HPP 101

FPC Author

04/02/2025 Added

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HPP 101 by Daniela Soto. 2025 High Pressure Processing and Dehydration Workshop

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[00:00:00.000]So, what you're seeing here is a Hyperbaric 55.
[00:00:07.760]So, we have five different models in our range of equipment.
[00:00:11.460]That number, specifically in the title of the machine, represents the size in liters of the vessel.
[00:00:17.860]So, in this case, the vessel is obviously 55 liters.
[00:00:21.720]So, our largest machine goes up to 525.
[00:00:25.300]So, it's a 525-liter vessel.
[00:00:28.240]In terms of throughput, with this machine, you can do about 600, 700 pounds per hour.
[00:00:33.380]It's going to depend mainly on the loadout.
[00:00:35.940]So, how much packages can you get inside those baskets?
[00:00:38.900]As you get into the larger machines, the diameter of those baskets get larger, and you get more baskets inside that vessel.
[00:00:47.300]In terms of main components, so, if we open up...
[00:00:52.300]Thank you.
[00:00:55.960]So, if we...
[00:00:58.200]So, if we...
[00:00:58.220]If we take a look inside, and don't feel afraid to get closer to the machine.
[00:01:02.220]So, what you're looking at here is the cylinder vessel.
[00:01:06.200]So, it's basically wire-wounded.
[00:01:08.640]So, this is a main critical component of the machine.
[00:01:12.580]Here, what you have is a plated yoke frame.
[00:01:16.860]So, it's several plates of stainless steel welded together to withstand these very, very high pressures.
[00:01:22.780]So, you have your vessel, you have your yoke and frame, and if you take a deeper look back in time,
[00:01:28.200]you'll see a piston. So, this particular unit just has one integrated piston.
[00:01:34.840]Usually, in our larger machines, you have double cabinet intensifiers.
[00:01:39.360]So, it's two pistons that are completely isolated.
[00:01:42.960]And our machines, depending on the model, you can scale up throughput by adding additional intensifiers.
[00:01:49.180]A pretty unique thing in our machines is that if one intensifier goes down,
[00:01:54.220]you need to provide maintenance to a particular intensifier.
[00:01:57.280]You can still keep it in place.
[00:01:58.180]You can still keep running with the other intensifiers in place.
[00:02:00.560]Excluding the 55-liter machine, on larger machines we have a return conveyor.
[00:02:07.120]So I'll explain what a full HPV cycle looks like.
[00:02:10.020]But once you finish that loadout, empty baskets will automatically travel to the loading stage of the equipment.
[00:02:17.000]So going back to the components of the machine, we have the vessel, yoke frame, the intensifier.
[00:02:22.340]So basically it involves a piston with a medium of hydraulic oil,
[00:02:28.160]it works in stroke format, so we're basically pumping out high pressure water
[00:02:33.160]and pulling in low pressure water to generate that pressure.
[00:02:36.160]All industrial HPP machinery can go up to 6,000 bar, 87,000 PSI.
[00:02:41.720]So you'll constantly in the industry be hearing 87,000 PSI or 6,000 bar for X amount of holding time at a set temperature,
[00:02:49.880]which are those key parameters that we're dealing with HPP.
[00:02:53.760]Any questions so far?
[00:02:55.200]What's your max temp that you put on this?
[00:02:58.140]So usually most customers are processing about 5 degrees Celsius, 6, 7.
[00:03:04.520]So what does a full HPP cycle look like?
[00:03:07.060]So basically, in this smaller machine, you would have two baskets,
[00:03:11.840]which you can see what the basket looks like right here.
[00:03:16.460]It is a super tiny one.
[00:03:17.640]So this entry-level machine is mainly used for R&D, academia,
[00:03:22.020]or even companies that are just doing seasonal production.
[00:03:24.880]So they don't need those high throughputs.
[00:03:27.320]So you'll have two baskets.
[00:03:28.120]On the loading, this conveyor will then push into this vessel.
