Pasteurization and sterilization solutions for cocoa, nuts … · · 2016-04-14BÜhler...

Pasteurization and sterilization solutions for cocoa, nuts and seeds.

2 BÜhler pasteurization and sterilization solutions

Safety for your food.Bühler pasteurization and sterilization systems.

For foods with a low moisture content, Bühler provides

a number of sophisticated solutions for effective pas-

teurization and sterilization – tailored to the processing

of cocoa, nuts and seeds. The technologies are char-

acterized by ease of use, reproducible results and high

effectiveness.

Both effective and gentle processes are needed to meet

increasingly stringent legal provisions and to guarantee

not only the safety but also the quality of food for the end

consumers. The targeted inactivation of microorganisms

is a must for ensuring the safety of end products and

their shelf life.

You can meet this responsibility with the pasteurization

and sterilization solutions from Bühler and secure the

safety, quality and success that your products deserve.

natural inactivation of germs using steam

The heat resistance of pathogenic germs strongly in-

creases as water activity decreases, so in dry foodstuffs,

the use of steam significantly improves inactivation. In

addition, steam is a natural medium, so your products

are not subjected to chemicals or radiation.

one of the most sensitive issues for the food industry is the bacterial contamination of end products.

serious illness in consumers or a severe loss of brand image are risks that can be avoided by utilizing the

steam pasteurization or sterilization solutions from Bühler.

tem

per

atur

e [°

C]

100 °C

sterilization process

pasteurization process

Parasiten

Moulds & Yeasts

e. Coli

Salmonella

time

Termophile spore forming microorganisms

Figure 1: Different heat resistances of microorganisms require modified time/temperature processes for inactivation.

BÜhler pasteurization and sterilization solutions 3

advantages for the customer:

– Individual solution: the right pasteurization or sterilization for every requirement and application

– Safe solution: Bühler batch systems with modern online process capture guarantee reproducible results

– Complete solution: extensive product support from planning, design, installation and startup through to

validation of the process (ProValid)

– Comprehensive service: Technical and technological support and comprehensive advice

Bühler solution Barth CCp Barth nr-Cep Barth debactM

product Nuts, peanuts Nuts, peanuts –

Cocoa beans – Cocoa beans

Spices, herbs, seeds, grains Seeds –

process Pasteurization or sterilization process with steam

Pasteurization with steam and then roasting

Sterilization process with steam

process control Control of steam temperature using pressure

Steam injection at atmospheric pressure into the roasting chamber

Steam injection at very high pres-sure (hTST process)

inactivation objective Vacuum process: Vegetative, pathogenic microorga-nisms, such as salmonella

Over-pressure process:Including thermophile spore formers

Vegetative, pathogenic microorga-nisms, such as salmonella

Vegetative, pathogenic microorga-nisms but also thermophile spore formers

Capacity 100 to 20,000 kg/h 100 to 2,000 kg/h 1.000 to 4,000 kg/h

Characteristic high flexibility through batch process and wide temperature range(75 to 120 °C)

roasting and pasteurization in one system

reduction of TPC to < 5,000 cfu/g in 100 seconds cycle time

proValid validation Possible Possible Possible


Barth CCP – Controlled Condensation Process. Pasteurization solution for diverse applications.

With the Barth CCp controlled pasteurization pro-

cess, Bühler offers a gentle processing solution

for all kinds of nuts, cocoa beans, oil seeds, spices

and other dry foodstuffs.

Barth CCp – forward-looking technology

Many sensitive products must be processed at tempera-

tures below 100 °C to maintain their unique properties.

It is therefore important for the required pasteurization to

be carried out at reduced pressure to keep the evapo-

ration temperature and moisture condensation low dur-

ing the process. On the other hand, a certain product

surface moisture is important to achieve the desired log

reduction of salmonella. In the Barth CCP system, this

technologically demanding challenge is met by a pres-

sure-controlled process and the pre-heating of the prod-

uct to a temperature just below the system‘s evaporation

temperature.

effective and flexible process

Controlled steam germ removal using the Barth CCP

reactor is based on a pressure-controlled batch principle.


