Source: NORTH CAROLINA STATE UNIV submitted to NRP
ADVANCED THERMAL PROCESSING AND PACKAGING OF FOODS AND BIOMATERIALS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
Reporting Frequency
Annual
Accession No.
1006226
Grant No.
(N/A)
Cumulative Award Amt.
(N/A)
Proposal No.
(N/A)
Multistate No.
(N/A)
Project Start Date
Apr 22, 2015
Project End Date
Sep 30, 2019
Grant Year
(N/A)
Program Code
[(N/A)]- (N/A)
Recipient Organization
NORTH CAROLINA STATE UNIV
(N/A)
RALEIGH,NC 27695
Performing Department
Food, Bioprocessing, and Nutrition Sciences
Non Technical Summary
Continuos flow microwave processing systems will be developed, assembled and integrated in standard continuous food and biomaterial processing installations (aseptic processing and packaging, hot-fill processing installations)Advanced methods of acoustic and mechanical continuous flow cooling optimization and enhancements will be developed and implemented at laboratory and semi-industrial scales.New methods and systems will be implemented to development and production of foods and biomaterials leading to superior sensory and nutritional quality over the time of shelf life.New intellectual property will be developed, protected and commercialized, leading to new products, start-up bussinesses and production facitilies.
Animal Health Component
60%
Research Effort Categories
Basic
10%
Applied
60%
Developmental
30%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
50174102020100%
Goals / Objectives
1. Development, implementation and operational testing under representative parameters: laboratory (benchtop), pilot plant, semi-industrial and industrial scale of new methods, devices, equipment and systems to improve and optimize all stages of advanced thermal processing operations for foods and biomaterials.Objectives:Improve and extend application areas for continuous flow microwave processing methods developed in our laboratoryImprove and extend application areas for developed methods and devices for acceleration of continuous flow cooling treatments2. Documentation, testing and implementation of new methods of process monitoring and process and product safety validation for continuous flow and advanced thermal processing.Objectives:Improve and extend application areas for developed thermophysica, chemical, bacterial and enzymatic methods of process and product safety validation developed in own laboratory and in collaboration with university and industry researchers and developers3. Generation, protection and commercialization of developed and validated inventions (invention disclosures, patents, new startup bussineses and production facilities).Objectives:Continue the successful track record of patented, licensed and commercialized intellectual property (12 US Patents, 20 international patents, 4 industrial production facilities, 5 start-up bussineses, over 100 commercialized products4. Improvement of sensory (flavor, color, texture) and nutritional (retention of vitamins, antioxidants and other thermo-sensitive food components and ingredients) quality of foods preserved through application of novel and advanced thermal processing procedures.Objective:Continue and expand implementation of developed methods and systems to industrial food production by further expanding their use to new foods, collaborating research and academic facilities and industrial R&D
Project Methods
1. Development, assembly and implementation of continuous flow microwave heating, pasteurization and sterilization systemsEvaluation by measurement of temperature profiles and heating ratesquality and nutritional paramented before and after processing and throughout the periods of storage and distribution2. Real time and post-process testing, monitoring, recording and documentation of representative process parameters relevant to the food and biomaterial product sensory quality and safetyEvaluation by chemical, enzymatic and biological quantification before and after processing3. Integration of developed processing systems into aseptic processing and packaging lines (pilot, semi-industrial and industrial systems)4. Development of new acoustic and mechanical methods of product mixing and temperature equalization during continuos flow cooling operationsEvaluation by measurement and comparison of cross sectional flow temperature profiles5. Implementation of developed methods to production of organoleptically and nutritionally superior food productsEvaluation by measurement of retention of thermosensitive ingredients before and after processing as well as over time of storage and distribution

