Table
of Contents
What Is
Georgia's Traditional Industries Program?
FoodPAC Organizational Chart [opens a new window]
FoodPAC 1998—1999 Calendar of Events [opens a new window]
FoodPAC Project Summaries
Environmental
Projects
Environmental
Technical Assistance Program for Georgia Food Processors Food Safety
Projects
Development
of a Quantitative Microbial Risk Assessment Model Low-Cost
Integrated Machine Vision System for Food Quality Grading
By-Products
Recovery Research and Pilot Plant
High
Pressure Pasteurization for Elimination of Salmonella and Listeria in Liquid Egg
Products
Process
& Product Competitiveness Projects
Marination
Technology and Process, Product, and Ingredient Interactions
Extending
the Quality and Utilization of Frying Oils and Improving the Quality of Fried Foods
Automated
Packaging System
An
Automated Approach to Continuous Curing and Post-Processing of Peanuts
Assessment
and Utilization of Beneficial Components in Georgia Agricultural Products and By-Products
UGA
Food Processing Center: Advanced Research Initiatives and Technology Transfer
Quality
Enhancement of Fried Foods Through Computer Visualization of the Frying Process
FoodPAC
Infrastructure Projects
FoodPAC
Implementation Projects
FoodPAC
FY 1999 Program Projects
.
What
Is Georgia's Traditional Industries Program?
Georgia's “traditional industries”
(pulp and paper; food processing; and apparel, carpet, and textiles) have historically
been the backbone of the state's industrial base. Virtually every county in Georgia
is home to at least one of these industries, which combined employ 260,000 Georgians,
almost half of the state's manufacturing work force. Despite their size, these leading
industries in Georgia face serious international challenges to their competitive
position, especially from companies in low-wage regions of the world.
Recognizing the importance of these industries to Georgia, the state established
the Traditional Industries Program (TIP) in 1994. TIP is designed to bring industry
leaders and university-based researchers together to develop and implement practical
solutions to improve the competitiveness of pulp and paper; food processing; and
apparel, carpet, and textile companies in Georgia.
Each of the three traditional industries has formed a public-private partnership
where industry identifies critical competitiveness problems, then works closely with
faculty from Georgia's colleges and universities to solve those problems. Since 1994,
the state has invested more than $34 million to provide research, technology development,
and technical assistance to Georgia's traditional industries, and industry has matched
the state's investment.
Georgia's Traditional Industries Program for Food Processing and FoodPAC Georgia's
Traditional Industries Program for Food Processing was established as part of the
state's strategic economic development thrust for traditional industries. The program
resulted in the formation of a public-private partnership among the food industry,
Georgia's institutions of higher education, and Georgia's state agencies. This partnership
is called the Food Processing Advisory Council or FoodPAC. In 1994, FoodPAC defined
its vision as seeking to make Georgia the national and international leader in food
processing in the 21st century. Toward that end, the Traditional Industries Program
for Food Processing was given the mission of seeking to enhance the competitiveness
of Georgia's food processing and allied industries in order to provide for economic
growth through expansion of existing industries and the attraction of new food-related
industries. The program addresses this mission by:
.
Environmental
Projects
Environmental Technical Assistance Program for Georgia
Food Processors
Project Number FP98-EN01
Co-Project Leader
- Jackie Sellers, The University of Georgia (706) 542-8382
- William Merka, The University of Georgia (706) 542-9151
- James Walsh, Georgia Institute of Technology (404) 894-8054
- Edgerton Whittle, The University of Georgia (706) 542-7690
- A. Estes Reynolds, The University of Georgia (706) 542-2574
Project Participants
- Tim Foutz, Peter Jacobs, Brian Kiepper, Jeff Tepper, and Mark Welford, The University of Georgia
- John Pierson, Georgia Institute of Technology
FY 1998 State Funding: $152,688
Industry's Concern
Georgia food processors are faced with increasing environmental issues that often
require compliance with federal, state, and local regulations.
Understanding these regulations and developing systems to meet regulatory guidelines
are of major concern to processors.
Project Objective
To provide technical assistance to food processors in a wide variety of areas primarily
related to environmental issues. Assistance efforts in FY 1998 focused primarily
on characterizing waste generation and improving water usage.
FY 1998 Project Activities and Outcomes
Project assistance efforts saved food processors an estimated $1.5 million annually,
while more than 20 individuals received training in loss minimization and pollution
prevention.
Project personnel also visited food processing plants and conducted in-plant assessments
to characterize water usage and wastewater discharge and evaluated wastewater treatment
operations and overall facility environmental compliance. Methods to reduce wastewater
outflow, achieve compliance with appropriate regulations, and to utilize possible
by-products were identified.
Training workshops were also held where food processors received instruction on the
proper procedures to characterize water usage and waste-water discharge, identify
inefficient systems, and develop solutions to current problems.
A dissolved air flotation (DAF) primer was completed. The 40-page primer provides
operators and managers with an overview of the theory of DAF system operation as
well as practical information on the actual operation of the system. The primer was
used in conjunction with on-site technical assists at six facilities. It is estimated
that a minimum of $50,000 can be saved at a typical food processing facility each
year.
A number of presentations on the requirements of a Risk Management Program (RMP)
were made to various groups across the state. An analysis of the release data for
ammonia, propane, and chlorine is being conducted to support the alternative release
scenario required by the program. Five years of data are being analyzed.
Water conservation audits were conducted at several facilities. These audits resulted
in estimated savings of $50,000 at each facility. Project staff also worked with
several groups in addressing water withdrawal from both ground and surface sources,
and permit provisions related to mass versus poundage limits for pollutants.
A review of the new general permit for storm water discharge from industrial activities
was conducted, and project personnel participated in several workshops where the
requirements of the new permit were presented. Several facilities were assisted with
the development of storm water pollution prevention plans.
