FIELD OF THE INVENTION

The present invention relates to a semi continuous steam sterilizer and pasteurizer apparatus with dehumidifier for powder and granular or whole material to render them suitable for human consumption and useful in the food and pharma industry. More particularly, this invention is in the field of food safety technology, processing for spices in order to control water content and preserve the desirable organoleptic properties of the product while rendering them safe for human consumption and storage with increased shelf life.

BACKGROUND AND SUMMARY OF THE INVENTION

Generally, two types of steam sterilizer and pasteurizer apparatus were available (1) Batch sterilizer (2) Continuous sterilizer. In continuous sterilizer, product is continuously fed and came out from machine while in batch type sterilizer process is intermittent, Continuous steam sterilizer and pasteurizer apparatus is large in size due to large size of conveyer, sterilizer, heater, continuous fluid bed drier etc, Proper shuffling of material is not achieved in continuous steam sterilizer and pasteurizer apparatus because of design and/or arrangement of stirrer/shaft. This leads to improper outcome of product and change physical properties of product like reduction in volatile oils and/or excessive change of moisture and/or change in colour etc.

Same way in batch type sterilizer, process is intermittent because product is loaded and sterilized and dried then unloaded. This said sterilizer is also large in size and requires trolley and man power for loading, sterile room and nonsterile room etc. Here also proper shuffling is not achieved because of design and/or arrangement.

In both cases, each and every particle of loaded product is not shuffled properly because of design. Rotating part is mounted vertically or axially which is in form of cylindrical or conical or other suitable shape. Along with these parameters, due to size and shape of blades of such type, proper agitating of contents is not achieved. Also, material gets adhered to machine which is not removed by currently available machine and there is loss of product, Hence, product/particle far away from rotating element cannot shuffle at proper temperature and proper time. All these parameters affect physical properties of product like volatility of oil, moisture and microbial content of product, taste and colour of product etc. Hence, real product is not achieved. Also, in both sterilizers large space is required.

US 4,844,933 discloses sterilization of agricultural food products without the use of radiation or chemicals to kill bacteria used in the food processing industry. But the sterilization through this apparatus and method was for dry vegetable products such as leafy herbs and spices but often conflicting criteria in order to arrive at a marketable product at a reasonable cost is disclosed in EP0556101A1 .

EP0556101A1 discloses a method and apparatus for the substantially continuous sterilization of volatile oil-bearing herbs and spices in order to preserve the desirable organoleptic properties of the herbs and spices while rendering them safe for human consumption, subsequent food processing and storage with increased shelf life. But this is continuous sterilization and for oil-bearing herbs and spices not for any powder and granular or whole material.

Indian application 2867/MUM/2015 solved aforementioned problems by providing semi continuous steam sterilizer. But in that water content was not controlled satisfactorily as per the area of the apparatus in the use like watery land or sea shore and hence not desirable organoleptic properties was achieved. Unexpectedly we observed that vacuuming is increasing sterilization but while devacuumizing the apparatus water content increases through air in the area of sea shore or watery land or are near river or in the seasons like monsoon and this is required to be controlled. An amazing achievement, we found an insertion of air which is dehumidified during sterilization and also during cooling can control water content of the product and hence organoleptic properties was achieved with long time storage and increased shelf life. Also, laboratory tested the item and received the reduced quantity of microorganism in the product. In the present invention less man power is required in the process as it is computerized. This also prevents the product from contamination even process being semi steam sterilization and pasteurization. Manpower is required only for feeding the product at loading hopper, to collect the product upon cooling from the cooling apparatus and managing computer system, dill that sterility is maintained from the filling of the product to the hopper and achieved the marketable is programmed in the computer system. Apparatus is at a reasonable cost providing a satisfactory level of sterilizaiion/pasteurization to render the products safe for human consumption.

OBJECTS OF THE INVENTION

The main object of present invention is to provide a semi continuous sterilizer and/or pasteuriser apparatus to control water content and microbial content in the final product using the dehumidifier during the process of sterilization and/or pasteurization.

