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Ashok Dhruv, LLC provides engineering and technology services to maximize profits for food and beverage processors. With over 35 years of experience across various industry segments, they help clients from concept to commercialization through technical solutions. Their multi-disciplinary expertise and analytical approaches help clients generate tangible economic benefits and competitive advantages.

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We provide Technology and Engineering services From Concept to Commercialization – Productivity and Growth It is all about business and finance - $$$ ……………………………………....…Under legal and ethical constraints… To all segments of the Food and Beverage Industry 35 years of experience and expertise – Comprehensive and Versatile By maximizing economic as well as consumer needs A distinctive approach – Competitive Advantage with Confidence With technical rigor appropriate to challenge First principle, statistical or empirical analysis – Robust decisions How and Why? Mission Food Processing Maximize 2 Ashok Dhruv, LLC. (720) 318 - 9000
Ashok Dhruv, LLC. (720) 318 - 9000 By: • application of scientific and engineering principles and practices • Leverage IT revolution • computing power • data access - internet • value generation • bridge gap between generation and use of information Mission – Provide tangible and material economic benefit To Food and Beverage Processors, On a Time Effective basis Because • Consumer wants and needs are rapidly changing • Technology is available With Employment of skills and resources on as needed basis 3
First things First – Fulfill a BUSINESS NEED Match resources – technology and engineering to need Product life cycle Growth share matrix Ashok Dhruv, LLC. (720) 318 - 90004
Proteins Casein Soy Isolate Carbohydrates Starches, Sweetners Bio-Ethanol Animal feed Bio-Waste Essential nutrients Fiber Vitamins and Minerals Fats and Oils Ghee, Butter Cookin Oil, Shortening Lard, Tallow Bio-Diesel Fractionation of Agricutural produce Commodity products are enablers for consumer products Agricultural products Fruits and Vegetables Corn, Soy, Peanuts, Beans Milk, Fish Meat - Poultry From farm to food – industry and commerce 5 Ashok Dhruv, LLC. (720) 318 - 9000
Concept to Commercialization – the journey 6 Ashok Dhruv, LLC. (720) 318 - 9000
Ashok Dhruv, LLC. (720) 318 - 9000 Services: Technology Sourcing and Selection- Selected examples Open Innovation In House - Incremental • Cross fertilization • Leverage Public Domain - Radical • USDA – Puffing Gun • NASA / Military Academia – • Know how and Expertise Consortia’s - Targeted • NCFFST • CAFT Acquisitions / Mergers - Radical Technology transfer to China • Nutritious meats / TSP • RBD Oil/Margarine/Soy Isolate • Caramel Color E/P/C services • Supercritical Extraction • MW applications • 130 MM Cereal plant • Bio-Diesel • Corn Wet milling Complex • Artisan Bread • Abattoir – Yield / PSE reduction Food and Beverage processors Orange juice / Concentrate Sports drinks / HF 7
Ashok Dhruv, LLC. (720) 318 - 9000 Services: Product and Process Development Product • Marketing - Consumer • Focus / CLT / HUT • BASIS • Product • Scale – Bench / PP • Formulation / Ingr. • Regulatory • Label / Std. of Identity • Functional properties • Safety / Sensory / S.Life • Margin / Contribution Process - Selection • Unit Operations / Processes • Characterize Ingr. Streams • Cause & Effect Correlation • Quantification -Modeling • Mathematical / Statistical • Empirical / 1st Principle • Pilot Planting - Verification • Scale Up / Start - Up • Pilot to Commercial  C P   8
Ashok Dhruv, LLC. (720) 318 - 9000 Services: Process Engineering Production of Engineering deliverable for Procurement 9