The oil and grease evaluations started last year continued. The objective is to evaluate
the use of a floatable oil and grease testing protocol for improving the operation
of grease traps for wastewater with emulsified oil and grease often generated by
cooking operations. Several field tests were conducted, but the results are inconclusive.
More tests are planned.
A seminar module has been developed to address issues related to air emission, risk
management, emergency planning and community right-to-know, and hazardous waste.
The module was presented at two workshops.
A newsletter was also published and distributed to 1,000 food processors.
FY 1999 Project Activities
Activities will help food processors identify more efficient water uses and product
recovery, uncover sources of operation inefficiency, establish a mode of operation
that eliminates the difficulties that result in loss of profits, and meet other new
and existing regulatory issues.
By-Products
Recovery Research and Pilot Plant
Project Number FP98-EN02 Project Participant FY 1998 State Funding
$197,000
Industry's Concern
Project Leader
The U.S. Food Experts Alliance for Strategic Technology (USFEAST) has established
a goal of developing environmentally friendly technologies for reducing waste generated
during food processing. The key to this is identifying methods to recover by-product
material either during or after processing.
Project Objective
To research and develop state-of-the-art processes for recovering by-products directly
from food processing waste streams.
FY 1998 Project Activities and Outcomes
Activities focused on four areas: adding value to poultry feathers by their use as
building insulation, upgrading solid carbohydrate waste, recovering and upgrading
waste soft drink effluent, and extracting chemical products from pecan pith.
Researchers performed a detailed investigation of the use of dequilled poultry feathers
as insulation by constructing several small model houses and studying their thermal
characteristics during the summer months. These studies reveal that poultry feathers
are equivalent to at least R-11 fiberglass insulation at one-fifth the cost, in addition
to having several environmental and health advantages. This technology may impact
the value of the state's feather waste by some $15–20 million annually.
A fermentation process was developed to convert a portion of solid carbohydrate waste
(generated from bakeries and processors of sauces and creams) into lysine. Researchers
are also working to convert the waste into ethanol. The goal of this particular initiative
was to increase value sufficiently to permit the capture of liquid bakery waste.
Researchers compared the chemical hydrolysis of mixed (raw) bakery waste using 12
different methods. The most effective chemical hydrolysis method combined high waste
concentration (40%), relatively low acid concentration (2% sulfuric acid), and long
reaction times (30 minutes). The yield could not be calculated on a dry basis because
of the heterogeneity of the bakery waste. However, more than 80% of the total carbohydrates
were hydrolyzed to reducing sugars. In addition, investigations of the enzymatic
hydrolysis of mixed bakery waste seemed to demonstrate that the enzymatic process
is more economical than chemical hydrolysis. Hydrolyzed starches were successfully
converted into lysine and ethanol with a yield of about 30% (normal for the fermentation
process used).
A process was also developed to convert soft drink into lysine. Researchers studied
the fermentation of a variety of soft drinks and juice drinks from a local bottler.
Final concentrations of 15 g/L lysine were achieved, corresponding to a yield of
30%. This amounts to approximately $200,000 of revenue annually, for a difference
of $400,000 annually for the bottler.
Preliminary research began on recovering value-added materials from pecan pith. More
than one million pounds of the material could be recovered annually from pecan pith
in Georgia, with a value of several million dollars. However, lack of industry involvement
slowed progress of this developmental study.
FY 1999 Project Activities
The project is completed, and a report has been generated.
Development
of a Quantitative Microbial Risk Assessment Model
Project Number FP98-FS01 Project Participants FY 1998 State Funding
$21,192
Industry's Concern
Project Number FP98-FS02 Project Participants FY 1998 State Funding
$94,680
Industry's Concern
Project Leader
Food-related illness in the United States is estimated to cost the economy several
billion dollars each year. A proper understanding of the risk involved in food-borne
illness could significantly reduce these costs. Minimum infectious doses are an important
part of this understanding. However, standard methodologies for dose-response assessment
are not yet formulated for microbial risk assessment. A perceived obstacle is the
variability in host/microorganism interaction. Identifying the appropriate model
will allow for comparisons among food-borne pathogens and will allow further development
of a risk assessment model for these pathogens.
Project Objective
To identify the most appropriate dose-response model for food-borne pathogens.
FY 1998 Project Activities and Outcomes
Central to microbial risk assessment is dose-response assessment. Dose-response modeling
of microbial hazards provides a standard scale of infectious potential. Especially
important for regulatory purposes are minimum infectious doses, generally a product
of dose-response modeling. An infectious dose (ID) is the ingested dose necessary
to cause infection or illness in a percentage of the population. That is, an ID01
is the dose necessary to cause infection in 1% of the population. To identify the
most appropriate dose-response model, researchers evaluated six statistical models:
log-logistic, log-normal, simple exponential, flexible exponential, Beta-poisson,
and Weibull-gamma. These models were tried on four organism groups (Shigella dysenteriae,
Shigella flexneri, Salmonella typhosa, and Campylobacter jejuni) to determine the
appropriateness of the response using the method of maximum likelihood. The data
sets represented a range of quality that is typical for microbial dose-response.
Infectious doses (ID01) were then calculated using each model. (See table, opposite
page.)
The Weibull-gamma model was the only model to fit all the data sets and proved the
most suitable for describing the food-borne pathogen dose-response data.
FY 1999 Project Activities
The project is completed, and a report has been generated.