The another main object of present invention is to provide a semi continuous sterilizer which comprises of sterilization vessel and cooling vessel where product is preheated, preconditioned and sterilized in sterilization vessel as well as continuously shuffled by horizontally oriented stirrer at the lower portion of vessel wherein said shuffling is essential to reduce loss of volatile oils and/ to prevent change of colour and/or to reduce excessive change of moisture in dry herbs or spices.

Another object of present invention is to design a semi continuous vertically oriented food processing machine with sterilization vessel and cooling vessel where product is sterilized, dried and cooled in above said vessel under vacuum as well as continuously shuffled by horizontally oriented stirrer at the lower portion of vessel.

The further object of present invention is to provide an insulating medium to reduce loss of heat in semi continuous vertically oriented food processing machine.

The further object of present invention is to provide a vacuum means for pre- conditioning in semi continuous vertically oriented food processing machine. Another object of this invention is to provide suitable methods for transfer of product load from sterilization vessel to cooling vessel.

Another object of this invention is to design a semi continuous vertically oriented food processing machine to reduce process time to 30 minutes.

Another object of present invention is to design a sterilizer for automatic processing of foods which requires less ground space and compact in size

Another object of present invention is to control water activity with the help of the dehumidifier

The foregoing and other advantages are explained in text description and by illustrated details considering the accompanying drawings, in which:

DETAILED DESCRIPTION OF THE DRAWINGS

Figure 1 is layout of schematic illustration of the apparatus used in carrying out the method of the present invention

Figure 2 is Top View of Sterilizer System

Figure 3 is Stirrer with scraping blades

Figure 4 presents Sterilization Process Graph

Figure 5 presents graph during vacuum Cooling process

In system of the present invention principal parts and subordinates with its functions mentioned below: a. Hopper: For loading / feeding Non-Sterile Product b. Sterilizer/Pasteurizer Cum Drying Vessel: For Sterilization and Drying Product with help of vacuum, steam and dehumidifier air c. Product Cooler Vessel: For Cooling Product with help of Chilled water and dehumidifier air d. Bunch of Piping: comprises A - Vacuum Line, B - Steam Line, C - Small Steam line to maintain Sterilization Temperature, D - Filtered air line, E - Pressure transducer connection line, F - Compound pressure gauge and G - Safety Valve connection e. Dehumidifier: Regenerate Dehumidified air and enter to vessel f. Man Hole: For inspection and maintenance inside sterilizer g. Jumbo Bag - To collect the sterilized/pasteurized cool product. Bag mouth is tightening with valve outlet so room air may not come in product contact or collect in the hopper h. One way valves at different level: Air Lock Valve at Hopper of loading to Control Feed of Product to Sterilizer, at product inlet to sterilizer, at product outlet from sterilizer to cooler, at product outlet from product cooler after cooling the product enter into Jumbo bag / hopper.