Progress 04/22/15 to 09/30/19

Outputs
Target Audience:Undergraduate and graduate students at NC State University Researchers, students and industry representatives from 12 major food processing companies at meetings of the Center for Advanced Processing and Packaging Studies, at NC State University, The Ohio State University, University of California Davis Students, Meeting attendees at the annual meeting of the Institute for Thermal Processing Specialists Meeting attendees at the annual conference and expo of the Institute of Food Technologists Researchers and professionals at several major global food processing companies National and Internatonal visiting students and government, industry and acadmic experts. Lawmakers, farmers and food safety experts at various meetings in North Carolina Students, Faculty, visiting faculty and several Uganda government agency representatives at the Makerere University in Kampala, Uganda International visitors from Sub-Saharan and neighboring countries at the Makerere University in Kampala, Uganda Students and Faculty at the Faculty of Agronomy, University of Zagreb, Croatia Students and Faculty at the Faculty of Food and Biotechnology, University of Zagreb, Croatia Students and Faculty at the Faculty of Food Technology, Josip Juraj Strossmayer University in Osijek, Croatia Efforts: Presentations at meetings, conferences, symposia, short courses, training and demonstration events, publications, press releases, interviews, posts on professional social networks(LinkedIn) Changes/Problems:Numerous problems have been encountered during the performance of the project but the large majority have been succesfully overcome. One learned lesson was the realization that the food industry in general, and particularly the so called major CPG companies are particularly resistant to innovation and introduction of new technologies. These hurdles and obstructions have been overcome by initiation of own processing facilities, start-up companies and collaboration with smaller, innovative businesses. In the last two years of project performance, project goals have been expanded to include continous flow microwave processing for extraction of bioactive ingredients from plant materials, development of novel systems for induction-heated cleaning in place installations and an emerging system for inductively heated fluid evaporation / vacuum concentration at the benchtop R&Dscale. What opportunities for training and professional development has the project provided?Numerous lectures, short courses, visiting lectures, presentations at scientific and professional meetings have been organized and delivered. How have the results been disseminated to communities of interest?Publications in scientific journals and professional magazines, published patent literature, book chapters, white papers, posts on socila media / LinkedIn professional network, interviews in professional magazines, TV and video clips and reports. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? 1. Application areas for continous flow microwave processing have been expanded to new products, new facilities and new markets. Work on the R&D of acceleration of continous flow cooling continues. 2. The application areas of our methods of process monitoring and product safety validation have been expanded. During the report period from the initiation of the project two first of their kind FDA letters of no questions / objections have been granted - one for the microwave sterilized, single solid ingredient aseptic particulate type / multiphase product - soup and another for themicrowave sterilized, multiplesolid ingredient aseptic particulate soup/ multiphase product . The methodology used to submit the filings resulting in thetwo FDA letters mentioned above established the protocol for process modeling, establishment and validation for both conventional sterilization (e.g. tube in tube heat exchangers) and advanced thermal sterilization of particulate aseptic products (continous flow microwave sterilization and continuous flow ohmic sterilization). 3. 7 new U.S. patents have been granted and issued during the reporting period for a total of 19 US Patents.5new additional US and International patent applications have been submitteed and are currently pending, 5 new R&D and processing facilities initiated based on licensed technologies during the reporting period, some currently under construction and some presently in production. Over 100 new products introduced to the US and European markets using developed technologies, methods, instruments and processing equipment. 4. Efforts continue to improvesensory (flavor, color, texture) and nutritional (retention of vitamins, antioxidants and other thermo-sensitive food components and ingredients) quality of foods preserved through application of novel and advanced thermal processing developed by our lab group and students.

Publications

  • Type: Journal Articles Status: Published Year Published: 2019 Citation: Truong, A. N., Thor, Y., Harris, G. K., Simunovic, J., & Truong, V.-D. (2019). Acid Inhibition on Polyphenol Oxidase and Peroxidase in Processing of Anthocyanin-Rich Juice and Co-product Recovery from Purple-Fleshed Sweetpotatoes. JOURNAL OF FOOD SCIENCE, 84(7), 17301736. https://doi.org/10.1111/1750-3841.14664
  • Type: Journal Articles Status: Published Year Published: 2019 Citation: Kopjar, M., Ivic, I., Vukoja, J., Simunovic, J., & Pichler, A. (2019). Retention of linalool and eugenol in hydrogels. INTERNATIONAL JOURNAL OF FOOD SCIENCE AND TECHNOLOGY. https://doi.org/10.1111/ijfs.14344


Progress 10/01/17 to 09/30/18

Outputs
Target Audience:Undergraduate and graduate students at NC State University Researchers, students and industry representatives from 12 major food processing companies at meetings of the Center for Advanced Processing and Packaging Studies, at NC State University, The Ohio State University, University of California Davis Students, Meeting attendees at the annual meeting of the Institute for Thermal Processing Specialists Meeting attendees at the annual conference and expo of the Institute of Food Technologists Researchers and professionals at several major global food processing companies Lawmakers, farmers and food safety experts at various meetings in North Carolina Efforts: Presentations at meetings, conferences, symposia, short courses, training and demonstration events, publications, press releases, interviews Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?Graduate students worked on developing the new methodology for microwave assisted extraction of bioactives - anthocyanins from purple fleshed sweet potatoes, from purple carrots and betalains from red beets. How have the results been disseminated to communities of interest?Communications through presentations at local, national and international meetings, guest lectures and hosting visits by students to established and pending installations using technologies developed using support provided by the project. What do you plan to do during the next reporting period to accomplish the goals?Continue implementation, testing, processing facility construction and commercialization of systems, processing lines and products developed under the goals of the project. Initiate construction of additional commercial processing facilities utilizing developed technologies and techniques. Establish new start-up businesses utilizing developed technologies.