High Pressure Pasteurization for Elimination of Salmonella
and Listeria in Liquid Egg Products
Project Leader
Egg products (liquid, frozen, and dried) are an important part of our food supply
due to their wide use as an ingredient in many food products such as bakery, mayonnaise,
salad dressing, and egg noodles. The Egg Products Inspection Act of 1970 led to regulations
requiring that all egg products be rendered free from Salmonella by the application
of appropriate pasteurization processes. However, despite adherence to the pasteurization
protocols recommended by the USDA for liquid egg products, outbreaks of food poisoning
from the consumption of egg products or foods manufactured with them as ingredients
are still occurring. This is due to survival of some vegetative and spore-forming
microorganisms capable of causing post- pasteurization spoilage, which may shorten
the shelf life of pasteurized egg products.
Project Objectives
To modify the high pressure intensifier unit to handle viscous products like liquid
egg and to control the temperature rise on the product after high temperature treatment;
to determine the effect of pressure, steps to convert potential energy to heat energy
after high pressure treatment, holding time after high pressure treatment on microbial
inactivation in liquid egg; and to determine the effect of different treatment variables
on quality of liquid egg products and compare properties with that produced using
conventional treatments.
FY 1998 Project Activities and Outcomes
Studies were conducted using two different high pressure throttling processes (HPT).
The first processing system consisted of a hydraulic-driven, double-acting pressure
intensifier capable of pressurizing the fluid to 45,000 psi (300 MPa), a high pressure
hold tube, a throttling valve, a low pressure hold tube, and a cooling heat exchanger.
Tests were conducted on inactivation of a suspension of 24h actively growing Pseudomonas
putida in nutrient broth, a suspension of 48h Lactobacillus sake cells in MRS broth,
and a suspension of 48h Zygosaccharomyces bailii cells in yeast malt broth. The test
fluids were treated as follows: 0.3s dwell at 35,000 psi (242 MPa) and 0.5s dwell
downstream of the orifice before cooling.
The HPT system successfully inactivated P. putida from an initial population of 108
CFU/mL to zero recovery at a 1:10 dilution. However, the HPT system only reduced
L. sake (gram positive) by 2 to 4 log cycles. A suspension of Z. bailii (ascosporogenous
yeast) containing 108 CFU/mL subjected to HPT was reduced 2.62 ± 0.05 log cycles.
Liquid whole eggs at 4ºC and treated at 30,000 psi (208 MPa) followed by rapid
cooling to 5ºC showed no adverse changes in viscosity or appearance and was
stable under refrigeration for at least 21 days. The second high pressure system
could exert a maximum pressure of 60,000 psi (415 MPa) together with a pre-cooler
shell and an attenuator to hold the product at the set high pressure while it was
maintained in continuous flow. Because of the high viscosity of liquid egg products,
preliminary tests of the unit were conducted using deionized water and skim milk.
During the tests with deionized water, product outlet temperature varied with exerted
pressure and was as high as 100ºC at 60,000 psi (415 MPa). A similar temperature
rise was found for skim milk. As a result, effort was directed to designing a means
of controlling the temperature rise, including the installation of a second micrometering
valve. For this purpose, a preliminary test was also conducted using a cooling coil
immersed in a constant temper-ature bath set at -20ºC and through which the
deionized water was passed immediately after high pressure treatment. With the additional
cooling coil after decompression, product temperature was reduced to about 20ºC
in about 15 seconds.
Researchers also conceived a heat sink for rapid removal of heat during depressurization
and initiated its preliminary design.
FY 1999 Project Activities
Efforts will focus on using a combination of high oxidation potential water to prewash
shell eggs and high pressure pasteurization protocols to achieve the desired level
of pasteurization for different liquid egg products (liquid whole egg, liquid egg
white, liquid yolk, and yolk with 5% salt and 5% sugar).
.
Process
and Product Competitiveness Projects
Low-Cost
Integrated Machine Vision System for Food Quality Grading
Project Number FP98-PC01 Project Participants FY 1998 State Funding
$195,650
Industry's Concern
Project Number FP98-PC02 Project Participants FY 1998 State Funding
$215,000
Industry's Concern
Project Number FP98-PC03 Project Participants FY 1998 State Funding
$159,950
Industry's Concern
Project Number FP98-PC04 Project Participants FY 1998 State Funding
$241,164
Industry's Concern
Project Number FP98-PC05 Project Participants FY 1998 State Funding
$116,902
Industry's Concern
Project Number FP98-PC06 Project Participants FY 1998 State Funding
$118,100
Industry's Concern
Project Number FP98-PC07 Project Participants FY 1998 State Funding
$336,700
Industry's Concern
FY 1998 Project
Activities and Outcomes
Project Number FP98-PC08 Project Participants FY 1998 State Funding
$159,974
Industry's Concern
Project Leader
Traditionally processors have relied upon the human eye to screen for surface quality
faults in food products such as fruits, vegetables, meats, and poultry. A significant
aspect of this screening involves distinguishing the color of the product. Today's
human screeners must manually inspect the product as it passes down the line at a
high rate of speed. However, human screeners are prone to making errors because the
method relies on the screener remembering the correct color as well as associating
the product's color with quality standards. Eye fatigue is also of concern as it
diminishes the accuracy of the inspection. Many companies, therefore, are embracing
the idea of automated screening systems. In 1996, as part of the Food Processing
Industry Initiative for Sensor Assessment and Evaluation, researchers began incorporating
an integrated digital color camera into a practical food quality screening system. Ideally
the system will be able to screen food products for overall quality at high-rate
line speeds, thus eliminating human error in grading, sorting, and quality control.
Project Objective
To develop an automated vision screening system for defect detection and grading
of fruits and meats.
FY 1998 Project Activities and Outcomes
The research team completed development of a prototype system for automated vision
screening of grapefruit. The PC-based, dual processor pentium machine with camera
component was interfaced with a commercial fruit handling system. Using G.E.O.R.G.E.
(Grapefruit Evaluation with On-line Recognition Grading Environment), researchers
were able to screen one grapefruit per second, which is an order of magnitude away
from the required 10 grapefruits per second. Work will continue to develop hardware
that will increase the system's speed to a point where it can screen 10 grapefruits
per second.