In detail to describe the figures of the present invention semi continuous steam sterilizer and pasteurizer apparatus with dehumidifier comprises Sterilizer/Pasteurizer Cum Drying Vessel 1 For Sterilization and Drying Product with help of vacuum and steam, has hopper at its top part for loading of material fitted with load cell which measures input load of the product and one way valve located in between hopper and sterilization vessel which allows product to drop only in downward direction, Product Cooler Vessel 2 For Cooling Product with help of Chilled Water and Air, Hopper 3 For Non-Sterile Product Feed, Air Lock Valve 4 Controlled Feed of Product to Sterilizer, Pressurized Air Inlet 5 From Blower to Sterilizer through Cyclone, Venturi 6 By Reducing Size of Pressurize Air Inlet Vacuum Generation so product sucking from Hopper Valve and Flow towards Cyclone, Long Curve Pipe 7 For Minimum resistance of Air and Product flow, Transport Pipe 8 For guiding product towards Cyclone, Cyclone 9 For separating product and pressurize air, Filter Bag 10 For separating pressurize air, Valve 11 For controlling product inlet to sterilizer, Man Hole 12 For inspection and maintenance inside sterilizer, Dehumidifier 16 attached with sterilizer and cooling apparatus for regenerative dehumidified air having pressurized air inlet, which will dehumidify air and enter into vessels through bunch of Bunch of Piping 13 comprises Vacuum Line A creates vacuum inside sterilization vessel to remove most air and gases from sterilization vessel and also utilized for drying and partial cooling by removing moisture content Steam Line B provided for injection of steam in sterilization vessel which is responsible for pre conditioning and sterilization of product Small Steam line C for maintaining Sterilization Temperature, Filtered air line D, Pressure transducer connection line E, Compound pressure gauge F, Safety Valve connection G, HEP A Filter With housing 14, serves the purpose of injecting bacteria free air from atmosphere to sterilization vessel and wherein said bacteria free air increases pressure inside sterilization vessel Stainless Steel Filter 15 During vacuum suction product may not travel towards vacuum pump, Dehumidifier 16 for Regenerative Dehumidified air having pressurized air inlet, which will dehumidify air and enter into vessel, Stirrer 17 is for product shuffling and having Teflon Scraping Blades for cleaning dish surface, Main Vessel 18, a Stainless Steel Vessel having hemisphere dish for product sterilization, cooling the product, a Stainless Steel Jacket 19 over main vessel for steam heating for sterilizer main vessel and chilled water cooling for product cooler, an Insulator 20 with Stainless Steel Cover to prevent Heat Foss, is attached with sterilizer and cooler Stirrer Drive Motor and Gear Box 21 for slow speed rotation of stirrer, Bearing Housing 22 Self aligned bearing for smooth running of stirrer with shaft sealing housing, Valve -a 23 For product outlet from sterilizer and product goes to product cooler, Valve-b 24 For product outlet from product cooler after cooling the product, Jumbo Bag 25 To collect the sterilized/pasteurized cool product, Bag mouth is tighten with valve-b 24 outlet so room air may not come in product contact and prevent contamination as well as loss of material, 26 is M.S. Structure for mounting sterilizer and cooler with platform for inspection cum maintenance, Teflon Scraper 27 To scrap Vessel hemisphere dish inner surface, so product may not stick, also help shuffling of product, Stirrer Arm 28 Connected to stirrer shaft and Teflon scrapers, 29 Hinge Stainless Steel Hinge to connect Stirrer Ring (30) and Teflon Scraper, 30 Vacuum Pump For Air and Gas Suction from Sterilizer and Cooler Water Ring type Vacuum Pump with Motor, 31 Water Tank Stainless Steel Water Tank to store water and recirculate through vacuum pump, 32 PHE-a (Plate Heat Exchangers) for Cooling water for Vacuum Pump, 33 PHE-b Plate Heat Exchangers for Cooling Suction of Steam/ Air from Sterilizer, 34 Chilled Water inlet from Chiller, 35 Chilled Water return line to Chiller, 36 PEC Panel PEC Control Panel with electrical switch gears to control entire controls for sterilizer and cooler, 37 Computer Panel For mimic view, parameters like temperature, pressure, vacuum, steam, air, no, of cycles, Also for data log in, SKADA software, team viewer, printer etc. Sterilization vessel consists of three layers of stainless steel which are inside layer, middle layer and outer layer. A space between inner layer and middle layer is called jacket, while a space between middle layer and outer layer is for insulation. In jacket, steam is passed which prevents condensation in sterilization vessel. In insulation space insulating material is inserted for the purpose of insulation.

The terms and expressions used in description of sterilization vessel are employed only for description but are not limited because modifications are there for achieving same purpose in different ways which are known to world. There is neither any limitation in achieving same purpose by other best suitable method nor sterilization vessel is limited to above description in any way.

DETAILED DESCRIPTION OF THE INVENTION

Process and apparatus for sterilizing related to semi continuous processing machine prior to present invention wherein said apparatus comprises of sterilization vessel and cooling vessel wherein said both vessels have stirrer for shuffling. It is semi continuous because sterilization process and cooling process are simultaneous as both vessels are independent from each other. Here product is sterilized above atmospheric pressure but because water content w as not controlled satisfactorily in the product outcome from that apparatus as per the area and season of use of the apparatus in use and hence not desirable organoleptic properties was achieved.

Present invention provides a semi continuous steam sterilizer and pasteurizer apparatus with steam, vacuum and dehumidifier for powder and granular or whole material to control water content of the product and reduced quantity of microorganism in the product.