– Pressure-controlled batch process provides

flexible process temperatures in the range from

75 to 120 °C at any residence time

– Controllable change in product moisture

– Patented and TerP-approved process

Barth CCP 50


All important parameters such as pressure, time and

temperature can be set individually to suit the spe-

cific product being treated. An optimal result is always

achieved, thanks to the numerous variation options within

a very wide range.

Guaranteed 5-log reduction

The Barth CCP process shows a reduction of more than

five logs in the bacterial count for Enterococcus faecium,

a surrogate for salmonella. During the treatment, the

process temperature is controlled via the pressure or the

vacuum.

A reduction in the pressure causes a drop in the evapo-

ration and condensation temperature and thus a reduc-

tion in the process temperature. Consequently, the inac-

tivation rate can be controlled by changing the pressure

conditions and the residence time in the pressure vessel

and the product is gently pasteurized.

As the process can also be operated at over-pressure

conditions and at temperatures of more than 100 °C, it

is also able to inactivate thermophilic microorganisms.

Barth CCP can therefore be used for dry foodstuffs

where there is a requirement for an extremely low total

plate count (TPC) level, such as for cocoa beans or

spices.

excellent product quality

After CCP pasteurization, products such as almonds or

pepper show no significant changes in terms of appear-

ance, taste, texture or color, therefore no skin loosening

and no significant changes in the volatile oil fraction.

Furthermore, the moisture content can be controlled and

adjusted.

terp approved

In 2008, an application was made to the Technical expert

review Panel (TerP) of the Almond Board of California

(ABC, Modesto, CA) to validate the pasteurization pro-

cess for a five-log reduction of Salmonella SE PT 30 in

almonds. After examining all the necessary information,

TerP approved the validation in April 2008.

the system at a glance

3

6

2

5

4

71

3

6

2

5

4

7

Conditioning system

Weighing hopper

Barth CCp vessel

Vacuum pump

steam injection

discharge hopper

Cooling system

Machine type Batch size [l]

Cycle time[min]

example of throughput for 300 kg/m³ bulk density[kg/h]

example of throughputfor 600 kg/m³ bulk density[kg/h]

Barth CCp 250 250 10 to 15 300 to 450 600 to 900

Barth CCp 500 500 10 to 15 600 to 900 1,200 to 1,800

Barth CCp 1000 1,000 15 to 20 900 to 1,200 1,800 to 2,400

Barth CCp 3000 3,000 15 to 20 2,700 to 3,600 5,400 to 7,200

Barth CCp 7000 7,000 15 to 20 6,300 to 8,400 12,600 to 16,800

1


Barth NR-CEP – roasting and pasteurization. Premium roasting quality for nuts and seeds.

at which nuts oxidize can be reduced by a factor of 2.5

when compared to conventional roasting processes.

pasteurization independent of the degree of roast

The patented roasting and pasteurization technology

achieves a better than five-log inactivation of pathogenic

microorganisms such as salmonella. The Barth Nr-CeP

system complies with the latest standards for modern

pasteurization technologies and can be adjusted for

many needs and requirements.

premium roasting results and a long shelf life

The Barth Nr-CeP nut roaster allows a huge variety of

parameters to be carried out. In batch operation, any

combination of roasting time and temperature is possible.

The partly fluidized roasting ensures that energy is

distributed evenly between each individual nut, thus

making a homogeneous and optimal aroma and taste

possible for the entire batch. Consequently, processing

will be equally effective, irrespective of whether hazel-

nuts, almonds, peanuts, macadamias, pecans, cashews,

pumpkin seeds or sunflower seeds are being roasted.