The team also tested and further trained the system's neural nets. To date, the neural
nets have been trained from a database of more than 1,600 images of quality defects
such as skin breakdown, wet bottom, sunburn, etc. During testing, the researchers
noted, however, that isolated spots or even texture on the grapefruit would be classified
as defects, resulting in a higher percentage of defective area on the grapefruit.
To alleviate this problem, a new approach was used that looked at a “window” around
each pixel being processed. This ensured greater accuracy.
Tests also showed that defect detection was not very good on the edges of the grapefruit,
due mainly to the effects of nonuniform lighting. Researchers found that an eight-light
(as opposed to a four-light) system was fairly adequate to ensure near uniform lighting.
In addition, researchers further improved the modeling of grapefruit. They were able
to develop a technique that showed a full view of all surfaces of the grapefruit.
This avoided image overlap and ensured optimization.
FY 1999 Project Activities
The project is completed, and a report has been generated.
Marination Technology and Process, Product, and Ingredient
Interactions
Project Leader
Marination technology is an increasingly common value-added process for muscle foods.
Ingredients in marinades have been shown to minimize off-flavor development, extend
shelf life, improve tenderness and juiciness, and increase yield. However, the complexity
of the process along with ingredient composition and subsequent interaction often
results in variability in pickup, retention, and product quality.
Project Objective
To use a combination of processing/marination technology, chemical, and enzyme technology
to provide high-quality, healthier, convenient, ready-to-serve muscle foods.
FY 1998 Project Activities and Outcomes
Specific projects evaluated the effect of types and concentration of phosphates and
phosphate blends and other process variables on quality parameters, including yield,
tenderness, and juiciness.
Water hardness studies showed that the type of phosphate used makes a difference
in cooked yield. A tripoly phosphate-diphosphate blend had a 3.4% higher yield compared
to diphosphate alone. This translates to an economic advantage of $4,000/day for
a processing plant that processes 39,000 lbs/day of breast meat just by using the
right phosphate in the formulation.
Studies also showed that cut-up poultry immediately after chilling is viable and
can result in cost savings in labor and cooler space. Choice of phosphate and optimization
of marination process may potentially further improve product quality and reduce
process time and costs. Alternatives to phosphates as water binding agents and development
of new poultry products were evaluated. Pectin as a purge control agent was found
to be as suitable as some phosphates and more desirable with some consumers. Researchers
also determined that consumers are receptive to the concept of fruit-based marinades.
Intensive studies were conducted to determine the effect of phosphates on the ultrastructure
of the muscle, the fate of phosphates, water binding properties of muscle proteins,
and the mechanical properties of marinated muscle. These studies using NMR, electron
microscopy, and dynamic mechanical spectroscopy with muscle proteins and pure phosphates
provide the fundamental base of knowledge to predict performance of phosphates and
phosphate blends on muscle texture. This should enhance the abilities of product
development technologists to choose phosphates, blends, and concentrations of phosphates
based on specific product needs in a processing plant.
The natural antimicrobial activity of spices and oils was evaluated as well as the
feasibility of recycling marinades. Successful use of 0.5% clove oleoresin (CLO)
and 0.5% pimento leaf oil (PLO) was apparent on samples stored at 4ºC that showed
an increased shelf life or reduced growth rate of the test organisms. The increase
in populations of bacteria in the recycled marinades over time was not unexpected.
The survey did indicate that there is a difference in the amount of growth and the
formation of the marinades. Differences were also noted that showed that less than
desirable sanitation practices could contribute to the counts and the magnitude of
the population increases. It is worth noting that E. coli counts, when monitored,
increased over time. This might be of concern to processors from both a safety and
sanitation standpoint.
Extension of the marination technology to other muscle foods, including beef and
seafood, was also evaluated. Marinated beef strips from less tender beef cuts would
provide increased consumer acceptability and convenience, provided tenderness and
juiciness are maintained. The utilization of phosphates to increase tenderness and
maintain juiciness and yield will provide low-cost beef cuts in a readily usable
form. Data show that these methods can be easily adapted to produce a wide variety
of marinated, ready-to-eat beef products of high quality, while utilizing less tender
cuts as a raw material.
Lastly, the development of an effective Outreach Program for the marination of muscle
foods has already had a direct impact on the U.S. food industry. Three marination
workshops have been conducted, with participation from more than 100 firms, including
Popeye's, KFC, Boston Market, Tyson, Cargill, ConAgra, Gold Kist, Golden Plump, Fieldale,
Seaboard, and many others. It is estimated that 13% of the nation's poultry is now
marketed as a marinated product. New product development efforts have also involved
shrimp and fish products, with several firms now marketing new marinated products.
Several Georgia firms have expanded operations to include marination, and knowledge
gained from these workshops ensures that this expansion can be sustained through
increased sales and higher profitability.
FY 1999 Project Activities
The project is completed, and a report has been generated.
Extending the Quality and Utilization of Frying Oils and
Improving the Quality of Fried Foods
Co-Project Leaders
Oils are used extensively in the processing and cooking of many Georgia agricultural
commodities. Fast food and food service operations rely heavily upon deep-fat frying
for cooking french fried potatoes, poultry, meat, seafood, battered and breaded vegetables.
Deep-fat frying enhances the sensory properties of fried foods. However, repeated
use of frying oils produces undesirable constituents that may pose health hazards
and lead to quality and economic loss to the processor.
Project Objectives
To improve and extend the quality of frying oils utilized in processing Georgia agricultural
commodities through regeneration technology; to develop a simplified objective assay
for routine analysis of frying oil quality; to evaluate the quality of products processed
using regenerated frying oil; to prevent migration of marination components from
the product into the frying oil and remove undesirable flavor components from the
frying oil.
