Learning About HPP Equipment

Avure/JBT AV40-70 and Hiperbaric 525L Equipment comparison side by side

In our First Session, About HPP Equipment we will cover the major components of a High Pressure Processing (HPP) Machine.

Image showing the core components of a High Pressure Processing Machine. #1 Vessel, #3 Plugs, #4 Yoke or Frame, #5 Water Pump
Learn About HPP Machines and their major components such as the Vessel, Plugs, Yoke or Frame, Water Circulation Pump

When learning about HPP equipment, there are 3 Major Component of the High Pressure Processing Machine you must talk about. The HPP Vessel, HPP Plugs, and HPP Yoke or Frame.

HPP Vessel #1

When learning about HPP Equipment, the Vessel depicted as #1, is the first major component of the HPP Machine. You can think of the vessel as a large tube of carbon steel. Because the vessel interior liner is stainless steel it meets food safety compliance. Therefore the vessel is two layers. The vessel holds tremendous pressure using miles of wire wrapped around the vessel like a golf ball. Stainless steel is used to wrap the vessel. To prevent corrosion of the wiring some companies use either oil or wax to coat the wiring. The vessel can be of various lengths and internal and external diameters. Since the vessel is a pressure component, most countries have strict certifications that must be followed. Such as ASME U3 in North America, CE in Europe, IBR in India and GOST in Russia. Countries such as China do not have such compliance.

Back side of the HPP Vessel and Rail system in the load position for the Avure/JBT AV40-70
Back side of the HPP Vessel and Rail system in the load position for the Avure/JBT AV40-70

HPP Plugs #3

Depiction #3 is the Plugs and they are the second major component of the HPP Machine. are two stainless steel plugs one for each side of the vessel. These plugs server many purposes. First, they maintain the seal with the wall so water doesn’t leak out of the vessel causing the vessel to lose pressure. Next, they allow low pressure and high pressure tubes to connect to the plugs to fill the vessel full of water while removing any residual air. These tubes also are connect to devices (pressure transducers) that monitor the pressure inside the vessel. Lastly, the high pressure tubes in the plugs serve as a way to release the pressure in the vessel (decompression). The plugs follow the same certifications as the vessel.

Avure/JBT AV40-70 Load Side Plug in the open position
Load Side HPP Plug in the open position for the Avure/JBT AV40-70

HPP Yoke or Frame (Frame) #4

When learning about HPP Equipment, Depiction #4 is the Frame and it is the third major component of the HPP Machine. The frame is what holds the plugs in place so that the vessel can be pressurized with the assistance of the wedges. Frame construction uses two different designs. The first design is to take many sheets of thick carbon steel and cut out the center for the plugs and vessel. Then create a lamented box. The second design uses the wire wound method used on the vessel by creating box out of blocks of carbon steel with a large hole in the center and then wrapping the outside of the box with miles of wire. Some designs coat with wire with oil or wax. And some systems have added air circulation between the stainless steel sleeve and the wiring to control condensation. The frame is sleeve in stainless steel.

Back side view of the Avure/JBT AV40-70 Frame and components.
Back side view of the Avure/JBT AV40-70 Frame and components.

Water Circulation Pump #5

The last piece depicted in this illustration is the Water Circulation Pump #5. The water circulation pump fills the vessel full of cold water. After the cycle is completed and the plugs are removed, it recaptures most of the water.

HPP Machine Wedges or Blocks, Hydraulic Valves, Decompression Valves, Stud and Bolts
Learn about HPP Machines and their major components such as Wedges or Blocks, Hydraulic Valves, Decompression Valves, Stud and Bolts

Wedges/Blocks #2

Depicted as #2 are the carbon steel blocks. Learning about HPP blocks is important as they keep the plugs in the vessel maintaining the seal during pressurization. The plugs are fully inserted into the vessel and then the vessel is positioned inside of the frame. There is a large gap between the back of the plug and the inside wall of the frame. The block fills the gap.