[00:03:33.940]This vessel will then get into place and align with--
[00:03:37.760]if you guys step a little closer,
[00:03:39.180]you guys will see two plugs on each side.
[00:03:41.980]Will partially get inserted into the vessel.
[00:03:44.740]We'll start filling up this vessel with low pressure water.
[00:03:47.720]So sporadically start pumping in low pressure water.
[00:03:51.640]We'll lock that in with the wedges on each side.
[00:03:54.620]And then start driving up that pressure up to 6,000 bar.
[00:03:58.100]We'll then be at a holding time stage, typically 180 seconds.
[00:04:03.140]Instantly decompress, and then the products with the baskets
[00:04:06.680]will then can be retrieved on the other end of the equipment.
[00:04:11.980]If there's no questions, I'm going
[00:04:14.500]to take you guys over to where we have a layout of all
[00:04:18.660]the commercial products that you can find in the market.
[00:04:20.900]Typically with HPP products, you'll
[00:04:23.760]be finding them in the perimeter of the retail store.
[00:04:26.600]Why?
[00:04:28.080]Because with HPP, we can inactivate bacterial spores.
[00:04:31.200]At 6,000 bar, we can typically get rid of things
[00:04:33.360]like salmonella, listeria, E. coli.
[00:04:36.860]So therefore, we need to preserve the cold chain.
[00:04:40.360]So now here are just some commercial examples
[00:04:43.440]that are currently available in the market here in the US,
[00:04:47.040]which you can find in any Goodfoods, Walmart.
[00:04:49.540]So first, let me introduce you to the Columbus Cured Meat
[00:04:54.280]products.
[00:04:54.840]So you can see here, this is a customer of ours.
[00:04:57.280]We use HPP.
[00:04:58.060]It's a post-lethal treatment.
[00:05:00.460]So what this customer do is they use the curing step
[00:05:04.740]as the first lethal treatment.
[00:05:07.180]And then they slice it up, and then they
[00:05:09.180]use HPP as a post-lethality in order
[00:05:11.980]to reach a log reduction of two to three log inactivation
[00:05:16.000]of Listeria mainly, which will be the main pertinent pathogen
[00:05:19.160]of concerning these product types.
[00:05:21.060]This is a product I just processed.
[00:05:22.960]So you can see that there are small white dots
[00:05:26.260]on the surface.
[00:05:27.280]So these white dots--
[00:05:28.040]these dots occur because of the air present in the packaging.
[00:05:31.660]So air under this high pressure isn't a gas.
[00:05:34.540]It's a liquid.
[00:05:35.420]It mixes into the food matrix.
[00:05:37.500]And during the depressurization, which
[00:05:39.240]is pretty instantaneously and pretty abrupt,
[00:05:42.320]this will come out of the food matrix.
[00:05:44.320]And after being mixed with protein and fat,
[00:05:47.520]it will create these small white dots.
[00:05:49.980]But these white dots will disappear after eight hours.
[00:05:54.440]So when customers add this type of map, they see that after some
[00:05:58.020]time it disappears.
[00:05:59.660]Also, Hormel, the brand with the most HPV machines in the world,
[00:06:06.080]they use HPV as a post-lethality treatment as well in their deli.
[00:06:10.280]As you can see, this cooked ham, you can see how it looks.
[00:06:15.640]It is a clean label product.
[00:06:17.840]They opted to replace conventional chemical nitrates for
[00:06:21.200]celery powder, and they use HPV to increase food safety.
[00:06:24.900]Also, we have here baby food.
[00:06:28.000]You remember, babies are the hardest consumers because they are super delicate,
[00:06:31.620]and moms are pretty worried about what to give to their babies.
[00:06:36.880]So this brand, called Once Upon a Farm, is very known here in the US.
[00:06:41.120]It is full of clean label products, fruits, vegetables, rich in vitamins.
[00:06:46.920]Also, we have here juices and beverages, which in the last,
[00:06:50.440]I've seen some products last 120 days, 180 days.
[00:06:54.460]Some customers just reduce it for 90 days.
[00:06:57.980]Juiceless, they are cold pressed, clean label.