Ashok Dhruv, LLC. (720) 318 - 9000 Services: Project Engineering – Support to PM Coordination of disciplines and other technical inputs 10
Services: Financial analysis – ROI, NPV, IRR Fixed and Variable costs – Factored Capital cost estimate Total project costs based on factors for project components Value and Basis of factors Category Engineers Aide PI CS Food/Pharm. industry factor SS Engineers Aide PI CS Food/Pharm. industry factor SS Equipment 20.70% 20.70% 34.31% 28.87% 28.90% 44.84% Installation 9.80% 9.73% 8.06% 13.67% 13.58% 10.53% I&C 3.70% 3.73% 3.09% 5.16% 5.21% 4.04% Piping and Valves and fittings 13.70% 13.66% 11.32% 19.11% 19.07% 14.79% Electrical and lighting 2.30% 2.28% 1.89% 3.21% 3.18% 2.47% Building and services 3.70% 3.73% 3.09% 5.16% 5.21% 4.04% Land and site work 3.30% 3.31% 2.75% 4.60% 4.62% 3.59% Utilities and service facilities 14.50% 14.49% 12.01% 20.22% 20.23% 15.70% Total direct costs 71.70% 71.63% 76.52% 100.00% 100.00% 100.00% Engineering, design, management 6.80% 6.83% 5.66% Construction expenses and fees 12.80% 12.84% 10.63% Total contingencies 8.70% 8.70% 7.20% Total indirect costs 28.30% 28.37% 23.49% Total project costs 100% 100% 100% 11 Ashok Dhruv, LLC. (720) 318 - 9000
Ashok Dhruv, LLC. (720) 318 - 9000 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 1.67 .10 6 3.33 .10 6 5 .10 6 6.67 .10 6 8.33 .10 6 1 .10 7 1.17 .10 7 1.33 .10 7 1.5 .10 7 1.67 .10 7 1.83 .10 7 2 .10 7 Refrigeration cost Facility cost Total cost, $ Figure 1: Time for cooling, hours Capitalcost,$ 2 10 7 × 0 c r c f c t 71 t hr Services: Financial analysis – ROI, NPV, IRR Freezing tunnel - Hog Carcass Chill Room 12
Ashok Dhruv, LLC. (720) 318 - 900013 Capital cost optimization - Example 80 90 100 110 120 130 140 150 160 170 180 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 Refrigeration systemcost Facility cost, @ 50 $/sq ft Total cost, FC @ 40 $/Sq.Ft. Total cost, FC @ 50 $/Sq.Ft. Total cost, FC @ 60 $/Sq.Ft. Capital cost minimization Time in chiller, minutes Installedcosts,$inMillions 2.5 0.5 RC t( ) 10 6- × FC 50 t( ) 10 6- × TC 40 t( ) 10 6- × TC 50 t( ) 10 6- × TC 60 t( ) 10 6- × 18080 t
Ashok Dhruv, LLC. (720) 318 - 9000 Services: Capital Project Management 14
Concept to commercializationBusiness Case Concept development Basic / Preliminary Engineering Detailed Engineering Procurement Construction / Installation Start-Up and Commisioning Evaluation of Business opportunity: Growth – New product / Line Extension Productivity – Cost reduction Business fit – strategic / tactical Research and Development Market insights- Share / Niche / Need Technical problem solving Refine techno-economic assumptions Feasibility studies – Process definition in detail Technical / Economical Sensitivity analysis PFD / P&ID / Data sheets Cost estimate +/-: 15-30 % Engineering and documentation Drawings / Specifications Request for Proposal / Quotation Bids / Quotes – analysis Cost estimate +/-: 10-20 % Purchasing and follow Up Bid award / Purchase orders Fabrication Assembly drawing approval Inspection /Expediting / FAT Construction / Installation Mobilize trades Dry runs Electro / Mechanical completion Cost estimate +/-: 10-15 % Start Up and Commissioning Wet runs / Training / SAT Commission/Qualify/Validate Cost estimate +/-: 10 % 15 Ashok Dhruv, LLC. (720) 318 - 9000
It is all about business and finance - $$$ ……………………………………....…Under legal and ethical constraints… To all segments of the Food and Beverage Industry 35 years of experience and expertise – Comprehensive and Versatile How and Why? Mission Food Processing Maximize 16 Ashok Dhruv, LLC. (720) 318 - 9000