Load Side Block in the open position for the Avure/JBT AV40-70
Load Side Block in the open position for the Avure/JBT AV40-70

Hydraulic Valves #6

The hydraulic valves control the movements of the machine as depicted in #6. the hydraulic valves control the movements such as the plugs being inserted into the vessel, the vessel being moved into the frame, the blocks being moved into the gap between the vessel and frame.

Decompression Values #7

There are several different designs for depiction #7, decompression valves. These valves release the very high pressures that are generated by the water being pumped into the vessel. Once the vessel has held pressure for the desired amount of time, either hydraulic valves or pneumatic valves will open the decompression valves and release the water from the vessel. These decompression valves slow the water down very quickly and dump this hot water into a decompression tank before either releasing it down a drain or reintroducing it to the recirculation tank. Some systems use a looping tube system to slow the water down before the water enters the decompression tank.

HPP Decompression System for the Avure/JBT AV40-70 Series
HPP Decompression System for the Avure/JBT AV40-70 Series

Studs and Bolts #8

Depicted as #8 the studs and bolts are part of the lamented frame design and serve two purposes. The studs and bolts keep the lamented pieces from shifting during pressurization. The large studs on each end of the frame used for the transport and moving of the frame for installation and relocation.

HPP Machine Water Filtration System, Hydraulic Pumps, and Intensifiers
Major Components of High Pressure Processing Water Filtration System, Hydraulic Pumps, and Intensifiers

Water Filtration System #9

Depicted in #9 is the water filtration system. The filtration uses 10 micron filtering system. Water in the vessel can become contaminated with packages and containers of product that leak out when pressurized. Also pieces of plastic from the containers can get in the water system. Since the systems want to conserve water and reuse it, the water filtration system makes this possible. Most HPP machines today utilize separate water systems for the intensifiers and the filling of the vessel.

Water System for the HPP Intensifiers and Vessel for the the Avure/JBT AV40-70
Water System for the HPP Intensifiers and Vessel for the the Avure/JBT AV40-70

Hydraulic Pumps and Intensifiers #10

Depicted as #10 the horsepower that drives the HPP machines. The hydraulic pumps are controlled by the hydraulic valves. In addition to providing the power that moves the vessel, plugs, blocks, the pumps provide the power that drives the intensifiers. These intensifiers are also known as superchargers.

So what is an intensifier? Well, an intensifier intensifies the low pressure water by forcing water into the vessel using what is called a plunger. The plungers come in both stainless steel and ceramic. How this works is that the intensifier has two components. The center of the component is a hydraulic cylinder with a piston that goes back and forth. This hydraulic cylinder’s diameter is 30 times bigger in inside diameter of the water cylinder. So when the hydraulic piston goes back and forth it causes the plunger to push water into the vessel at 30 times more pressure than the piston. To create the very high pressures of 87,000 psi/600 MPa, the hydraulic pump pressure is set at 3,000 psi/20 MPa. Coincidentally the waterside cylinders must be stainless steel.

Power Station for the Avure/JBT AV40 with Hydraulic Pumps (2) and Intensifiers (4)
Power Station for the Avure/JBT AV40 with Hydraulic Pumps (2) and Intensifiers (4)

What did you learn?

Hopefully you are learning about HPP and now you have a basic understanding of the major components that make up High Pressure Equipment for Cold Pressure Pasteurization. What you do with this new found knowledge is up to each individual reader.

What is Next?

The next module in this HPP Series will build upon what you just learned and apply it to the current HPP manufactures. We will introduce you to each company, the machines, and how the machines for different manufactures similar and what differentiates them. If you are in a hurry to learn more, make sure you sign up for the HPP Workshop coming in April 2019.

The Institute for Food Safety (IFSH) HPP Short Course Workshop and Blog

Students at the IFSH HPP workshop are working with packaged sample product

Understanding High Pressure Processing for my Business?

So you want an understanding of the HPP technology?  Because you think HPP can be good for the growth of your business.  Or maybe your boss asked you to evaluate HPP and you  don’t know where to begin.  The Institute for Food Safety (IFSH) Short Course Workshop and Blog is here to help.

