Root Vegetable Flame Pasteurization With Low Shrinkage
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Solution Overview
Problem
There is a growing concern of cross-contamination in the processing of root vegetables like onions, which are often exposed to pathogens during harvesting and storage, and existing peeling processes fail to effectively eliminate these pathogens, leading to food recalls and contamination risks in the food industry.
Innovation Solution
A flame pasteurization system that engulfs the surface of root vegetables in fire to kill pathogens, reducing the need for mechanical peeling and minimizing shrinkage, while ensuring the product's color and flavor remain unaltered, using a continuous flame grill or roaster that heats the surface to at least 145°F (62.8°C) for a sufficient time to achieve a significant reduction in pathogens like Listeria monocytogenes and other bacteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If mechanical peeling is used to remove outer layers of onions, then pathogens on the surface are reduced, but significant weight loss (10-20% shrinkage) occurs
Solution Approach 1:
The patent replaces the mechanical peeling system with a thermal treatment system. Onions are exposed to controlled heat (pasteurization temperatures) that kills pathogens on the surface without requiring removal of the outer layers, thus eliminating the mechanical action that causes weight loss while achieving the same food safety objective
Solution Approach 2:
The patent changes the operational parameters from mechanical force (peeling) to thermal energy (heat treatment). By controlling temperature and exposure time to achieve pasteurization, the system eliminates pathogens while preserving the onion's mass, transforming the approach from material removal to parameter-based pathogen control
2Productivity
If mechanical peeling machines are used to peel onions, then the peeling process is efficient and continuous, but cross-contamination occurs through contact with blades and equipment surfaces
Solution Approach 1:
The patent replaces contact-based mechanical peeling equipment with a non-contact thermal pasteurization system. By using heat radiation or convection to pasteurize onions, the system maintains continuous processing efficiency while eliminating the contact surfaces (blades, conveyors) that serve as vectors for cross-contamination
Solution Approach 2:
The patent introduces thermal energy as an intermediary between the processing system and the onion surface. This intermediary enables pathogen elimination without direct mechanical contact, thereby breaking the contamination pathway while maintaining processing efficiency
3Object-affected harmful factors
If flame pasteurization is used to kill pathogens on onion surfaces, then pathogen reduction is achieved, but the product may show roasted or charred characteristics
Solution Approach 1:
The patent precisely controls thermal parameters (temperature, exposure time, heat distribution) to achieve pasteurization without combustion. By maintaining temperatures sufficient to kill pathogens but below the threshold for charring or roasting, the system achieves pathogen reduction while preserving the onion's natural appearance and flavor characteristics
Solution Approach 2:
The patent applies partial thermal action - enough heat to achieve pasteurization (5-log reduction) but deliberately limited to avoid excessive heating that would cause charring. The treatment is calibrated to provide the minimum necessary thermal dose for pathogen control without exceeding the threshold that would damage sensory qualities
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The flame pasteurization process effectively reduces indigenous bacteria, yeast, and mold by 5-log, and Listeria innocua by 6-log, minimizing cross-contamination and reducing the need for mechanical peeling, with minimal impact on the product's flavor and appearance, and reduces shrinkage to about 3-5% weight loss compared to traditional peeling processes.
Implementation Method 1
heats the surface to at least 145°F (62.8°C) for a sufficient time to achieve a significant reduction in pathogens
Implementation Method 2
pasteurizes the surface of the root vegetable by engulfing it in fire so as to burn off the exterior layer or skin
Data Source
AI summary
A system and method for pasteurizing the surface of a food product includes a flame pasteurizing means arranged to transfer heat to an outer layer of the food product as it is carried by a cook belt. The flame pasteurizing means provides a medium that engulfs more than 50% of the surface area of the skin or outer layer and raises the temperature of the outer layer to at least 145° F. (about 62.8° C.). A washing means, arranged at an exit point of the flame pasteurizing means, removes the raised temperature outer layer and stops heat transfer to an adjacent inner layer of the food product. The pasteurized and washed product retains the same color and flavor as that of the unpasteurized product.