915 MHz Single Mode Microwave Technology for Food Safety - from development to

commercialization

Key elements: vision, team/competence, passion/persistence, delivery/resources

Juming Tang, Ph.D.Professor of Food Engineering

Department of Biological Systems EngineeringWashington State University, Pullman WA

Microwaveheating.wsu.edu

Challenges in Developing New Technologies

Conceptdevelopment

Pilot-plant testingEquipment

ProductMicrobial

Regulatory acceptanceScale-up &industrial

implementation

Lengthy canning processes (30-100 min at 121C) cause losses in texture, appearance

Two frequencies allocated by the US Federal Communications Commission (FCC) for industrial heating

applications

2,450+50 MHz (0.12 m) - domestic microwave ovens

- industrial heating systems

915+13 MHz (0.33 m)- industrial heating systems

5

WSU Microwave Consortium I (2001-2010)- initiated with support from US DoD Dual Use Science and Technology

(DUST) Program

Graphic Packaging

NFPA

Rexam

Kraft

Hormel FCINatick

WSUOBS

Masterfoods

Pilot-scale systems

Computer simulation & mock-up units

Process development

• Industrial implementation

915 MHz Single-Mode Microwave Sterilization Technology

Microbial studies

• Scaling-upRegulatory acceptance

Dr. Frank Liu, Project Engineer Computer simulation and experimental validation

Development of pilot-scale protocols

Dr.Frank Liu, Project engineer Engineering design and manufacturing

Measurement of food properties

29.5°C

91.6°C

40

60

80

AR01

WSU 2nd generation system - four single mode cavities, 40 kW max MW power, received FDA acceptance for first filing on Oct.

2009

Microwave assisted thermal processing system (MATS)

waveguidecavity

0 phase shift

Change of Shear Force in Pink Salmon Fillet Heated at 121˚C

30

50

70

90

110

130

150

170

0 20 40 60 80 100 120 140

Cooking time (min)

Shea

r for

ce (N

)

Chicken and dumplings in 8 oz pouches (Print-pack) processed

with WSU Microwave Sterilization System, produced for sensory studies at US Army

Natick Soldier Center

• Chicken and dumplings in 8 oz foil pouches by retort (control) for the sensory

studies

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On Oct. 7, 2009, we received first FDA approval

Visiting FDA Low Acid Food Team in DC, 2004

First FDA filing: mashed potato in 10 oz trays -2008

Engineers conducting heat distribution and heat penetration studies

NFPA strain 3679 (P.A.. 3679) as the surrogate.

D121C should be 3-4 times that of C. botulinum spores, so that we use smaller number of surrogate to validate 12 log reduction in C. botulinum spore populations

Microbial validation of food safetyTargeted microorganism – C. botulinum spores

Prepare samples for inoculated pack studies with PA 3679 spores

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On Oct. 7, 2009, we received first FDA approval

Second FDA filing: salmon fillets in sauce in 8 oz pouches - 2009

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Salmon filet, skinless and boneless

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8-oz Printpack pouch

Developing data to seek FDA approval for non-homogeneous foods

• Positioning Ellab sensor tip at the

location determined by heating pattern

Processing real food in MW system

• Data retrieval from Ellab temperature sensor

• Temperature profile overlay with MW system data

Inoculating PA 3679 spores to the cold spot in salmon fillets

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Incubation in Walk-in Incubator (~ 36°C)

• Positive pouches

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Process accepted on Dec. 15, 2010

Submitter: Kenneth Lum

PINK SALMON, SKINLESS AND BONELESS IN ALFREDO SAUCE

(processing method) MICROWAVE ASSISTED HEATING (finished pH) 6.3

(sterilizer) OTHER SEE COMMENTS; Microwave Assisted Prototype

(heating medium) WATER IMMERSION (process source)

Source Attached Document09/22/2010 -- LETTER

SCSI, subsidiary of Seafood Products Association, formerly NFPA NW Laboratory  

Process Source -- MW Filing Rec 9-22-10SG.pdfNotes: Process Recommendation letter  

(date filed) 12/15/2010

• Submitter: Kenneth Lum

Summary of Major Milestones• July, 01 Formed WSU Microwave Consortium I• July, 02 Developed first 915 MHz single mode pilot

system (10 kW)• Oct., 06 Received US patent for 915 MHz single

mode microwave sterilization system design • Aug.,07 Developed a second generation

system – semi-continuous system (40 kW)• Oct., 09 Received FDA acceptance for MW

sterilization of mashed potato in 10 oz trays• Nov. 10 Formed MW Consortium II, focusing on

commercialization• Dec. 10 Received FDA acceptance for MW

sterilization of salmon fillets in sauce in 8 oz pouches

• 2011 Filed petition to USDA FSIS for processing foods containing >2% egg, poultry and meats

WSU licensed exclusive rights for commercialization of this technology to Food Safety Chain (FSC) corporation (Maple Valley, WA). Formed MW Consortium II (Nov. 11, 2010).

Commercialization

WSU• Education• Research

• Computer simulation models• Processing filing protocols

Structure of WSU MW Consortium II

Food Chain Safety, Co.• Engineering design• Industrial systems• Supports/servicing

AmeriQual• 1st industrial system• Plant tests support

• Market testing

MW Consortium II11 Companies &SPA

WSU MW Consortium II sub-teams

1. Regulatory (preparing data and filing documents to FDA and USDA FSIS, guiding engineering team in system design)

2. Engineering (industrial system design, technology implementation)

3. Product development (formulations and processes for best products -unique to the technology)

4. Education and training (short-courses and hands-on training for industrial personnel)

5. Packaging (new packaging development, regulatory concerns)

Example: activities of product development sub-team at WSU

Packaging sub-team update at a concern meeting in Evansville, IN, May 2011

Industrial members in a microwave sterilization short course

Thank You

Microwaveheating.wsu.edu