FY 1998 Project Activities and Outcomes
Researchers have filed a patent application on the use of adsorbent combinations.
Seven commonly used filter aids (Silasorb, Britesorb, HB 600, Purifry, Frypowder,
Activated Carbon, and Magnesol) as well as two commercially unavailable adsorbents
(Sorbead AF and Calsilite) were studied. A number of AOCS official methods were used
to evaluate their adsorptiveness, free fatty acids (FFA), conjugated diene value
(CDV), total polar components (TPC), oxidative stability index (OSI), color, and
viscosity (V).
High performance size exclusion chromatography was employed to determine the amount
of polymers and low molecular weight compounds. When heated to 150ºC prior to
filtration, HB 600 was found to reduce FFA content by 84.5%. Frypowder improved oil
stability by 38.3%, and Magnesol lightened oil color by 46.3%. After statistical
analysis of the data, five of them were selected, two or three of which were blended
to obtain the most effective combination. The blending of HB 600 and Magnesol reduced
FFA and TPC by 90.8–93.7% and 6.0–17.8%, respectively, and improved oil stability
by 23.4–24.7%.
Studies also evaluated fluorescent pigment measurements as a reliable indicator of
frying oil quality. Data suggest that none of the nitrogenous compounds tested (carnosine,
chitosan, glycine, histidine, and lysine, 0.3–0.5 g) would serve as suitable reactants
in the monitoring of oxidative deterioration of frying oil.
Both home-type and restaurant-type fryers were used to study the effects of edible
films and coating methods on moisture, fat content, and quality of frying oils after
frying marinated foods. The edible film components used were hydroxypropyl methylcellulose
(HPMC) and methylcellulose (MC). Two viscosity grades (HPMC-E15 and MC-A15 at 15
cp, and HPMC-E4M and MC-A4M at 4000 cp) were selected. Applied edible films and methods
of coating had no significant effect on the moisture and fat content in the sample
core. The first method of coating in which samples were coated before breading resulted
in the lowest surface moisture and the highest surface fat content, for all treatments
except HPMC-E15. When it was used, significantly lower surface moisture contents
and higher fat contents were obtained for the second method of coating (samples coated
after breading). Among all the treatments, incorporating the edible film ingredient
in the breading mix resulted in higher moisture and lower fat uptake.
The effect of edible film coatings for marinated foods on the quality of frying oil
was also evaluated using one-day-old oil. Coating with HPMC-E15 incorporated in the
breading provided the highest moisture retention and lowest fat uptake in the product
surface. The other coating treatments were not significantly different from the control.
Researchers are now evaluating the quality of products processed using regenerated
frying oil and sensory attributes.
FY 1999 Project Activities
Researchers plan to design, develop, and test a safe filtration system for used frying
oil; determine the reliability of the fluorescence assay to monitor quality of commercial
regenerated oil; study the efficacy of the recovery system by evaluating the quality
of products fried using the regenerated frying oil; and prevent the migration of
marinating components from the product into the frying oil and remove undesirable
flavor components from the frying oil by providing an edible film coating to the
products.
Automated Packaging System
Project Leader
Today human operators working on the production line perform manufacturing tasks.
Although this technique has proven successful over the years, manufacturers are interested
in finding automated alternatives. For the last six years, researchers at the Georgia
Institute of Technology have conducted studies in the area of robotics and automation
in an attempt to produce more flexible machinery to be used on the production line,
i.e., machinery with similar performance criteria to that of the human.
Project Objective
To develop automation technology for loading bags of frozen food into top-load, paperboard
packaging cartons.
FY 1998 Project Activities and Outcomes
Researchers completed physical modeling of the alternative “Shoot” and used a video-based
motion analysis system on several trial drops.
Detailed configurations of the five design alternatives were completed, and the team
used a selection DSP technique to rank the alternatives, based on a number of attributes,
and recommended a final alternative. The final design selected was a system that
includes Georgia Tech's Integrated Intelligent Belt Manipulator (IIBM) system and
Kliklok's random-bucket-infeed (RBI) bag conveyor.
The team then made extensive alterations and additions to the IIBM robot, a system
initially developed for and tested on fresh packaged poultry handling. The modifications
addressed speed limitations and grasping changes and included adding a new gripper
design and vacuum system, changing software design, and interfacing pneumatic control
system and electronic system to existing industrial equipment.
In addition, Kliklok built and provided the RBI bag conveyor and an indexing carton
conveyor designed by its engineering team. The project team established a goal of
assembling an integrated prototype system employing both devices to test at Kliklok's
manufacturing facility in Decatur, Georgia.
A line study was also performed at Rich-SeaPak in Brunswick, Georgia, to gather downtime
data on Line 3 to define performance demands on the final system design.
FY 1999 Project Activities
Efforts are focused on transforming the IIBM and RBI systems into a functioning prototype
system that can be first bench tested then field tested under actual production conditions.
An Automated Approach to Continuous Curing and Post-Processing
of Peanuts
Project Leader
Peanuts are the second largest cash crop in Georgia, yet foreign imports and lagging
exports threaten this industry. One of the bottlenecks in peanut processing is curing
(or drying). Currently, the drying process is a batch process whereby peanuts are
dried in large trailers. The moisture measurements are taken manually. The result
is a process that is labor-intensive, with consequent effects on curing efficiency,
space utilization, and product quality.
Project Objective
To develop and demonstrate an integrated approach to the post-harvest processing
and curing of peanuts.