In general, sterilization refers to any process that removes or kills forms of life and other biological agent including transmissible agents which are present in a specified region, such as a surface, a volume of fluid, medication, or in a compound such as biological culture media. Sterilization is achieved by different methods such as heat, chemicals, irradiation, high pressure, and filtration. Heat sterilization includes different method such as steam, dry heat, flaming, incineration, tyndallization and glass bead sterilization. Chemical sterilization is achieved by different chemical agents such as ethylene oxide, nitrogen oxide, ozone, glutaraldehyde and formaldehyde, hydrogen peroxide and peracetic acid. Radiation sterilization is achieved by non-ionizing radiation sterilization and ionizing radiation sterilization methods. Sterile filtration is used for fluids that would be damaged by heat, irradiation or chemical sterilization such as drug products which can be sterilized by microfiltration using membrane filters. Food products are mainly sterilized by heat sterilization as it does not involve any chemical treatment or radiation.

Sterilization in the present invention is a process where all the living microorganisms including bacteria spores are killed. This is a more severe process which destroys microorganisms and may change the organoleptic qualities of the product. Sterilization process in the present invention uses a temperature in excess of 100 Celsius in order to destroy nearly all microorganisms present in a product. This is important as some microorganisms can form spores which have the ability to survive at high temperatures. If the correct temperature is not reached there is the possibility that the spores will germinate and grow and food poisoning could result. Some organisms can survive the sterilization process if not processed for enough time or a high enough temperature.

Semi-continuous process was disclosed by EP0556101A1 stating that in the semi- continuous process, the product to be sterilized is introduced batch wise into a closed container. But it was not with dehumidifier and other advantages as of the present invention. To state the uniqueness of the present invention more particularly, a semi continuous steam sterilizer and pasteurizer apparatus with vacuum and air dehumidifier comprises venturi through which by reducing size of pressurize air inlet vacuum generation so product sucking from hopper valve and flow towards cyclone and through dehumidifier having pressurized air inlet through which dehumidified air enter into vessel. During sterilization and cooling air inlet is necessary for drying of the product but common air even hot air during sterilization and chilled air during cooling cannot maintain water content of the product which entered during steam sterilization and atmosphere. In the present invention air inserted is dehumidified as hot air during sterilization and dehumidified chilled air during cooling to maintain water content of the product. This is via unique bunch of piping comprises vacuum line for maintaining vacuum pressure, steam line for steaming, small steam in line for maintaining sterilization temperature, filtered air in line through which dehumidified air is inserted, pressure transducer connection line, compound pressure gauge and safety valve connection.

Dehumidified air is regenerated in dehumidifier, attached with sterilizer and cooler, which is reducing humidity to insert into the vessel during drying process of sterilization and cooling because steam sterilization moisturises the product. Regeneration of air in dehumidifier to reduce humidity or absorb water content from air by using but not limited to silica gel, activated alumina, molecular silver, hollow fiber, moisture absorbing filter and the like.

By insertion of dehumidified air, with vacuum during sterilization and drying and also during cooling can control water content of the product and hence organoleptic properties was achieved with long time storage and increased shelf life. Also, laboratory tested, the item and received the reduced quantity of microorganism in the product.

In one embodiment of the present invention is a method and apparatus wherein steam, vacuum and dehumidifier amalgamated with computerized process. This computerized process is a complete computer panel for mimic view, parameters like temperature, pressure, vacuum, steam, air, no. of cycles. Also, for data log in. SKADA software, team viewer, printer etc.

In preferred embodiment, the present invention includes a process for semi- continuous steam sterilizer and pasteurizer to achieve the aforementioned product to render the product suitable for human consumption and useful in the food and pharma industry and achieve long time storage and increased shelf life as well as prevents the product from contamination and. change of colour of the product.

When introducing elements of the present disclosure or the embodiments thereof, the articles an, and “the” are intended to mean that there are one or more of the elements. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements. Process flow for sterilization/ pasteurization:

For providing an easy and safe way to kill or inactivate the microorganisms through an apparatus of present invention product passes through different phases without product outlet from the apparatus except final. Referring Figures construction, working of different phases from loading of product into the hopper till out come upon pasteurization are described below:

Phase 1: Loading / Feeding of product into the Hopper is Non-Sterile Product at room temperature and Air Lock Valve is closed for Product to go to Sterilizer.

