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Defrosting Technology

Defrosting Technology

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Defrosting Technology

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  1. Defrosting Technology Process Expo, Chicago IL, November 2011 Henrik Thrysoe

  2. GEA - Defrosting A controlled process for fast thawing of meat by means of low pressure steam and indirect heating to reduce defrosting time while improving food safety, logistics, shelf life and increasing yield. Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  3. Defrosting Application Drivers Food Safety Raw material availability and on-time delivery performance Costs savings Yield gains Environmental (sewage) Consistency in raw material quality Labor involvement Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  4. Defrosting/Tempering Solutions in the Market Defrosting in open vats with running water. Long defrosting time. Loss of meat juice (2 – 8% yield loss). Food safety issues. Drain / sewer issues. Defrosting cabinets with hot air fans. Long defrosting time. Loss of meat juice (3 – 6 % yield loss). Uneven defrosting temperatures. Low guarantee of food safety. Microwave tunnels with radio frequency waves. Only suitable for tempering (max. -10 C). Difficult to defrost uniformly (above 00 C) - product heat spots. Loss of meat juice (yield loss). Steam & Indirect heating defrosting. Short, automatically controlled process. High food safety and traceability. Low cost of ownership (no yield loss, low operating costs). High end product quality (bacteria killing process). Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  5. Many Challenges with existing process Defrosting rooms / cabinets with hot air fans. Double handling Spacers Labor heavy Pallet hot surface – cold centers Protein drip on floor Rewrapping to prevent meat falling on floor Microbial issues 48 hours to 72 hours process time Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  6. GEA Defrosting Process Part 1: Steam Step Part 2: Tempering Step Part 3: Massage Step Steam supply Heating Cooling Loading Defrost Marinade Further process Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  7. Vacuum impact on steam temperature 91 º F 212 º F = 1.00 bar = 0.05 bar (0 % vacuum) ( 95 % vacuum) Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  8. Energy content of cold dry steam Water at 100 oC / 212 o F contains 418 kJ/kg energy Steam at 100 oC / 212 o F contains 2.675 kJ/kg energy Steam at 33 oC contains 2.562 kJ/kg energy Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  9. Safety Working Process Zone 37,5oC 98 F 65 mbar 12,8oC 13,6oC 33oC 90 F 50 mbar Product temperature development during process = Possible steam temperature variation = Possible steam pressure variation = Product temperature peaks during process Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  10. PLC based defrosting - Total Process Control Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  11. Temperatures During Defrosting Process The graphs show that the product surface temperatures not to exceed 55°F / 12,7°C during the defrosting process, which is well below temperatures where there may be a risk of heat (protein) denaturation and of starting bacterial growth (above 800 F/280C). The entire process is under 50 mb vacuum (no / micro oxygen atmosphere) End product temperature typically: 33°F / +0.5 C to 37°F / 2.7°C Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  12. GEA Defrosting Range - Poultry Whole Chicken Chicken / Turkey Wings Chicken / Turkey Legs Chicken / Turkey Chunks Chicken / Turkey Drumsticks Chicken / Turkey Breast fillets Turkey Tenders ** ** Turkey Tenders in > 5kg / 11 lb blocks is not applicable Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  13. GEA Defrosting Range - Pork Pork Loins Pork Bellies Pork Middles Pork Inside/outside and knuckle Pork Riblets Pork Flanks Pork Necks Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  14. GEA Defrosting Range - Beef Beef Knuckles Beef Hearts Beef Liver Beef Tongue Beef – Various cuts Beef Top Rounds Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  15. Typical Defrosting Times Defrosting time is subject to block size, start temperature, accepted pick-up from steam and end-product specification. Chicken fillet IQF: 4-5 hours. Chicken /Turkey fillets in blocks: 6-8 hours. Chicken / Turkey wings IQF: 4-5 hours. Chicken / Turkey wings in blocks: 6-8 hours. Turkey thighs/breasts in blocks: 7-8 hours. Pork or beef in blocks: 6-9 hours. The defrosting time is calculated on basis of max. Filling degree of tumbler (36-38% = about 8,300 lbs / 3,800 kg batch in ScanMidi10). The above-mentioned capacities exclude loading and unloading. Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  16. GEA Chicken / Turkey Defrosting with Consistent Results Relevancy: No damage to product / meat fibers Yield 103% Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  17. GEA Defrosting Results 3% steam added Out of the Tumbler Pork Shank after defrosting Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  18. GEA Defrosting with Consistent Results No Damage ! No Meat dust ! Pork Insides and Outsides – 3% added steam – Yield = 103 Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  19. Beef Skirts for Fajita No damage to meat structure Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  20. Turkey Thigh Defrosting Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  21. Pork bellies for Bacon Defrosting high fat products (45% - 55%) Product: pork bellies,IQF frozen, Result Process time: 6 1/2 hours Steam addition: 3% Start temperature: -6,8 °CEnd temperature: +4 °C Product evaluation:Good, no fat smear on surface CFS Tempering Defroster Room (left) (right) End products Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  22. Block sizes for defrosting Turkey Breast 15 kg blocks 550 x 350 x 80 mm Chicken Inner Wings 15 kg blocks 500 x 350 x 100 mm Turkey Breast - US 18 kg blocks 470 x 460 x 100 mm Deboned Turkey Legs 19 kg blocks 490 x 320 x 130 mm Chicken Breast 2 kg blocks 300 x 250 x 50 mm Chicken Breast 20 kg blocks 540 x 350 x 50 mm Turkey Breast 10 kg blocks 540 x 340 x 50 mm Pork Riblets 10 kg blocks 470 x 280 x 100 mm Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  23. Block sizes for defrosting Pork Necks 31-35 kg blocks 560 x 340 x 220 mm (average) Raw materialfor sliced ham 35 kg blocks 560 x 360 x 220 mm Pork Loins 20 kg blocks 550 x 350 x 100 mm Beef cuts (1-10 kg) 25 kg blocks 580 x 370 x 130 mm Pork Silverside 25 kg blocks 540 x 340 x 150 mm Pork Ham Cuts 27 kg blocks 580 x 380 x 140 mm Block size range: 2 – 35 kg Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  24. GEA Defrost Installation Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  25. GEA Defrost Installation Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  26. GEA Defrost In Production Turkey Breast Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  27. Simple Block Feeding / Deboxing Deboxing and Frozen block feeding Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  28. Multi Purpose Functionality Tumbling during the day - Defrosting during the night !! Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  29. GEA Defrosting Sanitation / Food Safety Total visibility to food zone – No hidden corners or sharp edges ! Relevancy: Easy USDA inspection Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  30. Relative to: Existing Air Defrosting Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  31. Relative to: Fresh Meat Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  32. Independent Lab Quality Analysis ”Silliker BV” Institute for Food Safety & Quality Solutionwas asked to test, fresh material versus defrosted material Samples of Chicken Breast were performed according to the form: ”Routine Product Evaluation” from The National Food Laboratory Products were evaluated on:Chemical, Microbial and Sensoryaccording to the 5-point scale Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  33. Chemical Results The chemical compounds meet specifications, no difference between the fresh or defrosted meat. Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  34. Sensory Results Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  35. Microbial Results The microbial compounds meet specifications – no difference between the two tests. Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  36. Product Attribute Summary Microbial. Microbe numbers constant or reduced relative to frozen. Safer than water defrosting. Color/appearance: No difference. Aroma: No difference. Flavor: No difference. Texture: Only small difference – Defrosted meat lightly more tender compared to fresh meat. Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  37. Sensorial Results - Conclusion The Sensory evaluation shows only differences where all aspects meet specifications, also after hold on 65°C Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  38. Microbiological results from defrosted Riblets. Comparing frozen vs. Defrosted surface samples. Microbial Investigation 1 CFS defrosting process is a safe bacteriological process that contributed to a bacterial reduction in the order of up to log 2 . Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  39. Microbial Investigation 2 Microbiological results from defrosted Pork Muscles. Comparing surface microbes on CFS vs. air defrosted pork. CFS defrosting process is a safe bacteriological process that compares favourably to air defrosted meat. Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  40. Microbial development – Test Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  41. Microbial development = Zero Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100

  42. GEA Convenience-Food Technologies - Microbial Safety Statement Validation on microbial safety at customers and by local authorities has shown that GEA defrosting process is considered safe and even better compared to existing approved defrosting processes. CFS process has no microbial growth !!! Henrik Thrysoe – Toll Free 1800-388-2601 or 214-618-1100