[00:07:01.340]And also, this customer is still good, so you, what they do is they add.
[00:07:07.400]They add Bacillus coagulans, which is a spore former,
[00:07:10.780]and it's a probiotic micronism, which can help for your gut support.
[00:07:16.980]And it's pretty resistant to high pressure,
[00:07:19.180]because remember that we won't inactivate the spores.
[00:07:22.160]Also, DEEPS.
[00:07:24.140]DEEPS are compatible with the technology.
[00:07:26.360]They're pretty tricky.
[00:07:27.960]You package them into cups, because they're pretty sensible.
[00:07:31.800]And they break and present packaging malfunctions.
[00:07:34.820]But you'll remember in the presentation on packaging,
[00:07:37.420]they need to have a wide ceiling area,
[00:07:40.020]and also a reduced head space.
[00:07:41.860]Those ones are OK for HPP.
[00:07:44.340]This is a very interesting product,
[00:07:45.940]processed as well at 6,000 bars for three minutes.
[00:07:49.080]So before adding here in the cup, it is pretty liquid.
[00:07:52.380]And HPP will promote the creaminess and the texture
[00:07:55.460]of a very creamy deep.
[00:07:57.940]So they packaged it into this bottle
[00:08:01.080]and also into these cups.
[00:08:03.480]Also, this customer based in Rochester, New York,
[00:08:06.520]they do hummus.
[00:08:08.340]And they use lemon juice in order to help reduce the pH.
[00:08:11.920]And it is pretty tasty.
[00:08:12.880]And also, HPP will help leverage a very creamy hummus deep.
[00:08:17.820]And it can help extend the shelf life for 60 days
[00:08:20.640]as well as a clean label product, only natural
[00:08:23.840]ingredients.
[00:08:25.340]This other customer called Mush, it
[00:08:27.920]is all around the country.
[00:08:29.500]They create this ready-to-eat overnight oats.
[00:08:33.100]And what HPP will do is will help
[00:08:35.880]create that mushy texture, pretty like an overnight oats
[00:08:41.100]for only three minutes instead of storing it
[00:08:43.560]for 24 hours in your fridge.
[00:08:45.480]And it will help you protect against listeria, salmonella,
[00:08:47.940]coli, while also creating really attractive flavors
[00:08:52.680]and attractive products.
[00:08:54.980]Also, here we have more of the seafood sector.
[00:08:57.900]Which is highly compatible with the technology.
[00:09:01.200]Will this slide right off the show?
[00:09:03.280]Yeah.
[00:09:04.780]So everything that we've been talking about here
[00:09:06.780]is post-packaging.
[00:09:08.220]Once you start touching some of the seafood stuff,
[00:09:10.660]you do have that application of shucking.
[00:09:13.160]So at moderate pressures, so think 40,000 PSI
[00:09:17.140]with shorter holding times of 90 seconds,
[00:09:20.040]you're able to separate the adductor muscle of the meat
[00:09:23.020]and oysters, lobsters, and get an easy meat extraction.
[00:09:27.880]While still removing things like Vibrio and Norovirus.
[00:09:31.920]So you get food safety, extraction, minimized labor.
[00:09:34.960]So someone in the previous group asked,
[00:09:38.820]so we'll show you guys what the different color changes
[00:09:42.400]in meat looks like at various pressures.
[00:09:44.440]And this was processed at 3,000 bars for 120 seconds.
[00:09:51.200]And they asked, does the color change also inside?
[00:09:54.880]And the answer was yes.
[00:09:56.640]So if you do see...
[00:09:57.860]Yeah.
[00:09:58.520]So it gets paler.
[00:10:00.700]Pale, yeah.
[00:10:01.440]But still it looks raw in the interior.
[00:10:03.880]So yes, it helps promote protein coagulation.