FY 1998 Project Activities and Outcomes
A major activity involved investigating the feasibility of using dielectric heaters
(with a radio frequency oven) for drying peanuts. Approximately 500 pounds of donated
peanuts were used in experiments. Researchers dried small batches at different peanut
kernel temperatures for different lengths of time. It was found that the higher the
kernel temperature, the faster the drying rate. However, even a modest heater temperature
of 100ºF to 110ºF was sufficient to reduce the drying time from the 20
hours normally required by the conventional gas heaters to a new level of about 1
hour. This significant decrease in drying time makes the continuous processing of
peanuts more feasible. Post-processing quality tests indicate that using the dielectric
heater at low temperature levels does produce peanuts that have acceptable skin slippage,
germination, and shrinkage.
Researchers also examined a new method for modeling peanut drying. Magnetic resonance
imaging (MRI) proved an excellent technique for visualizing fluid distribution and
movement in solid substrates. Two-dimensional MRIs of peanuts were taken (see images,
opposite page). A series of such two-dimensional slices allows reconstruction of
the three-dimensional fluid distribution. When taken as a function of drying time,
the images could reveal how the internal fluid distribution changes during drying.
This information is needed in order to develop a realistic model of the drying process,
which can then be used to optimize the drying process.
FY 1999 Project Activities
The project was not renewed for second- year funding. A report of completed work
has been generated.
Assessment and Utilization of Beneficial Components in
Georgia Agricultural Products and By-Products
Project Leader
Nutrition and medical research continues to identify food components that have beneficial
actions in maintaining health or in treating pathological conditions. Nutraceuticals,
designer foods, and medical foods are playing increasingly large roles in food product
development.
Project Objective
To identify beneficial food components in Georgia commodities and to develop technologies
to expand their use, with an emphasis on food components and products with potential
to enter the food/feed ingredient market, benefit public health, and expand utilization
of Georgia commodities.
FY 1998 Project Activities and Outcomes
Research produced an improved method for quantification of vitamin E from peanuts
and peanut products. Direct solvent extraction with hexane: ethyl acetate (90:10,
v/v), saponification, and Soxhlet extraction with hexane were evaluated for their
usefulness as extraction methods to determine vitamin E in peanuts and peanut butters.
The direct solvent extraction procedure yielded higher values for each tocopherol
homolog in peanut and peanut butter compared to the other methods.
Folate stability studies were also conducted. In the extrusion cooking process, the
effects of temperature (120, 140, and 160ºC) and moisture content of feed material
(20, 30, and 40%) were studied on the stability of natural occurring folate. Researchers
also studied the effect of adding iron on folate retention. Folate in the extrudates,
as determined by a microbiological assay using Lactobacillus rhamnosus, decreased
as extrusion temperature increased (p<0.05). Moisture content had no significant
effect. Folate was most stable at the 120ºC and 40% moisture (89.2% and 96.3%
retention for the unfortified Fe-group and Fe-fortified group, respectively). Fe-fortification
appeared to have no influence on folate stability. The study showed that the natural
folate in peanut flour can withstand extrusion and that peanut flour can be a significant
nutritional additive to such products.
Researchers also produced extruded products made from a combination of partially
defatted peanut meal and raw sweet potato. Such products can be produced with as
much as 30% by weight raw sweet potato. Stability of b-carotene was excellent through
the extrusion process. Sweet potato was also extruded with cottonseed meal (44% protein)
to produce a poultry feed ingredient with excellent potential to partially replace
corn-soy in broiler rations. Preliminary feeding studies dramatically showed the
feed value of a ration containing 75% corn-soy and 25% of a 75%–25% cottonseed meal-sweet
potato extruded blend.
Peanut oil was utilized to produce structured lipids with increased caprylic acid
content to produce a medium chain length triacylglyceride with potential medical
uses. Structured lipid was synthesized by transeterification of peanut oil and caprylic
acid.
FY 1999 Project Activities
The project is completed, and a report has been generated.
UGA Food Processing Center: Advanced Research Initiatives and
Technology Transfer
Project Leader
In an effort to increase interaction between The University of Georgia (UGA) and
the food industry, the Food Processing Center or the Food Process Research and Development
Laboratory (FPRDL) was established. Industry personnel are encouraged to use the
facility, and FPRDL researchers perform applied research projects as requested by
industry.
Project Objective
To assist the food processing industry in identifying problems, conducting research,
and transferring results.
In FY 1998, at least 12 Georgia companies and four national companies conducted work
at FPRDL. Following are highlights of major initiatives. Bunge Foods of Atlanta,
Georgia, has produced a line of products using extrusion technology (tested at FPRDL),
which produces cold dispersible hydrocolloids to stabilize dairy products and baked
goods. Clayton Lewis of Lawrenceville, Georgia, used resources at FPRDL to develop
a canned wood chip to impart a wood smoke flavor to grilled products. The commercialized
product for gas grills is now marketed under the Blue Moon Woods label.
Pyramid Manufacturing of Tewksbury, Massachusetts, built and installed a working
model of a radiant wall oven at FPRDL. Research studies were conducted to understand
the chemistry of roasting under radiant heat and the effect of very rapid heating
on microbial inactivation and product characteristics. Pyramid has successfully placed
two of the units at a major meat processing corporation, and the company plans to
construct a manufacturing facility in Georgia to meet the increasing demand for these
units in the industry.
FPRDL has also cooperated with Wolf-tec, Inc. of Highland, New York, to explore applications
of injection marination to processed poultry products. Wolf-tec donated injection
equipment, and FPRDL researched the effects of marinade formulations, temperature,
injector pressure, and marinade flow rate on marinade dispersion and product texture.
Several national firms with operations in Georgia, including ConAgra, Continental
Grain, Seabord, Fieldale, and Tyson, now have injection marination operations, and
have benefited from this work.
Crider's of Lincolnton, Georgia, used resources at FPRDL to determine if a prototype
for canned white meat chunks could be manufactured at its plant. Marination, cooking,
and canning tests were performed at FPRDL. The company is still evaluating options.