Protect and Package Bulk Retail Raw materials Retrival and Storage Kinetics – Reactions Microbial Enzymatic Bio-Chemistry Transport processes Heat transfer Mass transfer Momentum transfer Input Water Carbohydrates Proteins Fats and Oils Output Food product • Safety – Microbial • Shelf life • Nutrition • Sensory aspects Return on Investment Food and Beverage Processing A generic outline – the common basis 17 Ashok Dhruv, LLC. (720) 318 - 9000
Cereals • General Mills • 130 MM Grassroots • Arizona • 35 MM Expansion • Cedar Rapids • 8 MM Addition • Bugles / W. Chicago Granola • Extruded corn @ F/L • Rumbles Ashok Dhruv, LLC. (720) 318 - 9000 Bakery: Experience by Industry Segments Selected examples Bakery • 20 MM Artisan Bread • 25 MM Duncan Hines • Aurora foods /Fru-con • 8 MM Gourmet Cake • Refrigerated Dough • Earthgrains • Single serve cup cakes • Sara lee / F-L • Hot Pockets - Fruit 18
Bakery 19 Ashok Dhruv, LLC. (720) 318 - 9000
Emulsified / Comminuted / Restructured meats • Pizza toppings • Doskocil foods • Dim Sum items – 3I • 50 % TSP • Simulates Steaks – 3I • Pet Foods - Ashok Dhruv, LLC. (720) 318 - 9000 Meat: Experience by Industry Segments Selected examples Bulk Meat • Kill floor design – Hogs • Freezer comparisons • PSE reduction • Drip loss • Mathematical model • Myosin Kinetics 20
X-101 Stun X-102 Position X-103 Stick X-104 Shackle X-105 Cold water dip X-106 Scald X-107 Dehair X-108 Gambril X-116 Head cut off X-115 Final wash X-114 Final shave Clip eye lids X-113 Hot water wash X-112 Singeing X-111 Toe-nails pinch off X-110 Manual shaving X-109 Cold water spray X-117 Open carcass X-118 Remove aitch bone X-119 Open breast bone X-120 Bung drop X-121 Eviscerate Lung, heart, liver,etc X-122 Eviscerate Thyroid X-123 Eviscerate Kidneys X-124 Eviscerate Split carcass X-132 Chilling X-131 Water spray X-130 Grading pH measure X-129 Scaling X-128 Washing Carcass / Neck X-127 Ham facing X-126 Leaf fat removal X-125 Trim Bruises and blemishes 102 From stunning 140 After leaf fat removal 138 From kidney Evisceration 134 To thyroid removal 136 To kidney removal 132 To evisceration 130 After aitch bone removal 143 To scale 146 To chilling 101 Hogs From supply pens 128 After head cut off X-133 Equilibration 147 To Equilibration 102 102 102 102 103 108 To Gambrieling 107 Hair and water 104 Fresh water 105 Scald Purge 109 Cold water supply 106 Hot water 140 F 110 111 Cold water discharge 112 115 To Singeing118 From Singeing 121 To final shave 126 From Final wash 123 To final wash 113 Shavings 114 Toe -Nails 117 Gas exhaust 116 Gas supply 119 Hot water 120 Hot water purge 122 Shavings 124 Hot water 125 Hot water purge 127 Cut Heads 129 Aitch bone 131 Bung 133 Liver, lung, heart etc. 135 Thyroid 137 Kidneys 139 Leaf fat 142 Wash water purge 145 Water discharge 141 Wash water 144 Water 148 To Fabrication 108 To Gambrieling 128 After opening carcass 130 To bung drop 138 To B&B trim 138 From B&B trim 140 After ham facing 143 From scale 143 To water spray Ashok Dhruv, LLC. (720) 318 - 9000 Experience by Industry Segments Meat Abattoir – Generic Flow Diagram 21
Consumer products • Real cheese • Edam / Gouda • Cheese spreads • Processed - American • Non Dairy - Analogs • Cream cheese • Mozarella • Processed American • Soy cheese Ashok Dhruv, LLC. (720) 318 - 9000 Dairy: Experience by Industry Segments Selected examples Commodities • Milk proteins - • Casein / Caseinates • Non Fat Dry Milk • Whey solids • Soy proteins • Isolates / Concentrates • Enzyme Modified Cheese • Yogurt 22
Ashok Dhruv, LLC. (720) 318 - 9000 23 Dairy – Stirred yogurt example Process improvement – P&F HX with corrugated tubes Source: Dairy Processing Handbook. Published by Tetra Pak Processing Systems AB, S-221 86 Lund, Sweden. pg. 249.
