American Cheese SocietyDes Moines, IA

2016

David SandelmanJDS Consulting

Neville McNaughtonSanitary Design Industries

Breaking the Cycle

This is the way we’ve always done it

This is why we

do it this way

Historically Local Conditions Dictated Style

History Teaches Us

ORIGIN: Normandy, FranceSTYLE: Very soft, aged on straw in farm creameriesCELLARS: Damp and DraftyTEMP: Moderate

Camembert

History Teaches Us

ORIGIN: British IslesSTYLE: HardCELLARS: Damp and DraftyTEMP: Cool

History Teaches Us

ORIGIN: ItalySTYLE: HardCELLARS: DraftyTEMP: Warm to Cool

Not all cellars are created equal

Cheddar, UK Burlington, VT28

21

-12

2

Not all cellars are created equal

Parma, Emiglia Roma Seattle, WA

26

30

1-1

Breaking the Cycle

This is the way we’ve always done it

This is why we

do it this way

One of mankind’s greatest architectural innovations (for holding up a ceiling)

A beautiful expression of symmetryFunction versus Fashion – Unintended Benefits?

A Brief History of the Arch

Cheeses were a product of the environment and empirical

knowledge of cheese makers

Survival of the Fittest

Cheese Making

Procedures

Limits of aging environment

Survival of the Fittest

Survival was insured by adapted techniques like:

Salt Water Washing Low humidity drying Heavily salting

But times have changed…We want to produce the same cheese consistently –

everywhere & anytime

We can control our make procedures & our aging spaces

Survival of the Fittest

Cave: a large underground chamber, typically of natural origin in a hillside or cliff

Cellar: a room below ground level in a house, typically one used for storing wine or coal

Aging Space: a room above ground level used for aging cheese or meat

Call it what you want…It is the function that is critical

What’s In a Name

Fail to Plan = Plan to Fail

Understand What Your Cheese Needs to be Happy

• Temperature• Dew Point/Vapor Pressure• Air Movement/Air Rolls• Air Changes

Set Your Spec – Then Design

GOUDA56°F

85% RHAir Rolls ?

Air Changes 1-2 DailyFloor & Ceiling R = Min 30

CAMEMBERT54°F

94% RHAir Rolls ?

Air Changes 2-4 DailyFloor & Ceiling R = Min 30

Movement•Recirculation of existing air and

everything that is in it (microbes, etc…)

Make Up or Air

Changes

•Introduction of fresh air & discharge of unwanted gases (conditioned or not)

Clearing The Air

Blown Away by Air Changes

Camembert Room = 3 Air Changes Per Day

10 x 20 room with an 8’ ceiling =1600 cubic feetMove/replace 4800 Cubic feet of air per day (1600 x 3)

200 cubic feet per hour (4800/24hr) or 3 cubic feet per minute (CFM)

Computer Fan40 CFM

Or 15X more than required!

Bathroom Exhaust Fan60-100 CFM

Or 20-30X more than required!

Too Much Make Up Air

Adding Unconditioned Air Can Lead To Unintended Consequences

System/Space stability can be compromised If it is not tempered…it is NOT part of the system Different cheeses require different conditions

Consider This:What happens in cheeses like Gouda & Parmesan vs

Roquefort & Camembert is night and day

Gouda & Parmesan are almost anaerobic vs Roquefort & Camembert which are Microbial and Fungal

Air Movement (Rolls)

Camembert Room = 5 Air Rolls per Hour10 x 20 room with an 8’ ceiling =1600 cubic feet

Roll 6400 Cubic feet of air per hourThat requires a fan with a capacity of 110 cubic feet per minute (CFM)

Fantec 110137 CFM

2 Fan Evaporator2000 CFM at full speed

The Ideal Room

Exhaust/WasteRemove from

lowest point in the room

Controlled Make Up Air

Filtered & Conditioned for Temp and Dew

Point

The Ideal Room Temperature Dew Point

Controlled Air Movement No condensation to drip

and contaminateMake Up Air

Control the Internal Space Inside the “Envelope”

The Compromised Room (typical)

Temperature∗Dew Point

∗Controlled Air Movement∗No condensation to drip and

contaminate Make Up Air ?

