Locally Developed Food Processing Equipment for MSMEs

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Locally Developed Food Processing Equipment for

MSMEs

(DOST-PCIEERD supported project)

Presented By:

NELIA ELISA C. FLORENDO Chief, Science Research Specialist

Industrial Technology Development Institute Department of Science and Technology

nel58ph@yahoo.com tsd@dost.gov.ph

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• One of the major contributors to the country’s growing economy is the manufacturing sector with food manufacturers as the top sub-sector.

An Overview:

Philippine Food Manufacturing Industry

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• Major sectors of the food processing industry:

fruits and vegetables; fish and marine products;

meat and poultry products; flour and bakery products; beverage and confectionery dairy foods; food condiments and seasonings;

food supplements; bottled water; snack foods and fats and oils.

An Overview:

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• The industry contributes more than 40%

of the total manufacturing output and approximately 20% of Gross Domestic Product (GDP) per annum.

An Overview:

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An Overview:

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• Food processing industry needs critical attention

• Local food processors are faced with challenges like:

- maintaining market share

- wide variety of imported processed foods readily enter the market due to increased trade liberalization

- innovating or introducing new products Issues and Challenges:

Philippine Food Manufacturing Industry:

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•

High capital investment and acquisition of state of the art equipment deprived our local manufacturers of the opportunity to expand product lines in order to meet

a diverse range of customer requirements and become globally competitive.

• Processed products, particularly food manufactured by ASEAN neighbours like Thailand, Malaysia and now

Vietnam, are more competitive (price and quality

wise) and are continuously being sold and patronized by the local market.

Issues and Challenges:

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Priority need of the food processors:

• Affordable equipment to increase

production efficiency and compliance to

standard requirements that will enable our food processors—MSMEs to become

more competitive (local and foreign market)

Issues and Challenges:

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HIGH IMPACT TECHNOLOGY SOLUTIONS (HITS)

• DOST’s leadership and drive towards industry development particularly, in the regions; and

• S&T intervention on localized fabrication of food processing equipment – vital in improving

MSMEs competitiveness and sustained growth.

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HIGH IMPACT TECHNOLOGY SOLUTIONS (HITS)

Design and Development of Process Equipment for Food Processing Firms

Implementation : May 2011 – December 2013 Implementing Agencies:

• DOST- Project Management Engineering Design Service Office (PMEDSO);

• Metals Industry Research Development Center (MIRDC); and

• Industrial Technology Development Institute (ITDI)

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HIGH IMPACT TECHNOLOGY SOLUTIONS (HITS)

Design and Development of Process Equipment for Food Processing Firms

GENERAL OBJECTIVE:

• To promote the development of locally

fabricated process equipment for the food

processing industry sector.

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HIGH IMPACT TECHNOLOGY SOLUTIONS (HITS)

Design and Development of Process Equipment for Food Processing Firms

SPECIFIC OBJECTIVES:

• Design and fabricate food processing equipment prototypes to substitute imports that are appropriate and affordable for use by food processors;

• Evaluate the performance of process equipment prototypes; and

• Monitor actual operating performance of equipment prototypes through field testing.

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HIGH IMPACT TECHNOLOGY SOLUTIONS (HITS)

SIGNIFICANCE:

• Reduce importation and address issue on high cost of equipment.

• Process equipment will be made available for commercial use at an affordable cost.

• Improve the performance and efficiency of local food processors.

• Project will benefit local equipment fabricators, domestic food processors and indirectly benefit farmers and

food growers.

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HIGH IMPACT TECHNOLOGY SOLUTIONS (HITS)

Food processing equipment prototypes

1. Water Retort 2. Freeze Dryer 3. Vacuum Fryer 4. Spray Dryer

5. Vacuum Packaging Machine 6. Immersion Freezer

7. Vacuum Evaporator

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Roll out of DOST Developed Food

Processing Equipment in the Regions…

GOOD NEWS….

• DOST Regional Offices will establish their regional Food Innovation Centers (FICs)

• Locally developed food processing equipment

will be showcased and tried out by potential

adopters

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DOST-PMEDSO ITDI MIRDC DOST Regional Offices (Lead: DOST 8) Design & Development of Process

Equipment for Food Processing Firms (May 2011 – Dec 2013)

7 Process Equipment Prototypes Designed, Fabricated, Tested

Roll-out of 5 Food Processing Equipment Prototypes in the Regions

(12 months)

Prototype of 5 Process Equipment by accredited fabricators

Phase 1:

DOST Food Innovation Centers (2013-2016)

Food Innovation Center (FIC) in every region

First 6 Regions:

2, 5, 6, 8, 10, 11

Vacuum Packaging Machine Water Retort

Vacuum Fryer Spray Dryer Freeze Dryer

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DOST-Developed Food

Processing Equipment

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Water Retort

Locally Developed Food Processing Equipment

DESCRIPTION:

• A cooking and sterilization vessel capable of withstanding extreme pressures

• Designed to destroy all microbes to prolong shelf-life and make products safe for consumption

• Utilizes water as a heating medium

• Sterilization applicable for various types of containers:

metal, cans, glass , bottles, retortable pouches/plastics

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Water Retort

BENEFITS/ADVANTAGES:

• Reduced process time translating to savings in cost of utilities, storage space, transportation costs;

• Provides an opportunity for food processors to shift to

using retort pouch as alternative packaging for thermally- processed products at lower cost; the use of retort

pouches provides other advantages like:

- Enables conformity to regulations for thermally processed foods - Increased convenience for consumers: packages are light-weight

and easy to open

- Better package presentation

- Readily available local expertise and technical support

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Water Retort

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Water Retort

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Water Retort

FEATURES:

• Batch type, non-agitating, vertical pressure

• Water used as heating medium

• All stainless steel construction

• Simple to operate

• Cheaper than comparable-sized retort

• Modular set up is ideal for micro-scale processors

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Water Retort

Ready to eat meals Ready to eat meals

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Vacuum Fryer

DESCRIPTION:

• Used for deep-fat frying; Designed to fry under

reduced pressure and in a closed system that lowers the boiling point of both oil and water in food.