Corrugated tube – Double tube design
•Generic approach • Assume pressure drop • Derive Viscosity, Velocity, Shear profile • Predict U, Derive T Vs length profile • Pick L for T< 100. Calculate Del P • Iterate with new Del P • Add Del P for elbows • Summarize results 25 Ashok Dhruv, LLC. (720) 318 - 9000 Provide Insight Explore ideas Evaluate design alternatives Challenge: Temperature and Pressure profile Double, multi tube – Corrugated or Spiral
Indian / Oriental • Dals / Sambhar • Curries • Veg. / Non- Vegetarian • Dairy (Non too) sweet dishes • Rabdi / Basundi / Ras-Malai • Liquid pre-mixes • Soups Ashok Dhruv, LLC. (720) 318 - 9000 Expertise by Industry Segments Selected examples: Thermally Processed Foods Western • Gravies • Meat a food dishes / Pet Foods • Dips - Cheese • Salsa • Soups with Particulates • Fruit fillings • Purees / Concentrates • Pie fillings 26
Ashok Dhruv, LLC. (720) 318 - 9000 Thaw Blend Heat Cool FillHold Soups, Gravy, etc.: Thermally Processed Food Generic Block Flow Diagram 27
Thermally Processed Foods – Soup 28 Ashok Dhruv, LLC. (720) 318 - 9000
Ashok Dhruv, LLC. (720) 318 - 900029 Typical ingredients to consider: HFCS Liquid Sugar “Base – concentrate” Fruit concentrates – Mango, Guava, Banana, etc Proteins Gums and processing aids Spices Allergen containing “Beads” – formulated additives Functional aids – nutrition, specific health benefit Ethnic ingredients – flavorings, etc. Physical properties: Density, Viscosity, Specific heat, thermal conductivity and surface tension Particle size and distribution Chemical properties: Reaction rate constants and Activation Energy Microbial properties: Ni, F0 , z, D TR for target organism / range. Above corresponding values for Enzymes. Example - Peroxidases, Pectin Galacto-Uranse for fruits and veggies, etc. And / or Reaction rate constants and Activation Energy Beverages – Hot Fill, Chilled, Aseptic Ingredient properties of interest
Beverages – Conceptual PFD Bulk bottles to rinsing 30 Ashok Dhruv, LLC. (720) 318 - 9000
Beverages – Conceptual PFD Blend to thermal 31 Ashok Dhruv, LLC. (720) 318 - 9000 T-2100 Pre-mix tank xx ft Dia X xx ft TT xx Gal. 316 SS T-103 Balance Tank xx ft Dia. X xx ft TT 316 SS T-2110 / 2120 Blend tank xx ft Dia. X xx ft TT xx Gal 316 SS P-2101 Pre- mix pump xx gpm @ xx TDH 316 SS P-2411 Balance tank pump xx gpm @ xx TDH 316 SS P-2130/2131 Blend pump xx gpm, xx TDH 316 SS E-201 Heater xx BTUH, xx Sq. ft. E-203 Divert cooler xx BTUH, xx Sq. ft. E-202 Trim cooler xx BTUH, xx Sq. ft. 223 Feed to hold tibe 222 Blend to Thermal 222 Blend to Thermal 224 Discharge from Trim cooler xx F 220 Blend xx GPM @ xx psi xx F 210 Premix xx GPM @ xx psi xx F 203 Bev Base 220 Blend 210 Premix E-202 RO water heater xx Sq. ft, xx BTUH 304 SS tube, CS shell 231 RO Water 230 230 HX - RO Water Recirculation loop xx GPM @ xx psi xx F P-23 294 PP-2411 Product feed pump 115 GPM @ 100 ft TDH T-2430 Filler supply tank 500 Gal. xx ft Dia X xx ft TT 316 SS PP-2434 Filler feed pump 105 GPM @ 35 ft 7.5 HP 225 Filler supply T-2431 Filler return tank 250 Gal. 316 SS E-97 252 Filler return to Divert cooler 251 Filler return xx GPM @ psi 178 F 221 Recycle xx GPM @ psi 90 F 225 Filler supply xx gpm @ xx psi xx F 202 Citric Acid 204 42 % Sucrose M-121 Pallet jack xx Tons A-2110/2120 Blend tank agitator xx rpm, xx hp M-2110/2120 BTA motor A-103 Blend tank agitator xx rpm, xx hp M-103 BT motor A-2100 Pre-mix tank agitator xx rpm, xx hp M-2100 PMT motor 201 Flavor Cloud xx lbs/hr xx F, 209 RO Water xx gpm @ xx psi xx F, 208 RO Water 205 55 % HFCS 206 RO Water xx GPM @ xx psi xx F, HP Stm. Xx psi Cond. return E-201 RO water pre heater xx Sq. ft, xx BTUH 304 SS tube, CS shell Stm. Xx psi Cond. Xx gpm xx F 207 RO Water xx gpm @ xx psi xx F, 291 293 295 CTR 290 CTS xx GPM @ xx psi 78 F 292 CTS
Beverages – Conceptual PFD Filling to bottle cooling 32 Ashok Dhruv, LLC. (720) 318 - 9000