Loss of ControlInside the “Envelope”

Think ‘Aging Room Envelope’

OutsideWalls

Non PorousVapor Tight

Monolithic Walls(sealed to floor)

A Dry Floor: Is desirable

Low microbial load A cleanable drain

Properly sloped to drain Works with environmental

control – not against it

Control From the Ground Up

The Ground is an Uncontrollable Source of Vapor Pressure

Monolithic (non porous) walls & ceilings are critical to controlling vapor pressure in the aging space

Understanding Walls & Ceilings

Outside – Wet ConditionsDry Bulb Temp 85°FDew Point 77°FVapor Pressure 31.61mb or 0.46 PSI

Outside – Dry ConditionsDry Bulb Temp 20°FDew Point 14°FVapor Pressure 2.86mb or 0.04 PSI

Desired Conditions Inside Room Everyday

Dry Bulb Temp 50°FDew Point 48°F

Vapor Pressure 13.21mb or 0.19 PSI

• Optimal wall materials are non-porous – Isolate the space

• Mold never belongs in your walls

Do I Need a Vapor Barrier on Both Sides of My Wall!?

But I do get good results, sometimes!

Even a broken clock gets it right twice a day!

For an aging room it is twice

a year.

Consistent Control of the Aging Space

It is all relative!

Taking Control…Which 93% Would You Like?

Temperature F 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60C 4.4 5.0 5.6 6.1 6.7 7.2 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6

Dew Point F40 4.4 100% 96% 93% 89% 86% 83% 79% 76% 74% 71% 68% 66% 63% 61% 59% 57% 55% 53% 51% 49% 48%41 5.0 ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 71% 68% 66% 64% 61% 59% 57% 55% 53% 51% 49%42 5.6 ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 71% 69% 66% 64% 61% 59% 57% 55% 53% 51%43 6.1 ---- ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 71% 69% 66% 64% 62% 59% 57% 55% 53%44 6.7 ---- ---- ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 71% 69% 66% 64% 62% 60% 57% 55%45 7.2 ---- ---- ---- ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 72% 69% 66% 64% 62% 60% 58%46 7.8 ---- ---- ---- ---- ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 72% 69% 67% 64% 62% 60%47 8.3 ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 72% 69% 67% 64% 62%48 8.9 ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 74% 72% 69% 67% 65%49 9.4 ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 89% 86% 83% 80% 77% 75% 72% 69% 67%50 10.0 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90% 86% 83% 80% 77% 75% 72% 70%51 10.6 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90% 86% 83% 80% 77% 75% 72%52 11.1 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90% 86% 83% 80% 78% 75%53 11.7 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90% 86% 83% 80% 78%54 12.2 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90% 87% 83% 81%55 12.8 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90% 87% 84%56 13.3 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90% 87%57 13.9 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93% 90%58 14.4 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96% 93%59 15.0 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100% 96%60 15.6 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- 100%

Both are 90%...

90%

90%6 oz18 oz

Both are 6oz...

20%

90%

6 oz 6 oz

Start ThinkingDew Point!

(aka Vapor Pressure)

Psychrometrics Made Easy in Aging Rooms

Vapor Pressure & Dew Point are related

e= 6.11 x 10(7.5 xT d /237.3+ T d )

e = Vapor PressureTd = Dew Point Temperature

If we know the Vapor Pressure we know the Dew Point

If we know the Dew Point we know the Vapor Pressure

Water activity or aw is the partial vapor pressure of water in a substance divided by the standard state partial vapor pressure of water.

Definition of aw:Where p is the vapor pressure of water in the substance, and

p₀ is the vapor pressure of pure water at the same temperature.

Water Activity

aw= p / po

Which Bottle is colder?

Which Mug is Hotter?

What is going on here?

Is there more air pressure in the Bottom or in the Top of the Tire?

It's Only Flat on the Bottom!

This is what happens when the pressure is greater on the inside then the outside, and there is a way for the high pressure side, (inside the tire) and low pressure side (outside the tire) to equalize.

Why Monolithic Walls?

