STERISTEP

®

Germ reduction for low moisture products

(spices, herbs, dehydrated vegetables, seeds, nuts…)

Process owned and worldwide patented by FCD

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CONTENTS

How was born STERISTEP

®

?

Process description Process control Products treated Sum-up of the advantages

Overview of existing technologies

1st generation:

Autoclave technology

IMTECH NAPASOL HOSOKAWA

Advantages:

 Sterilization ensured   Parameters controlled can treat powders and big particles size  can treat small lots Sterilizer and pasteurizer Fluid bed technology

VENTILEX

 

Limitations:

 Equipment , labor and maintenance costs (moving parts, filters, Cleaning Batch system Continuous Autoclave system

TEMA

  

Advantages

:   Vibration: no damage to particles Easy scale up as thickness of bed is regular, increasing capacity is increasing width.

Can treat powders of big forms Can achieve sterilization.

Perfect for a customer treating only one product like pepper (lot of sporulated forms)

Limitations:

 No small lots  Cleaning time is 50% of production time.

 Quantity of steam: roughly 10 times more than other technologies in continuous. So fragile products like thyme, sage or rosemary don't have any more essential oil at the outlet  Hygroscopic products like pistachios get very wet

2 nd Generation: Pasteurizing system

REVTECH

Advantages:

 Transport by vibration, no damage to particles  Product is heated by contact with tube, 10 times less steam than Ventillex or Tema  Can achieve pasteurization (not sterilization).

Limitations:

 Minimum of quantity is 250 KG, no small lots  Cannot treat powders (due to rheologic effect)  Cannot treat too big particles like cinnamon sticks  Can only feed the tube to 1/3  Impossible to guarantee the inside is clean  Long cleaning time (8 hours for 2 people to clean the line)  Poor bacteriological results when the sizes of particles have a big range: vibrations make segregations, fines go down, big particles go up, there’s no mixing in the tube so steam cannot treat the bottom products.

3rd generation: Safesteril pasteurization system (joule effect)

ETIA

Advantages:

  Can treat powders heat by contact, less steam is injected.

 product is heated by contact with tube, 10 times less steam than Ventillex or Tema  can achieve pasteurization ( not sterilization).

    

Limitations:

Transport by screw, risk of damage the particles when big especially in the bypass section Minimum of quantity is 250 KG, no small lots cannot treat too big particles like cinnamon sticks can only feed the auger to 1/3 long time to clean 8 hours for 2 people to clean the line

1. How was born STERISTEP

®

?

Elodie Janson & Nicolas Braun Die Traumfabrik Dubai

1. How was born STERISTEP ® ?

► ► ► ► ►

What are the key properties to have good process ?

► ► ► Possibility to treat large/sensible particles ?

Possibility to treat powders ?

Possibility to treat small lots ?

required

YES YES YES

Vibrations used Vibrations used No minimum feeding grade Homogeneity of the treatment ?

Easy, quick and accessible cleaning ?

YES YES

Steps ensure the mixing <3hrs for a 3,300lbs/h unit Low energy cost ?

Low maintenance cost ?

TERP validated process ?

YES YES YES

<90 kWh/ton < $1000/year 6log reduction of E. Faecium 

For the first time ever, a steam pasteurization equipment was designed in order to meet a need, rather than adapting from an existing technology

2. Process description

2. Process description General view of the process

CHILLER / AIR DRYER COOLING UNIT ”CS” HOPPER & DOSING DECONTAMINATING UNIT ”DS” STEAM BOILER

2. Process description Hopper and dosing system ► Hopper ► ► Level probes indicate the remaining level of product Possibility to control an automatic feeding system OPTION : hopper can be placed on a weighing system (indicates the flow of product treated in kg/h) ► Vibrating dosing system ► ► ► ► Vibration = no risk of breakage Continuous and regular flow Height (thickness) of the product is controlled for a homogeneous treatment Easily accessible for cleaning and inspection

2. Process description DS : Decontamination System (1/5) Conveying method ► ► ► ► ► smooth and continuous mixing of the particles “Staircase” design in stainless steel 9 steps regular exposure to steam homogeneous treatment and final product 2 vibrating engines Particles move from one step to another – from top to bottom Fine powders (2 microns) or whole products (chili pods, breakable herbs)

2. Process description DS : Decontamination System (2/5) HEAT and STEAM : two sources of energy for more flexibility and effectiveness

Direct heat

► Particles heated by contact with a heated stainless steel surface ► Heat comes from simple electrical resistances = low energy consumption ► 4 sides heated = condensation avoided = high heating surface/m 2 = fast rise of product temperature = = short residence time properties of the product

