Microwave (and RF) Heating in Food

Processing Applications
Juming Tang, Ph.D.
Professor of Food Engineering

Department of Biological Systems Engineering

Washington State University, Pullman WA

OUTLINE
1. Microwave and Radio Frequency (RF)
Heating Principles
2. Established Applications in Food
Processing
3. Development of Microwave Sterilization
Technology for Pre-packaged Foods

SPECTRUM

Electromagnetic Spectrum

The wavelength
MW

RF

l = c/f

with c = 3.108m/s

f
13.56 MHz(+/- 0.05%)

915 MHz

27.12 MHz (+/- 0.6%)

2450 MHz Domestic Ovens

40.68 MHz (+/- 0.05%)

10 12 18 GHz (plasma)

Very restricted bands

Can be used for ISM
applications

Generation of microwave

Magnetron

Waveguide

Magnetron

Microwave cavity (applicator)

Domestic Microwave Oven (2450 MHz)

Microwave Cooking of Meat Patties (APV system)

RF Heating Systems

Food

Plate Electrodes in RF Heater

Industrial Applications of RF Technology

- typical up to 85 kW per module

Food Dryer
Source: Strayfield, UK

Dielectric heating of foods

- Product temperature in electromagnetic field:
T
C p
= 5.563 10 11 f E 2 ''
t
Loss factor

- Dielectric property:
Dielectric constant

- Contributions of dipole rotation and ionic conduction:

Multi-mode Systems

Electric field pattern for a loaded microwave cavity at 2.4295 GHz.

(Chan and Reader, 2000)

Single - mode Systems

TM010 cavity resonator, 915 MHz (adopted from Regier and Schubert)

How Does RF or Microwaves Heat Foods?

Alternating Electric field

Space charge polarization

Orientation polarization

Mechanism of Dielectric Heating

RF

Ref: Tang et al., 2002, Scientific Press, New York

MW

Penetration Depth (mm)

RF

Ref: Wang et al.,2003. J. Food Eng. 57: 257-268.

Microwaves

2. Industrial Microwave (MW) and Radio

Frequency (RF) Technologies

-- Better quality
-- Reduced process times
-- New products?

MW COOKING DESSERTS
Cooking of desserts in pots

Microwave Tunnel

22 000 Pots / hour

Power : 144 KW.

MW COOKING/PASTEURIZATION OF VEGS

Nutripack (a French Company) solution with valve Valvo-PackTM

The valve allows a thermal treatment and the cooling of the product in the packing without
counter-pressure.
The valve is adhesive and is installed on the upper part (heat sealing film, cover) of a
packing (plastic, metal, paper, cardboard) that has been previously pierced.
Opening limit : 10 mbar 3 mbar
Closing limit : 5 mbar 2 bars

A similar concept developed by MicVac, Sweden

From their website:

http://www.micvac.com/

MicVac develops, markets and sells two methods

for processing and packaging convenience food.
Both solutions (for pasteurised and unpasteurised
foods respectively) use a valve that offers several
benefits for both the producer and the consumer.
The MicVac method is based on the principle of
cooking and pasteurising food using microwaves
directly in the sealed consumer package. The film
cover on the package has a valve that opens
during cooking, releasing the overpressure in the
form of steam and oxygen. After cooking, the
valve closes and a natural vacuum is created in
the package another of the products many
advantages.

MW COOKING/PASTEURIZATION

EXAMPLES OF PRODUCTS

Wokingham, UK

RF Finish Drying of Bakery Products

50kW RF Post Baking Unit - Courtesy of Foxs Biscuits, UK

Moisture profile at exit of an industrial bakery

oven, and after RF drying for 5 mins

Moisture % BDW

Before RF

After RF

At Packing

2.05
1.85
1.65
1.45
1.25
Working Side

Middle

Non-working Side

RF Post-Baking
Virtually Eliminates
Checking!

Sponge Products
Reduces Mold Spores
Increases Shelf Life
Increases Production

 Appetisers snack

Meringue
Puff pastry

Breakfast cereal
Bread crouton
Sponge product
Pretzel
Short bread
Profiterole

RF DRYING OF BAKERY
PRODUCTS

Manufacturers using RF
Heating and Drying

Kraft (Nabisco) (USA)

United Biscuits (UK)
Kelloggs (Keebler) (USA)
Foxs Biscuits (UK)
Weetabix (UK, Canada)
Arnotts (Australia/ New
Zealand/ Indonesia
National Biscuits (S.Africa)
Safeway (USA)
Ferrero (Italy)
Dancake (Portugal)
Ulker (Turkey)
Pepperidge Farms (USA)
M&M Mars (USA)

Parle (India)
Britannia (India)
Crown (Korea)
Horizon Biscuits (UK)
United Biscuits/Danone (Lu
France, Bagley Argentina)
Tong Yang (Korea)
Morinaga (Japan)
Dare Foods (Canada/USA)
Barilla (Italy)
ETI (Turkey)
Ralston Purina (Bremner) (USA)
Griffin (New Zealand)