The two-step roasting process developed and patented

by Bühler largely preserves the microstructure of the nuts

and thus achieves an unparalleled shelf life: the speed


– Pasteurization efficiency independent of degree

of roast

– Optimum aroma and extended shelf life of

roasted products

– Saves energy and space through pasteurization

and roasting being combined in one system

– Patented and TerP-approved process

Barth Nr-CeP 3000

the Barth nr-Cep system allows granular prod-

ucts to be pasteurized during the roasting process.

Here pasteurization is independent of the degree

of roast so that even debacterization without roast-

ing is possible.


safe and reproducible results

Safe pasteurization and high product quality are achieved

through controlled condensation of saturated steam on

the product surface. This is achieved by directing steam

into the roasting chamber for a defined period of time,

after a warming phase.

reproducible inactivation of pathogenic microorganisms

such as salmonella is achieved thanks to the good con-

trol and traceability during batch operation.

log-reduktion of Enterococcus faecium

(surrogate of Salmonella SE PT 30)

pasteurization time [min]

Trial 1 Trial 2 Trial 3

Target 5-log reduction

108

107

106

105

104

103

102

101

100

10-1Ger

m c

oun

t [c

fu/g

]

0 62 84 10

Components of a two-step roasting and pasteurization process

Machine type Batch size at 500kg/m³ bulk density [kg]

example of throughput with roasting process [kg/h]

example of throughput without roasting process [kg/h]

Barth nr-Cep 1250 50 100 150 to 200

Barth nr-Cep 2000 250 500 750 to 1,000

Barth nr-Cep 3000 500 1,000 1,500 to 2,000

1. Weighing hopper2. roasting zone3. Cooling zone4. Product discharge5. Supply air fan6. hot air generator7. Saturated steam injection8. exhaust air fan, roasting zone9. exhaust air cyclone,

roasting zone10. Fresh air fan11. exhaust air fan, cooling zone12. exhaust air cyclone, cooling

zone

6

9

2

1

105

7

4

11

8

3

12


Barth Debac™ – debacterizing system for cocoa. reduction in the germ count with flavor protection.

With the Barth debactM system, Bühler provides

a tried-and-tested process for reducing the germ

count to below the detection limit. this very gentle

treatment leaves the kernel, and therefore the co-

coa flavor, unchanged.

no compromises and safe germ reduction

The temperatures that occur during cocoa and chocolate

production are not sufficient to inactivate pathogenic mi-

croorganisms such as salmonella. These germs are pro-

tected by their low moisture activity and high fat content.

The DebacTM principle is an effective method of quickly

eliminating pathogenic and even thermophilic vegeta-

tive germs and their spores to below the detection limit.

Minimal treatment times are made possible thanks to the

unique combination of high pressure (up to 5 bar) and the

associated high temperature, and a film of moisture on

the bean’s surface.


– Consistent, efficient germ count reduction to

below the detection limit

– No effect on the taste and moisture content of

the cocoa kernel, as the shell provides protection

– “Puffing effect”: improved shell separation and

fewer fines in the nibs

– easy secondary drying, as the moisture on the

surface evaporates as a result of the cocoa

beans’ intrinsic energyBarth DebacTM 1


Barth Debac™ – debacterizing system for cocoa. reduction in the germ count with flavor protection.

The process control system of the Barth Debac™ system

provides seamless monitoring, control and documenta-

tion and thus reproducible results.

taste-neutral debac™ method

Thanks to the barrier function of the cocoa shells with

regard to temperature and moisture, the Debac™ method

is absolutely taste-neutral when it comes to the end

product. Chemical analyses show there is no increase in

the pyrazine content, which would point to undesirable

effects during the roasting process, and there is also no

rise in the water content of the cocoa nibs.