Beverages – Conceptual PFD Labeling to Warehouse 33 Ashok Dhruv, LLC. (720) 318 - 9000 W-401 Shrink Wrapper Case Packer VarioPack or Hi-Cone L-401 A/C Labeller Case Former A-401 Labeled Bottles Accumulator xx ft X xx ft, xx min 304 SS P-401 Palletizer 412 Formed cases 404 Labeled bottles 403 Labeled bottles 402 Label roll P-52 406 Pallets 405 Filled Cases P-55 401 Cooled bottles 500 BPM 90 F, 411 Case stock
Beverage Processing Equipment Ashok Dhruv, LLC. (720) 318 - 900034 •Ingredient storage environments – Atmospheric, refrigerated, controlled atm. •Mixers / Blenders – •Surge tanks – Blend, Balance, Filler Supply •Rinsing - Air only, Water – with conservation •De-Aerator - “Versator” type – Mono layer film under vacuum, Coalescing type •Convective diffusion type – pressure differential / Vacuum •Disk centrifuges •Evaporator - TASTE •Homogenizers - Piston type – perforated disk, Colloid mill, Shear pump •Heat exchangers – “Pasteurizer”, Trim Cooler, Divert cooler, Regen’s, Recoverer’s, Plate and Frame, Double tube – tube in tube, Multi – tube •Thermal microbial processors - Hold tube •“Warmers” – tunnel pasteurizers •Inverter / Side layer, Alternates •Filter •For small bottles – filler, capper •Bottle cooler
Ashok Dhruv, LLC. (720) 318 - 900035 Unit Operations:  Dissolution, Dispersion, Suspension  Hydration / Size reduction  Shearing – • Pipe flow, Pumps, Agitators, Filler inner tube, Valves, accessories  Homogenization / Emulsification • Desirable – Cloud - oil in water Un- desirable – foaming - air in water  De-aeration – Coalescence  Coagulation – gum thro  Diffusion – Oxygen control  Heating / Cooling / Regeneration / Heat recovery  Centrifugation  Evaporation Unit processes: HRM control – Hold tube Target organism – Bottle HF Target organism – Caps – inversion Product / process / package combinations for all other products Oxidation – Unsaturated fats and Oils rancidity Citric Acid Oxidation in Juices Enzymatic hydrolysis Enzyme de-naturation – pectinase Beverage Processing Unit Operations and Unit Processes
It is all about business and finance - $$$ ……………………………………....…Under legal and ethical constraints… By maximizing economic as well as consumer needs A distinctive approach – Competitive Advantage with Confidence How and Why? Mission Food Processing Maximize 36 Ashok Dhruv, LLC. (720) 318 - 9000
Ashok Dhruv, LLC. (720) 318 - 9000 37
Ashok Dhruv, LLC. (720) 318 - 9000 Increase profitability Yield Hog Carcass chilling and drip loss 38
Ashok Dhruv, LLC. (720) 318 - 9000 39 Yield - Hog Carcass chilling – Myosin denaturation in chilling , PSE and drip loss tc 0 5 300..Pdrip Percent drip lossPdrip 4 60 FractionMyoDe× FractionMyoDe FractionMyoDe 1 Convratio-  Convratio Convratio e LnConv LnConv LnConv 0 160 tcKrate tc -    d min× Conv 160  Conv tc  0 160 tcKrate tc -    d Krate 7  min 1- Krate tc  K0 e E Rgas TAvg tc ×       - × 10 1.3- pH tc × × TAvgF 45  RExpExp E Rgas TAvg 5 ×  E 43500 454× cal mole ×K0 2.13 10 34 × 60× min 1- ×pH 160  pH tc  7.0 .01 min tc× min×- Calculation of Myosin denaturation :
Ashok Dhruv, LLC. (720) 318 - 9000 40 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 0 10 20 30 40 50 60 70 Temp, Firmness and PG Conc. of peaches Time, minutes TempF,Firmness,N,PGConcentartion 70 0 T MW q( ) R Firm q( ) PG q( ) 100× 10 q Sensory perception - Texture – Peach firmness Combine time – temperature with Enzymatic Kinetics
Safety: F0 – Pasteurization and Microbial kill Ashok Dhruv, LLC. (720) 318 - 9000 LogRedClB 1.044 10 4- ´LogRedClB log e 10( ) LncitocfClB× CitoCfClB 1.00024CitoCfClB e LncitocfClB  LncitocfClB 2.403 10 4- ´LncitocfClB 0 t min qKClB q      d min× KClB 7( ) 3.534 10 3- ´ min 1- KClB q  K0ClB e EClB Rgas TAvg q( ) 460 R× × é ê ë ù ú û - × TAvg 8( ) 196.762 RExp 101.745Exp EClB Rgas TAvg 15( ) 460 R× ×  EClB Rgas 3.73 10 4 ´ KEClB 3.73 10 4 × Rgas× K×K0ClB 2 10 40 × s 1- × Calculation of Microbial kill : FTPast 37.228 sFTPast 0 t min q10 TAvg q( ) TRef- z     d min× t 4.359 min z 10 R×TRef 180 R× Calculation of extent of Pasteurization : Measure of Safety 41
