12/20/2012

SAC 2008 1
RetortSystems
1
RodneyWeaver
November2728,2012
Topics
HistoryofModernFoodProcessing
BatchSystems,Nonagitating
BatchSystems,Agitating
C ti C k
2
ContinuousCookers
EmergingTechnologies
CaseHistory:WhenThingsGoWrong
HistoryofModernFoodPreservation
1810 1820 1870
1795 1813 1858
EarlyStillRetort
4
VerticalStillRetort
Batchtype
Nonagitating
Nooverpressure
Basketusedtoholdproduct
Limited efficiency
5
Limitedefficiency
Bestsuitedforsmallbatches
Usedforprocessingmetalcans
Suitableformultiplepackagesizes
Manualoperationforloadingand
unloading
MaloCooker
Batchoperation
Nooverpressure
Cratelesssystem
Designedforprocessingmetalcans
Oftenconfiguredtofitexisting
f iliti
6
facilities
Loadedviaconveyor
Cansaredischargedintocanalsystem
forcooling
Efficientsystem
Singleoperatorcanmanagemultiple
retorts
12/20/2012
SAC 2008 2
MaloRetort ProcessDiagram
7
FullWaterImmersionRetort
Batchoperation
Stilloragitating
Overpressure
Firstusedforglassjars
Now used for a variety of package
8
Nowusedforavarietyofpackage
formats
Waterisheatedinavesselabove
thecookchamberto133C
Superheatedwaterisusedto
immersepackages
Acirculationpumpisusedto
ensureproperheatdistribution
PartialWaterImmersionRetort
Batchoperation
Stilloragitating
Overpressure
Selectedforcloselyfitcontainers
9
Highpowerpumpisusedtomove
waterthroughunit
Waterismovedtotransferheat
CommonapplicationsincludeTetra
Recartandsmalltins
WaterSprayRetort
Batchoperation
Stilloragitating
Overpressure
Usespumptoforcesuper
heated water (>121C)
10
heatedwater(>121 C)
throughoutthevessel
Nozzlesprovideveryuniform
heatingpattern
Improvedprocesscontrol
Optimalforpouchprocessing
WaterSprayProcess
2 Heating 3 Sterili ation 1 Water filling
11
2. Heating 3. Sterilization
4. Indirect cooling 5. End of cycle
1. Water filling
Steam/AirRetort
Sterilizationisthrough
introductionofsteam
Afancirculatesthesteamto
provideuniformheating
Suitableformultiple
12
Su tab e o u t p e
packagetypes
Packagesarecooledwith
recirculatedwater
Processmethodwas
inventedbyLagarde
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SAC 2008 3
HydrostaticCooker
Continuouscooker
Bestsuitedforlargequantitiesof
containers
Designedtoprocessmetalcans
Cansenterwarmwaterchamber
13
Conveyedintosteamchamber
Timeandtemperatureareset
basedonsterilizationneeds
Cansexitthroughcoldwater
Heightisoften12.2Meters
Cansmayberotatedtominimize
heatdamage
HydrostaticCooker
14
RotaryContinuousCooker
15
RotaryContinuousCooker
Continuoussystem
Usedextensivelyforcans
Lacksoverpressurecontrol
Cannotbeusedforpouches
16
Setforaspecificcansize
Cansarerotatedasthey
cyclethroughprocess
Targetedforhighvolume
applications
ACBHydrolockContinuousCooker
17
ACBHydrolockContinuousCooker
Continuouscooker
Overpressure
Multiplepackageformats
Metalcans
Glassjars

18
Plasticsbottles
Thermorformedtubs
Pouches
Highvolumeapplications
Retailproductswithcooktimeof
lessthan30minutes
12/20/2012
SAC 2008 4
Shaka
Batchoperation
Agitating
Overpressurecontrol
Bestsuitedforcans,plastic
bottlesorthermoformedtrays
19
Packagesmustbesecuredin
specialracks
Productisshakenvigorously
Smallbatchsets
Significantlyreducedcycletime
Reducedenergyconsumption
MicrowaveRetortProcessing
KnownasMATSorMicrowave
AssistedThermalSterilization
Batchoperation
Productofpartnershipbetween
industryandacademia
Si ifi li i
20
Significantqualityimprovement
forhardtoprocessproducts
Requiresmetalfreepackaging
materials
Thermoformedtraysand
pouches
Wellsuitedforthick,difficultto
processproducts
ProcessStepsforCannedFish CastleberrysFoodRecall
LargefoodcompanyinUSA
100+retorts
FDAproductrecall
Botulismoutbreak
Inspection found:
22
Inspectionfound:
Brokenalarms
Leakyvalve
Inaccuratetemperaturedevice
Failuretodoproperchecks
Recallcost:$38,000,000(US)
ThankYou.
23
RodneyWeaver
November2728,2012