Heatin gsurfac

preserves the organoleptic

2. Process description DS : Decontamination System (3/5) Steam (100 – 120°C / 220°F – 275°F) : necessary for decontamination Injected with nozzles at the bottom of each step :  To slightly condense on the product   To increase the heat conductivity To control the moisture of the product during the treatment steam injection with nozzles is controlled

2. Process description Heat and Steam Balance • Heat and steam can be adjusted for a greater flexibility. For herbs : For pepper : ► Plates ► Heat conduction ► Heat convection Plate temperature Steam quantity ► Steam

2. Process description DS : Decontamination System (4/5) Some of the products treated

Mushrooms Pistachios Cinnamon sticks Rice flour

2. Process description DS : Decontamination System (5/5) No minimal quantity required ► Possibility to treat small lots (5 – 10 kg) ► … and still have big capacities (20 – 40 tons) ► … on the same equipment !

2. Process description Bypass section (optional) Decontamination unit cooling unit bypass Isolates the “warm” area (decontamination) and “cold” area (cooling) ► If product has not reached sufficient temperature or residence time, it is ruled out.

Separates the treated and non-treated products ► No disruption of the decontamination cycle Run trapdoor can be adjusted with control parameters

2. Process description CS : Cooling System Product inlet cold water circulating Product outlet at room temperature

2. Process description CS : Cooling System Importance of the cooler : to stabilize the product and to pack it without risk of recontamination ► ► ► ► Vibrating plate cooled by water (cross-current) Filtered, cold and dry air injected at the input = to avoid condensation of the steam Product reaches a room temperature (20-30°C) No more bacterial development

2. Process description Annexes STERISTEP ® requires 3 fluids for the decontamination ► Steam generator : “culinary” steam produced for the decontamination unit (5% of the flow of treated product at 6 bars) ► Air dehumidifier : injection of filtered, cold and dried air at the input of the cooler to remove the moisture of the steam remaining within the hot product ► Water chiller : cold water (5-12°C) is circulating in the double jacket of the cooler. Closed loop (no water consumption)

2. Process description Maintenance and Online support Low maintenance and spare parts ► Main maintenance : change the fan filters Online support : control cabinet connected to the Internet with a modem ► ► ► Online troubleshooting Software update Assistance for the production

2. Process description Cleaning The key of success for a flexible production ► ► ► ► ► Designed for a quick cleaning Complete accessibility : no “hidden” area All parts can be visually controlled Dry cleaning : vacuum Wet cleaning : water and bactericides / washing soda

“Water fall” design

Water goes to one collecting point

2. Process description STERISTEP models 4 models from 550lbs/h to 2,640lbs/h are available ► ► ► ► STERISTEP 25 STERISTEP 50 STERISTEP 75 STERISTEP 100 Units can be doubled for more capacity !

2. Process description Configuration adjusted to your building layout

DS 1 Incoming product Area

Separation wall

“clean” area

2. Process description Configuration adjusted to your building layout

DS 1 CS 1

Separation wall

Incoming product Area “clean” area

2. Process description Configuration adjusted to your building layout

“clean” area CS 1 DS 1

Separation Wall (Recommended)

2. Process description Example of configurations

STERISTEP 50

1,100 lbs/h unit for herbs & spices

2. Process description Example of configurations

STERISTEP 75

6,600 lbs/h unit for almonds & pistachios

2. Process description Example of configurations

DOUBLE STERISTEP 75

2x 1,700 lbs/h unit for herbs & spices

2. Process description Video of the process Here is the link to a video showing the process : Video Link (or type

“FCD SAS”

in Youtube/Dailymotion)

3. Process control

3. Process control Control cabinet, PLC and supervision

Control of the process

► Motors, temperature probes, level probes, steam and air exhaust, control of the annexes..

Recipe function

► Parameters saved and programmable

Control panelview

► Possibility to send automatically the data per email at the end of a production

Connected to Internet for E-assistance

3. Process control Traceability software

Saves the “history” of the process

► Temperature, alarms… are recorded

Safe recording

► ► A new file is generated for each recording Access by login and password for each operator / administrator

Multiple input data for each recording

► Customer name and folder, batch numbers, order numbers, formula data…

Recall function

► ► To review a past production’s data Export in Excel format

4. Products treated

4. Products treated Application Pasteurization ► Inactivation of pathogens : E. Coli, salmonella, reduction of yeast, molds and other coliforms Sterilization ► ► Up to 5 logs reduction of the Total Plate Count (TPC) * Inactivation of pathogens : E. Coli, salmonella, reduction of yeast, molds and coliforms * FCD does not guarantee any effect on heat resistant forms such as spores, bacilli that might not be eliminated by treatment.