Ashok Dhruv, LLC. (720) 318 - 9000 0 1 2 3 4 5 0 20 40 60 80 100 120 140 160 180 200 Peroxidase activity drop in heat period Time in heating MC tube, minutes Activityratio,;AvgTempdegF 200 00 Ratio POD q( ) % T Avg q( ) R 50 t min q Extend shelf life – Enzyme deactivation Prevent enzymatic degradation with time 42
Nutrition Vitamin B1 – Thiamin kinetics Ashok Dhruv, LLC. (720) 318 - 9000 Calculation of Nutrition destruction : Based on Vitamin B1 - Thiamin, Kinetics K0B1 2.19 10 9 × s 1- × EB1 1.18 10 4 × Rgas× K× EB1 Rgas 1.18 10 4 ´ K Exp EB1 Rgas TAvg 15( ) 460 R× ×  Exp 32.187 TAvg 8( ) 196.762 R KB1 q  K0B1 e EB1 Rgas TAvg q( ) 460 R× × é ê ë ù ú û - × KB1 7( ) 1.074 10 3- ´ min 1-  LncitocfB1 0 t min qKB1 q      d min× LncitocfB1 7.046 10 4- ´ CitoCfB1 e LncitocfB1  CitoCfB1 1.000705 LogRedB1 log e 10( ) LncitocfB1× LogRedB1 3.06 10 4- ´ 43
It is all about business and finance - $$$ ……………………………………....…Under legal and ethical constraints… With technical rigor appropriate to challenge First principle, statistical or empirical analysis – Robust decisions How and Why? Mission Food Processing Maximize 44 Ashok Dhruv, LLC. (720) 318 - 9000
Ashok Dhruv, LLC. (720) 318 - 9000 45 Microbiology Enzymes Bio-Chemistry Organic Chemistry Heat transfer Mass transfer Momentum transfer Kinetics Why and How – Application of sound Science and Engineering Chemical engineering analysis Apply tenets of chemistry
Ashok Dhruv, LLC. (720) 318 - 900046 Physical / Chemical Process Equipment Mathematical Constitutive Eqn. Ini. & Boundary cond. Physical laws Laws of Math Product By-products Waste streams Raw materials Utilities Labor Physical properties Operating conditions Assumptions Microbial log cycle reduction Enzyme deactivation. amount Objective sensory quality Physical form Mathematical form Why and How – Mathematical modeling Application of sound Science and Engineering
Ashok Dhruv, LLC. (720) 318 - 900047 q tc x0 y0 z0  p q r Ax p Ay q × Az r × Bx tc p× By tc q× Bz tc r× Cx x0 p× Cy y0 q× Cz z0 r×        Tf tc x0 y0 z0  ta Ti ta-  q tc x0 y0 z0 × 460 R×- T Avg q  t fwall T fi t fwall-  e 4- U cal× D× q× min× d 2  f× C Pf× × Why and How – Time – Temperature Profile
Ashok Dhruv, LLC. (720) 318 - 9000 48 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 30 50 70 90 110 130 150 170 190 210 Time to heat fruit piece in puree Time of heating,minutes Temperature,degF 130 175 Tf tc 0 0 0  R 1- × Tf tc x in  y in  z in     R 1- × TAvgF tc  R 1- × 3 5 tc Why and How – Time – Temperature Profile in a particle
tc 0 5 300..Pdrip Percent drip lossPdrip 4 60 FractionMyoDe× FractionMyoDe FractionMyoDe 1 Convratio-  Convratio Convratio e LnConv LnConv LnConv 0 160 tcKrate tc -    d min× Conv 160  Conv tc  0 160 tcKrate tc -    d Krate 7  min 1- Krate tc  K0 e E Rgas TAvg tc ×       - × 10 1.3- pH tc × × TAvgF 45  RExpExp E Rgas TAvg 5 ×  E 43500 454× cal mole ×K0 2.13 10 34 × 60× min 1- ×pH 160  pH tc  7.0 .01 min tc× min×- Calculation of Myosin denaturation : Ashok Dhruv, LLC. (720) 318 - 9000 Why and How – Myosin denaturation – drip loss and PSE 49
Why and How – Application of Statistics Probability of Failure and Sample size ICMSF – International Committee on Microbial Safety in Foods Ashok Dhruv, LLC. (720) 318 - 900050
ICMSF – Enrichment implications and constraints Ashok Dhruv, LLC. (720) 318 - 9000 Why and How – Application of Statistics Probability of Failure, Sample size and Enrichment 51
Microbial death kinetics – Salmonella and Listeria Ashok Dhruv, LLC. (720) 318 - 9000 Why and How – Safety: Salmonella and Listeria Combining Heat transfer with Microbial death Kinetics 52
Ashok Dhruv, LLC. (720) 318 - 9000 0.015 0.01 0.005 0 0.005 0.01 0.015 0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 trace 1 Velocity in z direction Radial distance, in Velocity,ft/sec 3 0 v z r( ) ft s R iR i- r Required for Kinetics of Conversions Why and How: Non-Newtonian flow Velocity profile in a tube - 53