[00:10:07.220]protein denaturation and that is why it turns out like this but if you cook that
[00:10:11.530]raw piece of meat it will come out the same as if you cook an unprocessed raw
[00:10:16.750]meat so yeah for sure yeah some customers what they do is they marinate
[00:10:24.010]those raw meat products as a ready to cook in order to mask those color
[00:10:27.890]changes so the consumer won't see exactly that pale like appearance they
[00:10:32.950]only will place it in a pan cook it and it will turn out the same yeah there are
[00:10:39.190]some studies where there is increased flavor by infusing that marinade and
[00:10:45.370]tenderizing meat so here I'm gonna process some raw meat products one that
[00:10:52.870]is sous vide with marinade just to see the changes it has been cooked already
[00:10:56.950]marinated I'll only introduce it into the blue basket I'll also be introducing
[00:11:02.830]this raw poultry meat and also this raw beef patty grounded and also a piece of
[00:11:15.690]rustic you can see how red it is pretty bright we'll process it at high pressure
[00:11:26.050]so you can see how it turned out also I added use which here
[00:11:32.710]our colleague and to show him how it is how it works you can think that it is
[00:11:37.810]very rigid and yes the packaging is pretty rigid but still it's flexible
[00:11:41.330]enough to withstand the pressure it is PET and it is highly compatible also it
[00:11:46.750]is rounded it has the demi-sphere which will provide rigidity to the packaging
[00:11:52.210]to help withstand the high pressures that we'll be applying as well so here I
[00:11:56.230]will be able to manage the type of pressure level I'll be applying to classify the
[00:12:02.590]product I'll be processing the holding time that I'll be taking for this time
[00:12:07.690]I'll be processing at the most conventional HPP parameters which are
[00:12:11.030]87,000 psi 600 megapascals or 6000 bars for three minutes so this is what the
[00:12:18.370]industry currently uses as much so this is the smallest unit and usually bigger
[00:12:24.710]units they have a conveyor belt so when the products come out they'll come to
[00:12:29.290]the same place and it will be easier to manage it manually
[00:12:32.470]this machine only requires one person and maximum two to operate it sorry right
[00:12:40.750]now we're waiting yeah so we need to unblock the feeder yeah so the machine
[00:12:47.590]is very safe to to use it has a lot of sensors you can see let me see if here
[00:12:53.110]it has this is one sensor for example another one and if you if it is
[00:12:59.050]processing and you introduce your hand everything stops
[00:13:02.350]also it has what we call the transducers which will help monitor the pressure
[00:13:06.250]level and doesn't need to be calibrated so it is very safe
[00:13:11.410]I've heard different things about about calibrating the transducers is it like
[00:13:17.290]and more like an annual situation is that what kind of what you see more
[00:13:22.030]often because we were asked about it during audits and I was like honestly
[00:13:26.510]he didn't know much about it even I didn't know much about it either about
[00:13:30.370]how often most people
[00:13:32.230]a little different married by equipment suppliers I'm not sure for your
[00:13:37.170]supplier but typically that sounds about right and usually for our machines
[00:13:42.610]they're already like guidelines and our support equipment can help you in that
[00:13:47.350]but usually also the machine will show an alarm when a calibration is needed
[00:13:51.910]I've seen that with my machine and I just called service and they help me
[00:13:55.790]change it so I guess while they are taking care of that I wanted to
[00:14:02.110]show you the change in color and proteins this occurs because there's a
[00:14:06.490]protein denaturation like we learned yesterday in the presentations these is
[00:14:10.750]this is your control so this has not been processed here you have 3000 bar
[00:14:16.030]for 120 seconds and then here you have 6000 for 180 seconds you guys can touch
[00:14:22.610]see the change in texture changing color
[00:14:27.510]so once you start getting those very high pressures you get that
[00:14:31.990]cook like appearance
[00:14:35.930]when you fuck it still exposed to the process depending in your HACCP plan but
[00:14:45.330]usually HPP would act as a kill seven and then as a critical control so this
[00:14:51.890]is the myoglobin is in the native state so that is why it's very red then it
[00:14:57.750]turns out very pale because of the nature so here
[00:15:01.870]you see we are increasing the pressure level what you're hearing is intensifier
