retort Cartons: Retort cartons is a new entry on this segment with only Tetra Recart developing world's first retortable carton packaging system designed for low acid, shelf-stable food products with particles of almost any size. Tetra Recart cartons differs from other Tetra Pak cartons as the paperboard material used for this process are moisture resistant. Though it resembles in having six layer construction consisting of primary polypropylene layer that comes in direct contact with the product, then a second layer of an aluminium foil, again a layer of polypropylene, 65% then of (approx. composition of packaging), again a layer of polypropylene and lastly a lacquer protected flexo- printed graphics that has an appealing effect and promotes marketing. paperboard comes 3. Retort Pouch: Retort pouch is a flexible or semi- rigid package made from heat-resistant laminated into which food products are metal - plastic, placed, sealed and sterilized at temperatures up to 121°C. The resulting product is then sterile and shelf-stable. Retort pouches comes up in various styles such as three sided seal, four sided seal, stand up, stand up fitment and pre made form seal. Retort pouches are used in several countries for a wide range of processed ready-to-serve shelf- stable products. Laminate films used for retort pouch manufacture vary depending upon their specific application. Composition of Pouch Mainly these flexible pouches are constructed with 4-ply laminate consisting of four layers: 1.Polyester: It offers high temperature resistance, toughness and Printability. 2.Nylon: resistance It acts as puncture and Abrasion READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Vol .02-Issue .06-February 2023 3.Aluminium: It acts as a complete barrier to light, life, Gases, Microbes, odours, extended shelf stiffness. 4.Food Grade Polypropylene: It can be used as bonding and sealing layer, which gives strength and flexibility to the pouch. There are also disadvantages associated with retort pouches. One disadvantage is the lack of strength of the material compared to metal cans. Retort pouches are much more prone to abrasions and punctures that ruin package integrity and potentially the product. More care and expense is needed when packaging retort pouches. Another disadvantage of retort pouches in the mode of retort generally used. Many continuous agitating retorts currently in use in industry were designed for compatibility with metal cans, and retort the same pouches cannot be processed equipment. are retort frequently processed in less efficient still batch retorts resulting in higher operating costs. Batch operations are than continuous less efficient operations because of time needed for loading and unloading between batches. in pouches Therefore, Quality checks should be carried out on pouches: 1.Visual assessment: there are no defects on the pouches both decorative and that may have an adverse effect on the process and shelf-life of the product. to check 2.Seal strength: to measure the strength of the seal for processing and storage. 3.Burst testing: to ensure the pack has adequate seal strength and integrity. 4.Oxygen and water transmission rates: measure the barrier properties of the pouch. to 5.Bond strength: the pouch has sufficient strength to prevent delamination of the layers. to ensure Retort processing has evolved significantly since its into Department of Defence and incorporation NASA food system. While the technology still relies on aggressive application and penetration of heat throughout foods, recent advancement in process engineering coupled with evolution of packaging technology have allowed for overall improvement of the technology.Retort processing presents the advantage of increased shelf life with less loss of nutrients due to which it can be applied to process ready to meal, marinades, vegetable curry, soups and rice. t Reto r Packagin g PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ FSSAI creates a panel to examine RAFT kits and applications. Angel investors help Proost Beer raise Rs 8.5 crore in equity and debt. The FSSAI has established a committee to examine the use of Rapid Analytical Food Testing (RAFT) kits, apparatus, and procedures. The Rapid Analytical Food Testing (RAFT) Kit, Equipment, and Method Applications Review Committee has been established by FSSAI as part of the RAFT Scheme. However, before being adopted or put into practice, the Competent Authority and the Scientific Panel on Methods of Sampling and Analysis must accept the RAFT committee's recommendations. The food authority must ensure that the suggested quick kit, equipment, and procedure adhere to international standards and meet the Food Safety and Standard Regulations requirements. Proost Beer, a well-known player in the beer brewing sector with a Delhi base and a Shark Tank India participant, recently made an exciting statement on the success of its financing round. The round, led by Mumbai Angels, Hyderabad Angels, Speed Fund, GetVantage, Finvolve, and other illustrious angel investors, saw the company raise Rs 8.5 crore. Existing investors Dauble PTE and Dev Punj also participated in the round, demonstrating their ongoing commitment to the company and faith in its ability to develop. With the most recent cash infusion, it plans to increase manufacturing capacity, explore new markets, and meet its working capital needs. The business is excited about using these funds to accelerate its growth trajectory and solidify its position as India's top brewery. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Somerdale International introduces a new line of premium cheese for the Asia Pacific market. Chaayos introduces the Chai Frappe, a light takes on traditional milk tea. 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION At FHA Food & Beverage, Somerdale International, the top producer of British cheese to more than 50 nations worldwide, will introduce a new, opulent line of blended and infused Westminster-branded cheddars. The Chai Frappe, a new summer beverage, was just released by Chaayos, India's biggest and most popular chain of chai cafes, along with the equally distinctive and energizing campaign #AisaBhiHoSaktaHai. The event, held at the Singapore Expo from 25 April to 28 2023, is anticipated to draw more than 40,000 business travelers from the Asia Pacific region. It will give the Somerset-based company a significant opportunity to showcase its new line of products and 'fly the flag' for the best dairy products produced in the United Kingdom in a rapidly expanding export market. It defies the common misconception that chai should only be served hot by combining the spicy flavor of chai with the chill, creamy goodness of frappe. The #AisaBhiHoSaktaHai campaign encourages individuals to think outside of their comfort zones. It promotes creativity and ingenuity by dispelling clichés and adding an unexpected spin on what to expect at Chaayos. A creative take on the conventional chai, the Chai Frappe offers an incredible and decadent experience that beats the heat. Three energizing kinds of chai frappe are offered: caramel, dark chocolate, and magic spice. Positive results from the new study point to the UK and Irish food systems being decarbonized in 2023. New research from Tetra Pak shows that businesses and consumers are resolute in keeping their eyes on net zero objectives, especially those that may be attained through the decarbonization of food systems, when pressure on the world's food and energy supply chains is increasing. Although more than a third (36%) of managers, directors, and business owners in the food and beverage industry view the development of sustainable packaging as crucial, new research released today reveals that 41% of these individuals now experience supply chain issues or disruption. Raw material shortages and price hikes were the two main obstacles preventing the adoption of sustainable packaging choices at the moment. Twenty-four percent (24%) of respondents feel sustainability should continue to be their organization's top priority in 2023 despite the need to adopt more sustainable practices for food production and consumption while lowering food waste and loss throughout the system. 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 14 APRIL VAISHAKI The festival of Baisakhi is celebrated on 14 April. This festival marks the onset of spring in India and also the start of Punjabi New Year. The time of Baisakhi usually signifies the end of the harvest season, and is an occasion of tremendous joy and festivity for farmers. 15 APRIL WORLD ART DAY World Art Day is celebrated every year on April 15, to promote the development, diffusion, and enjoyment of art. 19 APRIL WORLD LIER DAY World liver day is observed on April 19 every year, to spread awareness about liver-related diseases. The liver is the second largest and the most complex organ in the body, except the brain. It is a key player in the body's digestive system. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION L I R P A PMG DID YOU KNOW? 1/2 2/2 Fact 1 The winemaking process, particularly the fining process, frequently includes small amounts of substances that vegetarian and vegan consumers may find objectionable. Because many of these ingredients are derived from animal bones, intestines, or other byproducts, not all wines are suitable for vegans or vegetarians. T E C H N I C A L C O N T E N T L I R P A PMG 1/2 2/2 Fact 2 (also known as Cauliflower naturally comes Broccoflower), purple, and orange coloured cauliflower are available. Although it does not have the same appearance as the popular white cauliflower, it has the same flavour: mild, sweet, and nutty. Orange and purple cauliflower contain more antioxidants than white cauliflower. in multiple colors. Green 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 1/2 2/2 Fact 3 Consumption of sugary and artificially sweetened beverages has been linked to cardiometabolic risk factors, which increase the risk of cerebrovascular disease and dementia. In the study by FHA (Framingham heart study) 2,664 participants were found to be 1.91 times more likely to develop Alzheimer's disease if they consumed one to seven servings of sugar-sweetened beverages per week. L I R P A PMG 1/5 2/5 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 3/5 4/5 Fact 4 Analysis of herbs and spices is a critical process in ensuring their quality, safety, and efficacy. There are several methods used for analyzing herbs and spices, including sensory evaluation, chemical analysis, and these microbiological analysis. methods, there are also various regulations and standards that govern the analysis and quality of herbs and spices. In addition to 5/5 L I R P A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Vol .02-Issue .16-April 2023 PMG ENGINEERING About PMG About PMG Delivering End-to-End Engineering Design & Construction Management in Food & Beverage Industry MAKING CUSTOMERS THE INDUSTRY LEADERS ENGINEERING MUST CREATE BUSINESS VALUE MEET THE EXPECTATIONS OF ALL STAKEHOLDERS OPTIMAL ENGINEERING Website Link Click Here Follow Us on

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