4. Products treated Family of products : NO LIMIT OF SIZE

Spices Herbs & Tea cuts Dehydrated fruits Seeds & Nuts Dehydrated vegetables … and more !

4. Products treated Other products

MUSHROOMS

TPC Enterobacteriaceae Yeast Molds

RAW

750 000 41 000 120 000 600

TEST 1

11 000 350 10 10

TEST 2

1 000 10 10 10

TEST 3

1 000 10 10 10

4. Products treated Other products

PARSLEY

TPC Enterobacteriaceae Yeast Molds

RAW

1 600 000 27 000 <10 280

TEST 1

1 000 <10 <10 <10

GARLIC SLICES

TPC Enterobacteriacea e Yeast Molds

RAW

540 000 <10 <10 <10

TEST 1

710 <10 <10 <10

4. Products treated Other products

CHILI PODS

TPC Enterobacteriaceae Yeast Molds

RAW

320 000 <10 > 30 000 > 30 000

CINNAMON STICKS

TPC Enterobacteriaceae Yeast Molds

RAW

410 000 110 1 200 7 300

TEST 1

<100 <10 <10 <10

TEST 1

120 <10 <10 <10

4. Products treated Other products

PEPPERMINT LEAVES

TPC

RAW

390 000 Enterobacteriaceae Yeast Molds 1 200 <10 <40

SAGE

TPC Enterobacteriaceae Yeast Molds

RAW

460 000 29 000 <100 18 000

TEST 1

2 100 <10 <10 <10

TEST 1

140 <10 <10 <10

4. Products treated Other products

PISTACHIOS

TPC Enterobacteriaceae Yeast Molds

RAW

320 000 210 <10 <40

WALNUTS

TPC Enterobacteriaceae Yeast Molds

RAW

530 000 80 <10 2 400

TEST 1

<40 <10 <10 <40

TEST 2

<10 <10 <10 <40

4. Products treated Other products

ALMONDS

TPC Enterobacteriaceae Yeast Molds

RAW

330 000 70 <10 59 000

TEST 2

120 <10 <10 <10

4. Products treated Other products

CINNAMON POWDER

TPC Enterobacteriaceae Yeast Molds

RAW

840 000 27 000 260 <10

TEST 1

380 <10 <10 <10

CHILI POWDER

TPC Enterobacteriaceae Yeast Molds

RAW

660 000 2 100 <10 150

TEST 1

46 000 <10 <10 <10

4. Products treated Other products

BLUE POPPY SEEDS

TPC Enterobacteriaceae Yeast Molds

RAW

570 000 3 600 <10 <10

TEST 1

1 800 <10 <10 <10

WHITE PEPPER

TPC Enterobacteriaceae Yeast Molds

RAW

27 000 000 1 600 <10 7 500

TEST 1

26 000 <10 <10 <10

4. Products treated Other products

CORIANDER SEEDS

TPC Enterobacteriaceae Yeast Molds

RAW

2 200 000 1 400 <10 100 000

TEST 2

850 <10 <10 <10

GINGER SLICES

TPC Enterobacteriaceae Yeast Molds

RAW

3 800 000 160 <10 <10

TEST 1

10 000 <10 <10 <10

4. Products treated Other products

TURMERIC POWDER

TPC Enterobacteriaceae Yeast Molds

RAW

750 000 <10 <10 <10

TEST 2

23 000 <10 <10 <40

FENNEL SWEET WHOLE

TPC Enterobacteriaceae Yeast Molds

RAW

3 000 000 160 000 <10 6 600

TEST 2

9 300 <10 <10 <40

5. Summary of the main advantages

5. Sum-up of the advantages ‘Conti-batch’: possibility to treat small lots (<10kg) even though system is continuous Vibrations are used to convey the product = possibility to treat all sizes of product (30cm cinnamon sticks…) = no breakage of sensible products (tea, leafs…) = possibility to treat powders Quick cleaning and product changeover (<3hrs for the complete line) Low electrical consumption (= 90 kWh/ton) Low maintenance (< 1,000€/year) Validated process – complete pasteurization guaranteed 1-5 TPC log reduction guaranteed

6. Other equipments proposed

NEW CONTINUOUS ROASTING/DRYING PROCESS !!

for dried fruits, cocoa, coffee…

www.fcd-system.com

[email protected]

ZA sycala cahors sud enteste 2 46230 Fontanes - FRANCE