A small volume per batch and the relatively high pressure

of the steam of up to 5 bar allow highly effective debac-

terization within a very short time. Depending on the

product, this allows the Barth Debac™ debacterization

system to achieve a throughput of 4 t/h.

progression of steam pressure in the reactor

1 32

5 5

4 66 1 32

1 process cycle (in continuous operation)

Machine type throughput [kg/h]

Batch-size [kg]

reactor diameter [mm]

system height[mm]

Barth debactM 1 1,000 30 665 2,760

Barth debactM 2 3,000 85 880 3,420

Barth debactM 3 4,000 120 1,000 3,980

1 Filling the reactorFlushing with steampressure build-upreleasing pressureFilling the dosing hopperdischarging the reactor

3

2

5

4

6

Filling the

dosing hopperFilling

the reactorFlushing

with steampressure build-up

releasing pressure

discharging


Services from Bühler. Practice-based pilot plant and laboratory trials.

In the Bühler pilot plant in Freiberg, all the debacterizing

methods offered by Bühler can be tested, evaluated and

optimized.

experienced process engineers carry out pilot trials

and test series with the customer prior to a decision on

whether to buy. These trials provide an insight into the

required dimensioning of the potential plant.

The available pilot plant enables trials to be carried out

on a small industrial scale to optimize products or pro-

cesses. Qualified food and processing engineers draw on

their expertise in the field to advise customers. The Büh-

ler central laboratory in Uzwil is the ideal point of contact

for demanding analysis tasks and also offers services

such as consulting, training and method development.

as a leading technology partner in the food industry, Bühler enables customers to test the performance

of its steam pasteurization or sterilization plants in advance. professional trials and analyses enable cus-

tomers to accurately evaluate the different methods and their results regarding the reduction of germs

and other impurities. these trials form the basis for selecting the optimum plant to meet customer re-

quirements and process the customer‘s products.


– State-of-the-art pilot plant for customer trials

– Product and process optimization

– Many years of experience in the field of cocoa and

nut processing

– Support from qualified food and processing engi-

neers

– Interdisciplinary exchange with other areas of

Bühler‘s expertise and with educational establish-

ments


ProValid: Validation service from Bühler.Comprehensive service from a single source.

the aim of Bühler‘s validation service is to provide

documented proof that a pasteurization or ster-

ilization process meets the previously specified

acceptance criteria in practical use.

Compared to sampling, validation offers greater reliabil-

ity that a process achieves the required log reduction in a

proven manner and in compliance with the defined con-

ditions. The process conditions are documented and can

be used as proof for audits, for example.

Validating a process

With ProValid Basic and ProValid Premium, Bühler offers

two validation packages with different service scopes.

Both validation packages include a process validation

based on microbiological indicators, for which non-pa-

tho genic comparison microorganisms, known as surro-

gates, are used. The advantage over measuring physi-

cal parameters is that the degree of inactivation can be

determined directly. The validation then focuses on the

critical process parameters that achieve the required log

reduction.

lo

g 1

0 re

du

cti

on

elements of the validation

proValidBasic

proValidpremium

Consulting

Initial check: Check on whether the system can be validated in principle • •

Definition of the requirements and creation of a validation plan • •

Definition of the surrogate as microbiological indicator • •

Check on premises and process steps – •

initial tests

Initial validation trials: Worst-case tests to define validation parameters – •

Comparative analysis of the pathogenic germ with a surrogate in the laboratory – •

Validation

Acceptance evaluation/IQ: check on equipment installation – •

Function evaluation/OQ: functional check of equipment under conditions at place of installation

– •

Inoculation of the product sample with the previously defined surrogate and evaluation of this • •

Performance check/PQ: check on performance based on microbiological indicators • •

documentation

Validation report • •

• = Included in package, – = Not included

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

6

5

4

3

2

1

0

Figure 2: Inactivation rates per product sample

Bühler Barth GmbH

Daimlerstr. 6

D-71691 Freiberg am Neckar, Germany

T +49 7141 705-0

F +49 7141 705-100

[email protected]

www.buhlergroup.com/cocoa-and-nuts

Pasteurization and sterilization solutions for cocoa, nuts … · · 2016-04-14BÜhler...

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