Ultra-High Pressure Homogenization for Sterilization Without Heat
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Solution Overview
Problem
Current sterilization methods, such as Ultra High Temperature (UHT) processes, often compromise the nutritional, organoleptic, and technological properties of food products due to high heat treatments, and existing ultra-high pressure homogenization (UHPH) technologies are insufficient for achieving complete sterilization and aseptic packaging of pumpable fluids.
Innovation Solution
A continuous system and procedure utilizing ultra-high pressure homogenization (UHPH) that includes preheating, high-pressure treatment up to 600 MPa, followed by rapid cooling, and aseptic packaging, minimizing heat effects and ensuring commercial sterility without additives, while maintaining product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional UHT sterilization at high temperature (135-150°C) is applied, then commercial sterility is achieved, but nutritional and organoleptic properties are compromised
Solution Approach 1:
The patent replaces the thermal sterilization system with a high-pressure homogenization system operating at 200-600 MPa. This mechanical action achieves commercial sterility through intense shear forces, turbulence, and cavitation that destroy microbial cell structures without requiring high temperatures, thereby preserving nutritional and organoleptic properties while achieving the same sterilization reliability.
Solution Approach 2:
The patent changes the fundamental sterilization parameter from temperature (135-150°C for 4-15 seconds) to pressure (200-600 MPa). This parameter transformation allows sterilization to occur at ambient temperatures, eliminating thermal damage to nutrients and sensory properties while maintaining effective microbial destruction through mechanical forces.
2Reliability
If conventional heat sterilization is used, then microbial destruction is achieved, but physical stabilization is compromised due to phase separation
Solution Approach 1:
The patent replaces thermal sterilization with high-pressure homogenization that simultaneously achieves microbial destruction and physical stabilization. The intense mechanical shear forces and turbulence generated at 200-600 MPa break up fat globules and prevent phase separation, while the same process destroys microbial structures, eliminating the need for separate stabilization treatments.
Solution Approach 2:
The patent merges sterilization and physical stabilization into a single high-pressure homogenization process. Instead of applying heat for sterilization and then adding stabilizers or applying additional mechanical treatment for stabilization, the system combines both functions into one operation, achieving microbial destruction and emulsion stability simultaneously through high-pressure mechanical action.
3Stability of the object's composition
If high pressure homogenization is applied, then physical stabilization is improved, but complete sterilization and aseptic packaging are not achieved
Solution Approach 1:
The patent extends the pressure parameter range to 200-600 MPa, significantly higher than conventional homogenization pressures. This extreme pressure level generates sufficient shear forces and cavitation to achieve both physical stabilization and complete sterilization, destroying microbial spores and vegetative forms while maintaining emulsion stability without requiring subsequent packaging sterilization.
4Stability of the object's composition
If additives are used for stabilization, then phase separation is prevented, but product quality is compromised
Solution Approach 1:
The patent extracts and eliminates the need for stabilization additives by using high-pressure homogenization as the sole stabilization mechanism. The intense mechanical action at 200-600 MPa physically breaks up and redistributes fat globules and prevents phase separation through turbulence and shear forces, achieving stabilization without any chemical additives that would compromise product quality.
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 system achieves commercial sterility, stabilizes food products without additives, prevents precipitation and phase separation, and maintains original flavor, aroma, and nutritional values, addressing the limitations of conventional sterilization methods.
Implementation Method 1
an ultra-homogenizer with a valve capable of working at high pressures through which, previously heated fluid at temperature Tp is introduced at a pressure Pu between 200 and 600 MPa
Implementation Method 2
the high pressure generated moves the liquid at high speed. At the valve end, the liquid movement speed drops abruptly and the extreme turbulence generated produces an intense shear rate
Implementation Method 3
Other forces intervening in the process of reducing particle size are the collapsing of air bubbles (cavitation) and the impact forces created at the valves during the liquid trajectory
Implementation Method 4
direct systems where the product is heated by direct contact with the heating medium (water steam), and indirect systems where heat is transmitted through a separation surface, in a heat exchanger
Implementation Method 5
sterilization is performed at high temperature: 135-150° C., which allows a very short time for processing: 4-15 sec
Implementation Method 6
a second heat exchanger in which the temperature of the fluid coming from the ultra-homogenizer is reduced to a desired cooling temperature value Te
Data Source
AI summary
Continuous system and procedure of sterilization and physical stabilization of pumpable fluids, food, or other type of fluids, through ultra-high pressure homogenization (UHPH) includes a first heat exchanger 1 which preheats the fluid at temperature Tp between 40 and 90° C.; an ultra-homogenizer 3 through which fluid at temperature Tp is introduced at a pressure Pu between 200 and 600 MPa increasing its temperature up to a final value Tu. A second heat exchanger 4 has its cooling temperature adjusted at value Te. An aseptic tank 5 receives the cooled down fluid at value Te, from which it is pumped by sterile air pressure into an aseptic packaging machine, for the packaging of the final product.