Castleberry's of Augusta, Georgia, performed tests to determine if using mechanical
vacuum on cans of chicken white meat will prevent discoloration in the canned product.
FPRDL also worked with WTCS Inc. of Atlanta, Georgia, to produce product prototypes
to use as samples for showing to potential customers. The company is seeking to market
microwaveable heat-sterilized entrees in thin profile thermostable plastic containers.
Simcha Catering of Newnan, Georgia, worked with FPRDL in establishing a production
facility to produce frozen Kosher entrees for airlines. Advice was given on production
line layout, product handling, and packaging.
A project supported jointly by Golden State Foods of Conyers, Georgia; Hickory Specialties
of Brentwood, Tennessee; and Pyramid Manufacturing of Athens, Georgia, resulted in
the development of a process for fast cooking (1.5 minutes) of hamburgers to a temperature
(170ºF internal) needed to kill pathogens followed by rapid freezing. The continuous
flow high pressure throttling process, developed at FPRDL, is now being commercialized.
The new technology removes pathogenic microorganisms from juices without loss of
fresh-like flavor, in contrast to the flavor deterioration concomitant with heat
pasteurization processes.
FPRDL also acquired new equipment designed to increase its capability to assist Georgia
processors with demonstrating “proof of concept” and troubleshoot process or product
quality problems. Major equipment additions include: an Inframetrics Therma-Cam,
a sophisticated infrared camera recorder and data analysis software, which can be
used for noncontact measurement of temperatures in products during the cooking process;
a Rheometrics rheometer for measuring textural properties of liquid and solid foods;
and a portable high pressure intensifier, which can be easily installed in a processing
plant to demonstrate the effectiveness of high pressure pasteurization of fruit,
juice, egg, milk, or sauce/condiments.
Lastly, a total of 569 participants attended 20 short courses/workshops, which focused
on issues such as poultry and meats marination, process control, quality control,
sanitation, candy technology, and HACCP development/implementation. Four issues of
the Food Processing Lines newsletter, which highlights research results, were also
published.
FY 1999 Project Activities
The project is completed, and a report has been generated.
Quality Enhancement of Fried Foods Through Computer Visualization
of the Frying Process
Project Leader
Recent studies have reported that more than 500,000 institutional and commercial
restaurants in the United States are involved in deep-fat frying operations (source:
Proctor & Gamble, National Restaurant Association). Health organizations throughout
the country have long called for lowering the caloric intake from food products.
Reducing the contribution of calories from fat is at the center of this national
initiative. In fact, the U.S. Surgeon General recommends that fat consumption be
reduced by 25 percent. In response to this, the food industry is continually seeking
innovative processes that will result in new products with reduced fat content, appropriate
moisture content, and improved quality attributes.
Project Objective
To develop a computer visualization tool to simulate physical and chemical changes
in food products during deep-fat frying.
FY 1998 Project Activities and Outcomes
Research activities focused on breaded food products, including butterfly shrimp,
popcorn shrimp, and French toast.
The research team successfully created mathematical models to accurately reflect
the frying process for complex food shapes, and developed an initial computer visualization
application software prototype to test and evaluate internally.
Mathematical models for heat, moisture, and fat transfer in multiple products during
deep-fat frying were developed. These models were later validated using data collected
from laboratory and production-scale frying. Comparison of regression model and experimental
results indicated that the model agreed closely with observed temperature, moisture,
and fat contents of the products during deep-fat frying.
The computer visualization software prototype delivered striking visual images, which
proved helpful in understanding the food frying process. Researchers believe the
industry will be able to more readily make decisions regarding quality and process
conditions during new product development using this new software tool.
FY 1999 Project Activities
The project was not renewed for second- year funding. A report of completed work
has been generated.
.
FoodPAC
Infrastructure Projects
During FY 1998,
FoodPAC provided state funding for two major infrastructure improvement projects.
Food Science Building Renovations
FY 1998 State Funding: $1,900,000
Major renovation
of existing pilot plant and associated research laboratories (Phase 1 of proposed
three-phase project) at The University of Georgia's Food Science Building
FoodPAC funding was used for architectural planning and renovations to the first
floor of the Food Science Building. Plans for the renovation of the building were
completed, and construction is underway. The renovated floor will house three separate
pilot plants: cooked foods processing, fresh fruits and vegetables processing, and
raw meats/poultry/seafood processing. Offices for outreach personnel will also be
added.
FY 1998 State Funding: $300,000
Renovation and
expansion of the By-Products Testing Laboratories at The University of Georgia's
Pilot Plant
The rapid growth and impact of by-products research have placed extraordinary stress
on the limited laboratory and related space originally allocated for such activities.
Currently utilized space is located in two adjacent buildings, and the space has
received no renovation or upgrading since the buildings were originally occupied
in the early 1960s. FoodPAC funding is being used to design, renovate, and expand
these existing facilities. Plans call for upgrades to portions of the existing structures
as well as construction of new laboratories and office space. This facility development,
when completed, will give the pilot plant excellent facilities for conducting industry-driven
studies in this growing and important focus area.
.
. Project Leader
Project Participant
Project Objective
FoodPAC
Implementation Projects
During FY 1998,
FoodPAC undertook two implementation projects to improve communications regarding
operations and project activities.
FoodPAC Website
To create a website that provides up-to-date information about FoodPAC operations
and funded projects.
FY 1998 Project Activities and Outcomes
A website was developed that contains pages highlighting what's new at FoodPAC, an
overview of the program, a summary of Georgia's food industry, FoodPAC's organizational
chart, a directory of FoodPAC members, and digital copies of FoodPAC publications.