OutsideWalls

Non PorousVapor Tight

Monolithic Walls(sealed to floor)

Vapor Pressure in Your Aging Space

Aging Space

Desired Conditions in Room Dry Bulb Temp 55F Dew Point 52F Relative Humidity 90% Vapor Pressure 13.21mb or

0.19 PSI

Vapor Pressure in the Winter

Aging Space

Outside Winter DayDry Bulb Temp 20FDew Point 14FRelative Humidity 80%Vapor Pressure 2.86mb or .04 PSI

Desired Conditions in RoomDry Bulb Temp 55FDew Point 52FRelative Humidity 90%Vapor Pressure 13.21mb or 0.19 PSI

Vapor Pressure in the Summer

Outside Summer DayDry Bulb Temp 85FDew Point 77FRelative Humidity 80%Vapor Pressure 31.61mb or .46 PSI

Aging Space

Desired Conditions in RoomDry Bulb Temp 55FDew Point 52FRelative Humidity 90%Vapor Pressure 13.21mb or 0.19 PSI

Where's the Water Going?When Evaporator Coil is in a Typical Space

Room Conditions = Compressor OnDry Bulb Temp 53F

Dew Point 30FVapor Pressure 5.6mb or 0.08 PSI

Coil Conditions = Compressor RunningDry Bulb Temp of Coil 28F

Dew Point 28FVapor Pressure 5.2mb or 0.08 PSI

Desired Conditions of SpaceDry Bulb Temp 55F

Dew Point 52FVapor Pressure 13.21mb or 0.19 PSI

Outside Summer DayDry Bulb Temp 85FDew Point 77FVapor Pressure 31.61mb or 0.46 PSI

Outside Winter DayDry Bulb Temp 20FDew Point 14FVapor Pressure 2.86mb or 0.04 PSI

Where's the Water Going?When Evaporator Coil is in a Typical Space

Room Conditions – Compressor OffDry Bulb Temp 56F

Dew Point 77F Summer / 14F WinterVapor Pressure 13.21mb or 0.19 PSI

Coil Conditions = Compressor OffDry Bulb Temp of Coil 55F

Dew Point NoneVapor Pressure Same as Room

Desired Conditions of SpaceDry Bulb Temp 55F

Dew Point 52FVapor Pressure 13.21mb or 0.19 PSI

Outside Summer DayDry Bulb Temp 85FDew Point 77FVapor Pressure 31.61mb or 0.46 PSI

Outside Winter DayDry Bulb Temp 20FDew Point 14FVapor Pressure 2.86mb or 0.04 PSI

The Annual Cycle

Increasing Dry B

ulb Tem

peratureD

ecreasing Dry B

ulb Tem

perature

Decreasing Dew Point Temperature

Increasing Dew Point Temperature

Winter

Summer

Proper Control

1. Control the outside ambient conditions impacting aging room. Room constructionOutside air management

2. Independent control of Dry Bulb and Dew Point3. Fully modulating control of Dry Bulb and Dew Point

After Proper Control

Proper Design & Drains

Non Porous Construction

Seals, Insulation & Vapor Barriers

Sanitary Air Management

Controlled Temperature & Dew Point

Higher Profit

Sound Building At Every Step Pays Off

Less…WasteManagement HasslesRework

Floor

Wall &Ceiling

SealedEnvelope

Air

Control

Results

The Final Value of

Your Cheese

Labor

Aging

overhead

Milk

The Value Mix

A Not So Simple Equation

YOUR AGING SPACE

MILK

LABOR

OVERHEAD

Aged Cheese To Market3X Inputs

Your Aging Space multiplies the value of your inputs significantly

The Least Expensive InvestmentBrings High Returns

HTST Room $650/Sq Ft

Mechanical Room$350/Sq Ft

Production Room$500/Sq Ft

Proper Aging Space (20x10x8)$63-$135/Sq Ft

Can I Afford NOT to Fixmy Aging Space?

CONSIDER THIS:In the Aging Space – where our cheese spends most of its life, we spend the least dollars and realize the most value

50,000 lbproduction

annually at $10.00 Wholesale Selling

Price

7% Unsaleable product due to unstable aging

conditions

3500 lb = $35,000Lost Topline Sales

in One Year

About $11,000 Lost Gross Profit

in One Year

Discussion