Phase 2: Pressurized Air Inlet from Blower to Sterilizer through Cyclone where Venturi is Reducing Size of Pressurize Air Inlet Vacuum Generation so product sucking from Hopper Valve and Flow towards Cyclone. Cyclone For separating product and pressurize air.

Phase 3: Through filter bag placed for separating pressurize air, product inlet to sterilizer.

Phase 4: During sterilization product faces vacuuming, sterilization and dehumidifier together one after another repetitively till completion of sterilization as per the computer programming. Injecting sterilizing steam into the sterilization vessel to achieve pre-assigned % of sterilization temperature or pressure. Product stay in sterilization vessel / chamber preferably for 30 minutes. In sterilization maintain temperature up to pre-set time, drying of product by vacuum and air through HEPA Filter and dehumidifier up to set drying time. Then breaking of vacuum causes ending of process in sterilization vessel. Said apparatus comprises horizontal stirrer where said stirrer shuffle continuously product from start of the process till end of process of sterilization. This said stirrer assembly consists of horizontal shaft, boss and integrally connected rod and scraping blades. This stirrer is to prevent loss of material which gets adhered to vessel. Speed of stirrer is low.

Sterilizing vessel / chamber is closed and formed with only necessary openings which are closed by valves like opening of filter bag, opening for bunch of pipes, manhole valve joining to cooling vessel. Manhole is only for inspection and maintenance of the vessel.

Phase 5: Through valve For product outlet from sterilizer and product goes to product cooler opens automatically as per set-up upon completion of sterilizing process or can operate manually.

Phase 6: Vacuum Cooling process by vacuuming, to set parameter cooler, jacket cooling by Chilled Water, vacuum break to set parameter by air injection through HEPA Filter and Dehumidifier. This Cooling process up to set time, Product temperature sense by temperature probe and controller. Colling process is required to cool the hot product to take about at room temperature. Cooling process is over.

Phase 7: Collection of sterilized/pasteurized cool product in Jumbo Bag. Bag mouth is tightened with valve outlet so room air may not contaminate product.

As the machine is operated by PLC (Programmable Logic Control) based controller, required data is stored in computer for further analysis in future.

The terms and expressions used in description of cooling vessel are employed only for description but are not limited to disclose invention because modifications are there for achieving same purpose in different ways which are known to the world. There is neither any limitation in achieving same purpose by other best suitable method nor cooling vessel is limited to above description in any way.

The semi continuous steam sterilizer apparatus is compact in size and requires low ground space as compared to batch steam sterilizer and continuous steam sterilizer. Steam sterilizer of present invention with a unique design of horizontal stirrer is responsible for continuous shuffling of input material at set temperature for enough time. The orientation of sterilizer can be vertical, horizontal, inclined or any other suitable orientation depending on space available and capacity of machine, preferably in vertical orientation. In wide-ranging the application time and temperature for sterilization depends mainly on the presence of microorganisms, properties of the food product, initial temperature the products, pH of the product and microbial count. Nevertheless, to control water content in the product duration at each phase may be adjusted based on the quantity and nature of product as well as land and season of use of apparatus.

Further trials were performed on but not limited to few items and found remarkable difference between the product pasteurised without using dehumidifier and with using dehumidifier. These differences are in the form of moisture content and microbial count of the product. Microbial count of the product is calculated by Total Plate Count (TPC) of Bacteria, colony-forming unit (CFU) per gram of the item passed through the machine.

Table 1

Without Dehumidifier Pasteurisation Result

Table 2

With Dehumidifier Pasteurisation Result

The above result shows that after sterilization/pasteurisation using dehumidifier also reduction in moisture content and bacterial count of the product at least by 10% which makes the product safe and stable for long time. The invention is disclosed here completely in best possible way with 5 (five) drawings. There is neither any limitation in achieving same purpose by other best suitable method nor invented machine is limited to above description in any way. Words such as spices or herbs or foods are employed only for illustration by example but not limited to this particular case. Same invented machine can be utilized at other best suitable place or industries.

It should be understood that various changes and modifications to the various aspects/embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the subject matter of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered within the scope of the present invention and claims.