Ashok Dhruv, LLC. (720) 318 - 9000 Measure of Mechanical Damage 1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 110 60 10 40 90 140 190 240 Shear rate, radially Shear rate, axially Shear rate as afunction of radius,SSHE Radial distance, inches Shearrateinpersecond 240 110- g q r in×( ) s× g z r in×( ) s× 10× 31.5 r Why and How: Scarped Surface Heat Exchanger Shear rate in radial and axial direction 54
Ashok Dhruv, LLC. (720) 318 - 900055 Why and How – Disk Centrifugation Application of sound Science and Engineering
Beverage Processing – Unit operations: Evaporation Ashok Dhruv, LLC. (720) 318 - 900056 Why and How – Evaporation Flavor and Aroma loss in Juice Processing
Hot fill Vs Aseptic Process - Beverages in PETWhy and How – Heat recovery in HF Application of sound Science and Engineering 57 Ashok Dhruv, LLC. (720) 318 - 9000
Hot fill Vs Aseptic Process - Beverages in PETWhy and How – Temperature profile in HF – Bottle cooling comparisons 58 Ashok Dhruv, LLC. (720) 318 - 9000
Hot fill Vs Aseptic Process - Beverages in PETWhy and How – Hot Fill Vs Aseptic comparison 59 Ashok Dhruv, LLC. (720) 318 - 9000
Open Innovation – Evolution Research and Develop Acquire and Develop Connect and Develop 60 Ashok Dhruv, LLC. (720) 318 - 9000
What is Open Innovation Anyway – Really? The exact opposite of NIH – Not Invented Here Syndrome Ashok Dhruv, LLC. (720) 318 - 900061
What is Open Innovation Anyway? Open Innovation is a term promoted by Henry Chesbrough, a professor and executive director at the Center for Open Innovation at Berkeley. The central idea behind open innovation is that in a world of widely distributed knowledge, companies cannot afford to rely entirely on their own research, but should instead buy or license processes or inventions (i.e. patents) from other companies. In addition, internal inventions not being used in a firm's business should be taken outside the company (e.g., through licensing, joint ventures, spin-offs). In contrast, closed innovation refers to processes that limit the use of internal knowledge within a company and make little or no use of external knowledge. Some companies promoting open innovation include Procter & Gamble, Innovation Exchange, NineSigma, InnoCentive, yet2.com, and IBM. Prior to World War II, closed innovation was the paradigm in which most firms operated. Most innovating companies kept their discoveries highly secret and made no attempt to assimilate information from outside their own R&D labs. However, in recent years the world has seen major advances in technology and society which have facilitated the diffusion of information. Not the least of these advances are electronic communication systems, including the internet. Today information can be transferred so easily that it seems impossible to prevent. Thus, the open innovation model states that since firms cannot stop this phenomenon, they must learn to take advantage of it. It is the business model of the firm that determines what external information to bring inside, and what internal information to take outside. Ashok Dhruv, LLC. (720) 318 - 900062
Our current market Our new market Other firm´s market Open innovation External technology insourcing Internal technology base External technology base Henry Chesbrough, 2004 Internal/external venture handling Licence, spin out, divest Ashok Dhruv, LLC. (720) 318 - 900063
Ashok Dhruv, LLC. (720) 318 - 900064
Ashok Dhruv, LLC. (720) 318 - 900065
Ashok Dhruv, LLC. (720) 318 - 9000 Ashok Dhruv Acumen @ Business Sound Technically Highly Motivated Out of the Box Keen on Results Dedicated to team Hands on Robust @ Financials Universal Approach Varied Experience 66
9958 E. Maplewood Ave., Englewood, CO 80111 Ashok_dhruv@productivityandgrowth08.com http://www.productivityandgrowth08.com Ashok Dhruv, LLC (720) 949 – 6498 (Off) (720) 318 – 9000 (Mob) 67 Ashok Dhruv, LLC. (720) 318 - 9000

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Introductory Presentation

  • 1.
