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How does the commercial microwave processing work?
Our commercial offerings use continuous flow processing. This means that product continually flows through pipes in the system from start to finish. There are applicators at different points of the system where the microwave energy is transferred to the product to heat it . The heating is volumetric, meaning that microwaves penetrate the entire volume of product flowing through the pipes at a uniform rate. This is different from conventional forms of continuous flow processing where heat is applied to the outside of a pipe and eventually works its way to the center. The total heating time is typically less than one minute and provides an efficient gentle rapid heating to the product.
Is it safe?
Absolutely! Our small scale processing unit uses the same frequency as your home microwave (2450MHz). The larger scale unit uses the FCC approved commercial frequency (915MHz). For both units, the application zones are fully enclosed, meaning the chances of any energy leaking out are virtually none. These frequencies are considered radio frequencies and are similar to those used for cellular and Wi-Fi. Our systems do not approach frequencies that utilize ionizing radiation and thus, there are no health or safety risks and no specialized safety training or regulations around the use of the equipment.
What is the difference between the Nomatic, Pilot, and Commercial Scale Systems?
The Nomatic is our small scale processing unit and incorporates continuous flow microwave technology at 2450MHz. It is ideal for commercial applications where limited quantities are needed and small frequent runs are optimal. These systems are portable and designed to accommodate throughputs from 0.5 – 3 liters per minute (lpm). The Nomatic systems can range from 6kW to 18kW of applied microwave power.
The Pilot and Commercial Scale systems are for larger scale processing and operate at 915MHz. These systems are designed to accommodate throughputs from 2 – 100 gallons per minute (gpm). They can range from 75kW to over 1,000kW.
Why the different frequencies between the systems?
It has to do with the actual length of the wave and how far it penetrates through the pipe. The 2450MHz wave can only penetrate to about one inch, so this frequency is best suited for the smaller diameter pipes used in the Nomatic. The 915MHz wave can penetrate up to a little more than two inches hence it is optimal for the larger units.
What kinds of products can I run in these systems?
If it is pumpable, you can run it! These systems are highly versatile, meaning they can be used to process thin, liquid-type products such as juices or milk all the way up to thick and viscous products such as mashed potatoes or hummus. The larger systems can also run products that contain particles, including salsas, soups, and fruit purees with chunks.
Can these systems process particles?
The Nomatic systems are not designed to handle particles due to the smaller pipe diameters. The larger systems are designed to handle particles. The maximum particle size that these systems can accommodate is 0.75in (~18mm). Low acid particulate products sized up to 15mm have been validated on these systems and filed with the FDA.
What are the wear parts?
The magnetron needs to be replaced about once a year (similar to how a lightbulb burns out) and will cost about $5k per magnetron (on the 915 systems).
How is the system cleaned?
It can be CIPed like a normal tube in tube system.
What are the main advantages of microwave processing?
Volumetric heating results in less burn on and less overheating because it heats through the cross section of the pipe instead of from the outside in, which results in retained nutrients, color, and flavor in comparison to a conventional tube in tube system.
The system is very compact.
The system is flexible, meaning that it can run a variety of products on the same line without any mechanical changes.
Are there hot spots and cold spots?
Our technology is designed to have uniform heating. Unlike a home microwave oven where the energy is scattered, the energy travels concurrent with the product and exists in a highly predictable wave pattern. Our controls system is also highly tuned to be able to compensate for a desired heating pattern (microwave #1 can be set for a specific temp, #2 for another, etc., in a series).
How efficient is microwave processing?
About 80% of electric energy becomes microwave energy and about 95% of microwave energy becomes thermal energy, so overall about 78% efficient. As a comparison, steam is about 30% efficient.
Can you run Low Acid aseptic?
Yes! Most of our commercial systems are configured for and are currently running low acid aseptic products.
Our commercial offerings use continuous flow processing. This means that product continually flows through pipes in the system from start to finish. There are applicators at different points of the system where the microwave energy is transferred to the product to heat it . The heating is volumetric, meaning that microwaves penetrate the entire volume of product flowing through the pipes at a uniform rate. This is different from conventional forms of continuous flow processing where heat is applied to the outside of a pipe and eventually works its way to the center. The total heating time is typically less than one minute and provides an efficient gentle rapid heating to the product.
Is it safe?
Absolutely! Our small scale processing unit uses the same frequency as your home microwave (2450MHz). The larger scale unit uses the FCC approved commercial frequency (915MHz). For both units, the application zones are fully enclosed, meaning the chances of any energy leaking out are virtually none. These frequencies are considered radio frequencies and are similar to those used for cellular and Wi-Fi. Our systems do not approach frequencies that utilize ionizing radiation and thus, there are no health or safety risks and no specialized safety training or regulations around the use of the equipment.
What is the difference between the Nomatic, Pilot, and Commercial Scale Systems?
The Nomatic is our small scale processing unit and incorporates continuous flow microwave technology at 2450MHz. It is ideal for commercial applications where limited quantities are needed and small frequent runs are optimal. These systems are portable and designed to accommodate throughputs from 0.5 – 3 liters per minute (lpm). The Nomatic systems can range from 6kW to 18kW of applied microwave power.
The Pilot and Commercial Scale systems are for larger scale processing and operate at 915MHz. These systems are designed to accommodate throughputs from 2 – 100 gallons per minute (gpm). They can range from 75kW to over 1,000kW.
Why the different frequencies between the systems?
It has to do with the actual length of the wave and how far it penetrates through the pipe. The 2450MHz wave can only penetrate to about one inch, so this frequency is best suited for the smaller diameter pipes used in the Nomatic. The 915MHz wave can penetrate up to a little more than two inches hence it is optimal for the larger units.
What kinds of products can I run in these systems?
If it is pumpable, you can run it! These systems are highly versatile, meaning they can be used to process thin, liquid-type products such as juices or milk all the way up to thick and viscous products such as mashed potatoes or hummus. The larger systems can also run products that contain particles, including salsas, soups, and fruit purees with chunks.
Can these systems process particles?
The Nomatic systems are not designed to handle particles due to the smaller pipe diameters. The larger systems are designed to handle particles. The maximum particle size that these systems can accommodate is 0.75in (~18mm). Low acid particulate products sized up to 15mm have been validated on these systems and filed with the FDA.
What are the wear parts?
The magnetron needs to be replaced about once a year (similar to how a lightbulb burns out) and will cost about $5k per magnetron (on the 915 systems).
How is the system cleaned?
It can be CIPed like a normal tube in tube system.
What are the main advantages of microwave processing?
Volumetric heating results in less burn on and less overheating because it heats through the cross section of the pipe instead of from the outside in, which results in retained nutrients, color, and flavor in comparison to a conventional tube in tube system.
The system is very compact.
The system is flexible, meaning that it can run a variety of products on the same line without any mechanical changes.
Are there hot spots and cold spots?
Our technology is designed to have uniform heating. Unlike a home microwave oven where the energy is scattered, the energy travels concurrent with the product and exists in a highly predictable wave pattern. Our controls system is also highly tuned to be able to compensate for a desired heating pattern (microwave #1 can be set for a specific temp, #2 for another, etc., in a series).
How efficient is microwave processing?
About 80% of electric energy becomes microwave energy and about 95% of microwave energy becomes thermal energy, so overall about 78% efficient. As a comparison, steam is about 30% efficient.
Can you run Low Acid aseptic?
Yes! Most of our commercial systems are configured for and are currently running low acid aseptic products.
Curious about the quality of foods that have gone through our systems?
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