Impacts
What was accomplished under these goals? Simulated food particles for validation of continous flow sterilization and pasteurization of multiphase / particulate containing aseptic products. Methods of production of polyphenol / protein complexes developed and implemented. First commercial product - protein rich gummies containing the developed polyphenol/protein complexes successfully marketed in collaboration with a local (North Carolina) small bussiness (Glean LLC) Co-founded a new start up business - SinnoVita Inc and registered a brand of polyphenol / protein complex nutritional ingredients - VItero Vitero ingredients elected as finalist for the nutritional ingredient of the year for 2018 at the annual meeting of IFT in Chicago. Completed construction and use of SinnovaTek processing line utilizing equipment, methods and techniques developed by the project R&D. Initiation construction of processing facility Panacea Nutrition in Danville, VA, utilizing developed microwave sterilization technologies for production of personalized nutrition products.

Publications

  • Type: Journal Articles Status: Published Year Published: 2018 Citation: Computer-aided design and experimental testing of continuous flow cooling of viscous foods October 2018Journal of Food Process Engineering DOI: 10.1111/jfpe.12913 Project: Enhancement of Continuous Flow Cooling Using Hydrophobic Surface Treatment George Stoforos, Josip Simunovic


Progress 10/01/16 to 09/30/17

Outputs
Target Audience:Students in the fields of food science, food processing and food engineering. National and international consumer grocery product processing companies. U.S. Regulatory agencies, particularly FDA North Carolina lawmakers and government representatives National and international educational institutions North Carolina Department of Agriculture North Carolina Biotechnology Center Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?All industrial installations of our technologies in North Carolina (Yamco, Wright Foods and SinnovaTek) have been visited by food science students, and have provided assistanceto researchers and training, internship and employment opportunities for students and graduates. How have the results been disseminated to communities of interest?Scientific publications, interviews and articles in standard press and on social media (esp. LinkedIn). Presentations and participation at professional meetings and expos, white papers on commercially available technologies. What do you plan to do during the next reporting period to accomplish the goals?Continue with research and development, commercialization and implementation of developed technologies, as well as intellectual property protection for the ones emerging from our R&D

Impacts
What was accomplished under these goals? New aseptic processing pilot plant constructed based on patented technologies under continued development New start up bussines formed - SinnovaTek Inc. in Raleigh, North Carolina

Publications

  • Type: Journal Articles Status: Published Year Published: 2017 Citation: Winterization strategies for bulk storage of cucumber pickles? Joscelin T.Diaz Ilenys M.P�rez-D�az JosipSimunovic K.P.Sandeep Journal of Food Engineering Volume 212, November 2017, Pages 12-17


Progress 10/01/15 to 09/30/16

Outputs
Target Audience:Undergraduate and graduate students at NC State University Researchers, studentsand industry representatives from 12 major food processing companies at meetings of the Center for Advanced Processing and Packaging Studies, at NC State University, The Ohio State University, University of California Davis Students, Faculty and researchers at consortium of3 Universities with Food Science programs: NC State University, Clemson and Viriginia Tech University Meeting attendees at the annual meeting of the Institute for Thermal Processing Specialists Meeting attendees at the annual conference and expo of the Institute of Food Technologists Researchers and professionals at several major global food processing companies Lawmakers, farmers and food safety experts at various meetings in North Carolina Efforts: Presentations at meetings, conferences, symposia, short courses, training and demonstration events, publications, press releases, interviews Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?Numerous opportunities have been provided for students, industry professionals and academic collaborators. How have the results been disseminated to communities of interest?Short courses, seminars, symposia, press releases, interviews, presentations at professional and non-professional meetings. Training and demonstration sessions for students, professionals and employees at food processing facilities. What do you plan to do during the next reporting period to accomplish the goals?Continue R&D as outlined in the project description - through the program at NC State University and collaboration with academic, industrial processing companiesand government agencies, partcularly regulatory agencies tasked with the food safety and consumer protection for foods and pharma - FDA and USDA.