[00:15:10.290]responsible of increasing that pressure working so it is pulling low pressure
[00:15:15.890]water and it is pumping high pressure water into the vessel to increase that
[00:15:21.170]pressure level so it is going to one side and then to the other how we are
[00:15:27.410]reaching that pressure we want to reach which will be I think 80
[00:15:31.750]seven thousand feet size six thousand bars so we'll be reaching here once we
[00:15:36.490]reach that pressure level we will start counting so that's the holding time so
[00:15:42.030]we will be counting right now for a hundred and eighty seconds three minutes
[00:15:46.870]so in this screen we can see what's going on
[00:15:50.290]this time can be reduced by filling more the baskets so the more filled up the
[00:15:57.370]baskets are the less time will be required to increase that pressure level
[00:16:01.630]so the machine will need to add more and more water because it is already occupied
[00:16:06.730]by that product all the packaging and not only void spaces so in order to
[00:16:12.490]increase productivity with HPP we suggest increasing that vessel filling
[00:16:17.350]ratio with more products reducing the air content in the packaging because the
[00:16:22.150]machine will require more time to fill up those void spaces caused by air or
[00:16:28.270]gas inside of it so the less air the more
[00:16:31.510]product inside of them will help increase those rapid like those
[00:16:35.950]velocities increase pressure level so here we just reach 6,000 bars that's why
[00:16:41.890]right now we're not listening to intensifiers working because right now
[00:16:45.490]we're above that pressure level so the hyperbaric machines will never be
[00:16:50.650]processing below the pressure level you introduce if you if you are below the
[00:16:56.510]6,000 bars the cycle will stop an alarm will come up and say the cycle failed
[00:17:01.390]but usually it is always above that pressure level so right now you'll see
[00:17:05.770]here that we're at 6,026 bars and that is because it'll never never be below
[00:17:10.710]6,000 the power goes down in this three minutes oh it's a fail cycle okay so
[00:17:22.930]it's still safety for the product yeah so basically what I've seen when I have
[00:17:27.310]a fail cycle because I don't know I did something wrong with with it or I
[00:17:31.270]decompressor or something happened what I do is the machine will tell me fail
[00:17:36.610]cycle redo again so the processor inside the machine the pressurized for safety
[00:17:43.770]reasons and I'll continue the cycles and it'll count again so that's one thing
[00:17:49.490]that happens also it is very easy to don't mix products and because you have
[00:17:55.730]the unprocessed side and the process side on the other side so it's difficult
[00:18:01.150]to mix them in bigger machines when you have a lot of products for the conveyor
[00:18:05.150]belt that helps also divide that but yeah also this machine has a chiller a
[00:18:11.950]chiller that helps cool the processing water the chiller is on the other side
[00:18:16.270]and it helps maintain those cold temperatures and it also has a external
[00:18:23.970]hydraulic pump for the intensifier as well and a lot of the water is recycled
[00:18:31.030]in industrial equipments right now we're developing a system that can help
[00:18:35.510]to recover a hundred percent of the water to reduce water waste but yes very
[00:18:40.510]clean
[00:18:42.790]so now we're still counting for the three minutes this is still under
[00:18:48.090]pressure it requires 40 seconds more to complete the cycle and you'll see how
[00:18:53.990]when the cycle ends the pressure will drop instantaneously and it will be
[00:18:58.470]super abrupt it will take
[00:19:00.910]less than a second yeah it's very cool
[00:19:05.790]so when you receive for example the meat you pack it straight away and then it
[00:19:15.410]goes straight away for for the high pressure process yeah and it's to be in
[00:19:19.570]its final packaging that's what we suggest in order to avoid
[00:19:22.990]recontamination which is one of the main objectives with HPV there's other
[00:19:26.830]applications which are furtherly processed in a clean room
[00:19:30.790]um but yeah it needs to be in the final packaging only bivalves and it's a
[00:19:37.870]depressory station and the shocking aren't packaged yeah you can see how
[00:19:42.190]instant it went
[00:20:00.670]here there was nothing but yeah
[00:20:10.150]- Thank you.
[00:20:10.990]Thank you.

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HPP 101

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