The FY 2000 Call for Program Proposals format is currently online at the What's New
page. A copy of The 1997–1998 Annual Report and copies of past issues of The Food
Chain newsletter can be found on the Publications page. Visit FoodPAC at http://foodpac.gatech.edu
FoodPAC Brochure
Project Leader Project Participant Project Objective
To update FoodPAC brochure.
FY 1998 Project Activities and Outcomes
The FoodPAC Brochure, which was first created in FY 1996, was updated. The revised
brochure reflects changes to FoodPAC's operating strategy and leadership roles. It
also outlines the program's investment strategy, general operations, and describes
how research results are reported. An updated section highlighting the Food Industry
in Georgia is also featured.
.
FoodPAC
FY 1999 Program Projects
Environmental Projects
Georgia Environmental Technical
Assistance Program for Food Processors
(Continuation
of Project Number FP98-EN01)
Project Number: FP99-EN01
Co-Project Leaders
- Jackie Sellers, The University of Georgia, (706) 542-8382, jsellers@bae.uga.edu
- James Walsh, Georgia Institute of Technology, (404) 894-8054, jim.walsh@gtri.gatech.edu
- William Merka, The University of Georgia, (706) 542-9151, bmerka@uga.edu
- A. Estes Reynolds, The University of Georgia, (706) 542-2574, ereynold@uga.cc.uga.edu
- Egerton Whittle, The University of Georgia, (706) 542-7690, ewhittle@uga.cc.uga.edu
FY 1999 State Funding: $179,500
Project Number: FP99-EN02
Project Leader
- Romeo Toledo, The University of Georgia, (706) 542-1079, cmsromeo@uga.cc.uga.edu
FY 1999 State Funding: $216,000
Project Number: FP99-EN03
Co-Project Leaders
- S. Edward Law, The University of Georgia, (706) 542-0866, edlaw@bae.uga.edu
- Michael Doyle, The University of Georgia, (770) 228-7284, mdoyle@cfsqe.griffin.peachnet.edu
FY 1999 State Funding: $149,500
Project Number: FP99-EN04
Project Leader
- Mark Eiteman, The University of Georgia, (706) 542-0833, eiteman@bae.uga.edu
FY 1999 State Funding: $150,000
Project Number: FP99-FS01
Project Leader
- Yen-Con Hung, The University of Georgia, (770) 412-4739, yhung@cfsqe.griffin.peachnet.edu
FY 1999 State Funding: $99,390
Application of an I.O. Biosensor: An Innovative Approach for Detecting Foodborne
Microbial Pathogens (Listeria monocytogenes, E. coli, and Salmonella Species) During
Slaughtering and Processing of Poultry
Project Number: FP99-FS02
Co-Project Leaders
- Nile Hartman, Georgia Institute of Technology, (404) 894-3503, nile.hartman@gtri.gatech.edu
- Daniel Campbell, Georgia Institute of Technology, (404) 894-3627, daniel.campbell@gtri.gatech.edu
- Paul Edmonds, Georgia Institute of Technology, (404) 894-3737, paul.edmonds@biology.gatech.edu
FY 1999 State Funding: $79,017
Project Number: FP99-FS03
Project Leader
- Michael Doyle, The University of Georgia, (770) 228-7284, mdoyle@cfsqe.griffin.peachnet.edu
FY 1999 State Funding: $39,924
Project Number: FP99-PC01
Project Leader
- Romeo Toledo, The University of Georgia, (706) 542-1079, cmsromeo@uga.cc.uga.edu
FY 1999 State Funding: $267,800
Project Number: FP99-PC03
Co-Project Leaders
- Casimir Akoh, The University of Georgia, (706) 542-1067, akoh@flavor.fst.uga.edu
- A. Estes Reynolds, The University of Georgia, (706) 542-2574, ereynold@uga.cc.uga.edu
FY 1999 State Funding: $155,700
Project Number: FP99-PC04
Project Leader
- Wayne Daley, Georgia Institute of Technology, (404) 385-0034, wayne.daley@gtri.gatech.edu
FY 1999 State Funding: $141,279
Project Number: FP99-PC05
Project Leader
- Ronald Eitenmiller, The University of Georgia, (706) 542-2286, eiteman@bae.uga.edu
FY 1999 State Funding: $66,890
Project Number: FP99-PC06
Co-Project Leaders
- Wiley Holcombe, Georgia Institute of Technology, (404) 894-6144, wiley.holcombe@gtri.gatech.edu
- Gary McMurray, Georgia Institute of Technology, (404) 894-8057, gary.mcmurray@gtri.gatech.edu
FY 1998 State Funding: $245,000
.
Major
Infrastructure Improvement Projects
Food Processing Technology Research Building, Georgia Institute of Technology
FY 1999 State Funding: $200,000
Planning grant for a design feasibility study
FY 1999 State Funding: $187,000
Planning grant for major renovation of existing pilot plant and associated research laboratories (Phase 2 of proposed three-phase project)
By-Products Pilot Plant, The University of Georgia
FY 1999 State Funding: $100,000
Final renovation and expansion of existing pilot plant
FoodPAC Research Study Testing at The University of Georgia
FY 1999 State Funding: $87,000
Purchase of an Instron Universal Testing Machine (to measure the physical properties of foods which can be correlated to the quality characteristics of food products) for the Center for Food Safety and Quality Enhancement and a Reach-in Environmental Chamber (to study the shelf life of processed products and to determine changes in quality during storage) for the Food Processing Center
.
Return to the FOODPAC Homepage . . . . . . . . . . Return to FoodPAC Publications
Authored by the
Food
Processing Technology Division
Georgia Tech Research Institute
Atlanta, Georgia 30332-0823 USA
Telephone: 404-894-3412
Make comments pertaining to this website to:
Steven
Thomas <steven.thomas@gtri.gatech.edu>
Copyright © 2000
FoodPAC
Last Modified: January 2000
URL: foodpac.gatech.edu