As soon as you start the process, the questions will start mounting, such as what are the HPP applications in food processing?  What testing do I need to do with my product?  Who does this testing? What equipment do I need?  How does HPP work? What is involved to  operate a Machine?  How do I know when I should buy a machine?  What do I need to consider in this purchase decision?  Who makes the HPP Machines?  And what is the difference between the machines? In particular who has the best HPP Machine for my business? Above all  what is the actual cost of this High Pressure Processing Process?  And how can I get the best pricing?   The questions go on and on and on…….

Who Needs to Understand the HPP Business Model?

Whether you are a food technologists, a food safety professional, an operation manager, an or an executive leader from the refrigerated food and allied industries you will benefit from this Blog. As at the conclusion, you will have a well rounded understanding of High Pressure Processing and start the process of making a well informed decision.

How is this HPP Blog is going to Help You?

This Blog is going to help you address all these questions over the next several months as there is far too much information to be included in one post.  What we want you to take-a-way from this post is knowing you have a resource to get your questions answered.  The audience we are targeting wants a well round high level understanding or High Pressure Processing.  They want to know the questions that they need to be asking and have a foundational knowledge base. 

I don’t have 12 Months!  My Boss wants answers Now!  We have a large account that wants us to HPP our Product and the RFQ is coming due SOON!

Well you are in luck!  In April of 2019 you can get much of this information in 4 Days!  Yes that is correct.  We have developed in cooperation with The Institute of Food Safety (IFSH) a 4 Day High Pressure Processing Short Course and Workshop.  Call it a mini introduction to a Masters Degree in High Pressure Processing.  You wont’ be an expert at any one thing.  BUT you will know enough to be dangerous.

The Institute of Food Safety (IFSH) HPP Short Course Workshop and Blog is April 8 to April 11, 2019. In short, you can Register and get more Information by Clicking this Link. Hence, this is our 2nd Workshop with our first being sold out in 2018!  Our own Gerald Ludwick introduced the HPP Workshop and the Framework for the HPP Center of Excellence at the 2017 IFSH Annual Meeting.

IFSH HPP Short Course Workshop
Gerald Ludwick Introducing ISFH HPP Workshop and Future HPP Center of Excellence at IFSH Annual Meeting 2017

Who are the HPP Instructors?

Instructors:  Kathiravan Krishnamurthy, Ph.D., Jason Wan, Ph.D, Alvin Lee, Ph.D., Josh Warren, and Gerald Ludwick

The First Topic we will Covering will be determined by our Readers. Fill out the Contact From below and Lets us know what you are most interest in!

Safety/ Basic Maintenance / Sanitation of HPP Equipment

HPP Maintenance Checklist

Safety, Sanitation, and Basic Maintenance of HPP Equipment are the fundamental building blocks on the machine side of the equation for a successful HPP Operation

Why does HPP Maintenance seem to get ignored while HPP Safety and HPP Sanitation don’t?  Well, first off, Safety and Sanitation are front and center of an operation. 

Q&A Inspectors, FDA Inspectors and USDA Inspectors are routine conducting onsite inspections Safety and Sanitation many on a daily basis. Therefore,  providing multiple layers for check and balances.  Next, certifications like BRC, SQF, and GFSI that provide a very structured repeatable framework.  And these certifications and audits further ensure the knowledge base that is spread from top to bottom throughout the organization.

When it comes to HPP Maintenance there are no standard certifications.

Let me explain…

HPP Maintenance Training Programs today lack mandatory Manufacturer Compliance.  Therefore, Operator and Maintenance personnel are not tested and certified on the machines prior to taking acceptance.  Consequently, there is no ongoing training and recertification.  Subsequently, over time and through attrition the company ends up with operators and maintenance personnel that have little to structured training.

Increased HPP Machine Downtime is a pattern you see over time.  Increased HPP Machine Downtime would seem logical with continued use.  However, if the daily and periodic High Pressure Processing Maintenance schedules are being proactively followed the  HPP Machine Downtime should remain constant.

The following download is a presentation that was done at the HPP Workshop at the Institute for Food Safety and Health (IFSH) in April of 2018.  The presentation provides a framework for implementing a successful HPP Maintenance Program regardless of the brand of HPP Equipment.