Impacts
What was accomplished under these goals? 1. Further expansion of industrial installations and processed products introductions to consumer and B2B markets, as finalized products and ingredients for further processing. Progress and introductions of advanced cooling technologies still in preliminary R&D stages compared to the full and growing commercial impact of microwave processing (Due to the initiation of advanced cooling R&D program lagging behing MW program by about a decade), but with continued progress and positive momentum 2. Next generation of instruments, implants and software developed (doubling the frequency and location capacity of the sensing system, with increased sampling and data collection capacity). First test installation at NC State University Department of Food. Bioprocessing and Nutrition Sciences Pilot Plant. 3. 6new invention disclosures submitted followed by submission of 4 new US Patent applications . 2 US Patents Granted, Issued and licensed for commercial use. One new company co-founded: SInnovaTek 4. Numerous new nutritionally and sensorially superior products introduced to the ingredient and consumer products markets, driven and produced by developed technologies, primarily continuous flow microwave heating, pasteurization, sterilization and aseptic packaging

Publications

  • Type: Journal Articles Status: Published Year Published: 2016 Citation: Food and Bioproducts Processing Volume 100, Part B, October 2016, Pages 551-559 Thermal mixing via acoustic vibration during continuous flow cooling of viscous food products George N.Stoforos, Brian E.Farkas, JosipSimunovic North Carolina State University, Department of Food, Bioprocessing & Nutrition Sciences, Raleigh, NC, USA


Progress 04/22/15 to 09/30/15

Outputs
Target Audience:Students in the fields of food science, food processing and food engineering. National and international consumer grocery product processing companies. U.S. Regulatory agencies, particularly FDA North Carolina lawmakers and government represeantatives National and international educational institutions Efforts: Lectures as a guest lecturer with a variety of courses at NCSU Department of Food, Biprocessing and Nutrition Sciences Short courses and seminars presented at NCSU and at respective industrial processors of foods, beverages and biomaterials. Presentations at meetings and symposia Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?We have held short courses and training sessions for conventional thermal, conventional aseptic and advanced aseptic and microwave processing in individual companies as well as open access for attendees and trainees from different companies. How have the results been disseminated to communities of interest?Publications, press releases, interviews and announcements in trade press. What do you plan to do during the next reporting period to accomplish the goals?Continue with activities as described above. Continue R&D, training and commercial production efforts.

Impacts
What was accomplished under these goals? 1. Application areas extended and implemented industrially as planned. One major indutrial processing facility (Wright Foods in Troy NC) constructed and put into full production, another facility finalizing construction (Carolina Dairy in Biscoe NC). Previously initiated production of microwave sterilized sweet potato puree and other fruit and vegetable purees (Yamco, Snow Hill, NC) continues successful operation, providing a healthy, nutrition ingredient line to bakeries and infant and baby food processors. 2. Original protocols, instrumentation and software developed, commercialized and implemented for microwave sterilization and aseptic packaging of foods containing single type and multiple types of particulate ingredients. Received the first ever awardedUS FDA Letterof No Questions for microwave sterilized single particulate containing aseptically packaged products Receive the first ever awarded US FDA Letter of No Questions for microwave sterilized multiple particle type containing aseptically packaged shelf stable product line 3. In addition to construction and production initiation of two new processing facilities in North Carolina, introducton of new products and product line extensions in thirs, collaborated with Nestle, Pepsi andUnilever on validation of safety of new products introduced in commercial consumer markets in the U.S. and Europe 4. Implemeted a novel developed technology (continuous flow microwave processing, pasteurization and sterilization) to preservation and commercial production of new nutritionally superior foods and beverages: vegetable purees and blends, soups, salsas, beverages, shelf stable smoothie line, fruit purees and baby and infant food products.

Publications

  • Type: Journal Articles Status: Published Year Published: 2015 Citation: Mitochondrial DNA Fragmentation as a Molecular Tool to Monitor Thermal Processing of Plant Derived, Low Acid Foods, and Biomaterials Jane M. Caldwell Ilenys M. P�rez?D�az KP Sandeep Josip Simunovic Keith Harris Jason A. Osborne Hosni M. Hassan
  • Type: Journal Articles Status: Published Year Published: 2015 Citation: Mitochondrial DNA Fragmentation to Monitor Processing Parameters in High Acid, Plant?Derived Foods Jane M. Caldwell Ilenys M. P�rez?D�az Keith Harris Hosni M. Hassan Josip Simunovic K.P. Sandeep