Approximately 500 RF food processing systems

sold over 37 years

3. Development of Microwave Sterilization

Technology for Pre-packaged foods
(~50 years)
All past MW sterilization systems used 2450
MHz

Conventional Retorting Relies on Heat

Convection and Conduction in Foods
Retort
Convection

Target: C. botulinum spores

A Multi-mode 2450 MHz Microwave Cavity

2450 MHz microwave heating system for food in plastic

pouches at US Army Natick Soldier Center in 1970

 Microwave pasteurization equipment with module

open to show alternating placement of magnetrons
(Berstoff, 1992)

Microwave pasteurization line for prepared meals

(Berstoff, 1992)

Microwave sterilization unit with external covering removed

(overpressure of 2.5 bar,OMAC, 1992)

Continuous microwave sterilization system

(OMAC, 1992)

Otsuka plant
in Japan (2008)

TOPS FOODS
Olen, Belgium (2000)

The 2nd generation Microwave Sterilization

System2000

The 3d Generation of Microwave Technology at

Tops Foods, 2004

Sterilized products produced by TOPS Foods

MW pasteurized, processed to 80C

shelf-life 35 days at 7C

MW sterilized, shelf-life 1 year

at room temperature

4. Research on Microwave Sterilization

Technologies at Washington State University

4. Engineering and Scientific Challenges in

Developing MW Sterilization Processes
1. Technology/systems to provide stable
electromagnetic field patterns with high
energy efficiency
Single mode, high coupling efficiency

2. FDA Approval
Stability of system and processes
Scientific base/means for process development
Food Safety

3. High quality foods

4. Scaling-up and economic viability

MW STERILIZATION CONSOTIUM (2001-)

Washington State University
Microwave Company: Ferrite Component, NH
Food Packaging Companies:
Rexam Container, MO
Graphic Packaging, CO
Food Processing Companies:
Kraft Foods, ILL
Hormel, MN
Masterfoods (MARS USA), CA
Ocean Beauty Seafood Inc., WA
Technical Consultant: NPA
Supported by DoD DUST Program and US Army Natick Soldier
Center

Development of Microwave Sterilization Technology

Computer simulation
System development

Microbial studies

Process development

FDA Approval

Scaling-up

Industrial implementation

0 phase shift

cavity
waveguide

WSU 915 MHz Single-Mode 10 kW Pilot Scale Sterilization

System (2001-2008)

Steps involved in identification of cold and hot spots with mashed

potato sample

Computer vision to measure

M-2 color of processed
trays.

M-2 Kinetics
Fo vs M-2 yield relationship

Checking repeatability of
hot and cold spots with different
tray sizes and level of salt

Identification of cold/ hot location

For different tray size.

Verification of location
Using fiber optics probes

77 min heating time (steam at 247

F)

MW sterilization of salmon
April 15, 2003
(Run-1)
140

circulating water tempture

120

parameters

100

80

temperature of salmon
60

40
MW heating: 2.4 min;
Total processing time: 10 min.

F0=8.4

20

0
0.00

2.00

4.00

6.00
time [min]

8.00

10.00

12.00

Change of Shear Force in Pink Salmon Fillet Heated at 121C

170

Shear force (N)

150
130
110
90
70
50
30
0

20

40

60

80

Cooking time (min)

100

120

140

Eggs

Mashed Potato

Microwave sterilized salmon and fried rice

Maximum and minimum C values for food in a 10 oz tray after

a F0=6 process, water temp=121 C
Process time
(min)

Max cook
value

Min Cook
value

Ideal
Retort

6
33+4

39
212

39
93

Microwave

9+4

58

50

C values for food in a 10 oz tray after a F0=6 process, water

temp =125 C
Process time
(min)
Ideal

2.4

Retort

27+4

Microwave

3.9+4

Max cook
value

Min Cook
value

22

22

279

78

36

32

56

Sensory and self-life studies at US Army

Natick Soldier Center
50 trays chicken
were produced for
Natick in January
2004
Chicken product:
Natick evaluation,
shelve study and
taste panels

Hedonic score
(1-9 scale)

Chicken Breast, OVERALL Acceptability

o
Averages over 6 months storage at 100 F
8
7
6
5
4
3
2
1
0

y = -0.0796x + 6.7086
R = 0.6015 (Microw ave)
2

y = -0.0865x + 5.4943
R2 = 0.946 (Retort)

Microwave
Retort

Months in 100o F Storage

Linear (Microwave)
Linear (Retort)

WSU 2nd generation system developed for FDA approval

- four single mode cavities, 40 kW max MW power

Potential applications for microwave

sterilization/pasteurization technologies

- new processes
- new products
- new markets
For more information
http://www.microwaveheating.wsu.edu/

MW and RF Technologies are much more

complicated than conventional methods.
Successful development of new applications
requires extensive R&D efforts based on good
understanding of MW and RF heating principles
and the systems.
Pilot-scale studies are necessary for scaling up to
industrial processes

Thank You