• Food dehydrates at a lower temperature thus, its natural color and flavor are retained

• The product is crunchier in texture and absorbs less amount of oil in the process

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Vacuum Fryer

BENEFITS/ADVANAGES:

• Simple and easy to operate

• Local fruits and vegetables like banana, mango,

pineapple, durian, jackfruit, papaya, okra and carrot can be vacuum fried.

• Final products are crunchy, low in fat and high in fiber content.

• Process results in minimal changes in color and flavor

• Longer shelf-life, requiring no preservatives

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Vacuum Fryer

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Vacuum Fryer

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Vacuum Fryer

FEATURES:

• LPG fuelled

• Equipped with digital temperature controller

• All stainless steel construction

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Vacuum Fryer

jackfruit

tahong (mussels)

papaya

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Vacuum Packing Machine

Locally-developed Food Processing Equipment

DESCRIPTION:

• Vacuum packaging is a method of removing air (oxygen) from the container, thereby prolonging food shelf life.

• Stores the food in minimum-air environment, preventing the growth of microorganisms and protecting the food

from spoiling thereby extending the shelf-life of food significantly.

• Usually applied for long term storage of dry foods such as cereals, nuts, cured meats, cheese, smoked fish, coffee and potato chips (crisps)

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Vacuum Packing Machine

BENEFITS AND ADVANTAGES:

• Enhances product quality

• Maintains the freshness and flavor of food

• Vacuum packing results to savings in the food industry (in terms of minimized storage and ease of transport)

• Can be used for a wide range of plastic bags like tri- laminates, retortable bags and PPE

• Can be used for products that require nitrogen flushing

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Vacuum Packing Machine

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Vacuum Packing Machine

FEATURES:

•

A table-type unit that can be widely used in vacuum sealing of food products such as

seafood, meat and dried fruits/vegetables – in flexible pouches

• Can be used for products that require nitrogen

flushing

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Vacuum Packing Machine

rice

corn tinapa

crispy pata

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Spray Dryer

DESCRIPTION:

•

Used in converting liquids into dry powder

• The system subjects atomized liquid raw material to heated gas in a drying chamber, causing

instantaneous evaporation

• Powder is discharged continuously from the

drying chamber and collected in a cyclone-type

dust collector

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Spray Dryer

• Preferred method of drying thermally-sensitive materials such as foods and pharmaceuticals

• Efficient and rapid methods of drying most liquid materials/food solutions or suspensions

• Can be used for heat-resistant and heat-sensitive products

• Offers better control of powder quality in terms of particle size and bulk density

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Spray Dryer

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Spray Dryer

FEATURES:

• High pressure pump/plunger pump

• Evaporation capacity : 5-6 kg of water/hour

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Spray Dryer

Cow’s milk

Carabao’s milk Mango

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Freeze Dryer

DESCRIPTION:

• Used to dehydrate heat-sensitive materials via process involving the sublimation of water content under vacuum

conditions

• Used to preserve a perishable material or make the material more convenient for transport

• Freeze dried products may be stored at room temperature without refrigeration

• Enables retention of most of the quality characteristics of the unprocessed food material

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Freeze Dryer

• Can dry food materials below 40°C

• Dried material retains its shape & color

• Flavors, smells and nutritional content generally remain unchanged.

• Preserves temperature–sensitive products (e.g. enzymes, blood plasma, vaccines)

• Provides solution to certain delivery problems

• Freeze dried products can be rehydrated quickly

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Freeze Dryer

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Freeze Dryer

1 Vacuum Chamber Assembly

2 Ice Condensing Chamber Assembly 3 Pirani Gauge

4 Vacuum Pump 5 Condensing Unit

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Freeze Dryer

FEATURES:

• Consists of vacuum chamber with five adjustable trays

• Condensing capacity of up to 4L/24 hours

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Freeze Dryer

Before ^During ^After

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Freeze Dryer

durian avocado tahong

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EQUIPMENT PROTOTYPE

SPECIFICATION OF

PROTOTYPE APPLICATIONS PRODUCTS TESTED EQUIPMENT

COSTING

1. Vacuum packaging (sealing machine)

Sealing Length: 450mm Sealing Element: Nichrome Avg Cycle Time: 20-30secs Vacuum Pressure: 90kPa

Sealing of foods in flexible packages under vacuum condition

1. Rice

2. Monggo, corn 3. Fish (dried) 4. Crispy Pata

Php 110,000

2. Spray dryer 1 to 5 kg/hour Drying of food and herb extract, Fruit juice, Dairy product into powder form

1. Maltodextrin 2. Milk (Carabao)

Php 850,000

3. Water retort Capacity: (by batch) 250 sardines cans, 500 pouches (250ml)

Retorting of products packed in pouches

1. Suman sa lihiya 2. Ready-to-eat meals

Php 135,000

4. Vacuum fryer Capacity : 10 kg per process (using tahong)

Vacuum pump capacity : 2 hp Oil volume : 80L

For vacuum frying of fruits, vegetables, root crops, shellfish and other marine

1. Banana chips 2. Potato

3. jackfruit

4. Tahong (mussels)

Php 650,000

5. Freeze dryer Capacity: 4trays (300mmx500mm)

Condensing Rate: 3L/24hrs Ice condenser temp: App. -20 °C

For freeze drying high value food products and

pharmaceutical products

1. Carrots 2. Potato

3. Langka (jackfruit) 4. Durian

Php 600,000

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