  • 2.
    We provide Technologyand Engineering services From Concept to Commercialization – Productivity and Growth It is all about business and finance - $$$ ……………………………………....…Under legal and ethical constraints… To all segments of the Food and Beverage Industry 35 years of experience and expertise – Comprehensive and Versatile By maximizing economic as well as consumer needs A distinctive approach – Competitive Advantage with Confidence With technical rigor appropriate to challenge First principle, statistical or empirical analysis – Robust decisions How and Why? Mission Food Processing Maximize 2 Ashok Dhruv, LLC. (720) 318 - 9000
  • 3.
    Ashok Dhruv, LLC.(720) 318 - 9000 By: • application of scientific and engineering principles and practices • Leverage IT revolution • computing power • data access - internet • value generation • bridge gap between generation and use of information Mission – Provide tangible and material economic benefit To Food and Beverage Processors, On a Time Effective basis Because • Consumer wants and needs are rapidly changing • Technology is available With Employment of skills and resources on as needed basis 3
  • 4.
    First things First– Fulfill a BUSINESS NEED Match resources – technology and engineering to need Product life cycle Growth share matrix Ashok Dhruv, LLC. (720) 318 - 90004
  • 5.
    Proteins Casein Soy Isolate Carbohydrates Starches, Sweetners Bio-Ethanol Animal feed Bio-Waste Essentialnutrients Fiber Vitamins and Minerals Fats and Oils Ghee, Butter Cookin Oil, Shortening Lard, Tallow Bio-Diesel Fractionation of Agricutural produce Commodity products are enablers for consumer products Agricultural products Fruits and Vegetables Corn, Soy, Peanuts, Beans Milk, Fish Meat - Poultry From farm to food – industry and commerce 5 Ashok Dhruv, LLC. (720) 318 - 9000
  • 6.
    Concept to Commercialization– the journey 6 Ashok Dhruv, LLC. (720) 318 - 9000
  • 7.
    Ashok Dhruv, LLC.(720) 318 - 9000 Services: Technology Sourcing and Selection- Selected examples Open Innovation In House - Incremental • Cross fertilization • Leverage Public Domain - Radical • USDA – Puffing Gun • NASA / Military Academia – • Know how and Expertise Consortia’s - Targeted • NCFFST • CAFT Acquisitions / Mergers - Radical Technology transfer to China • Nutritious meats / TSP • RBD Oil/Margarine/Soy Isolate • Caramel Color E/P/C services • Supercritical Extraction • MW applications • 130 MM Cereal plant • Bio-Diesel • Corn Wet milling Complex • Artisan Bread • Abattoir – Yield / PSE reduction Food and Beverage processors Orange juice / Concentrate Sports drinks / HF 7
  • 8.
    Ashok Dhruv, LLC.(720) 318 - 9000 Services: Product and Process Development Product • Marketing - Consumer • Focus / CLT / HUT • BASIS • Product • Scale – Bench / PP • Formulation / Ingr. • Regulatory • Label / Std. of Identity • Functional properties • Safety / Sensory / S.Life • Margin / Contribution Process - Selection • Unit Operations / Processes • Characterize Ingr. Streams • Cause & Effect Correlation • Quantification -Modeling • Mathematical / Statistical • Empirical / 1st Principle • Pilot Planting - Verification • Scale Up / Start - Up • Pilot to Commercial  C P   8
  • 9.
    Ashok Dhruv, LLC.(720) 318 - 9000 Services: Process Engineering Production of Engineering deliverable for Procurement 9
  • 10.
    Ashok Dhruv, LLC.(720) 318 - 9000 Services: Project Engineering – Support to PM Coordination of disciplines and other technical inputs 10
  • 11.
    Services: Financial analysis– ROI, NPV, IRR Fixed and Variable costs – Factored Capital cost estimate Total project costs based on factors for project components Value and Basis of factors Category Engineers Aide PI CS Food/Pharm. industry factor SS Engineers Aide PI CS Food/Pharm. industry factor SS Equipment 20.70% 20.70% 34.31% 28.87% 28.90% 44.84% Installation 9.80% 9.73% 8.06% 13.67% 13.58% 10.53% I&C 3.70% 3.73% 3.09% 5.16% 5.21% 4.04% Piping and Valves and fittings 13.70% 13.66% 11.32% 19.11% 19.07% 14.79% Electrical and lighting 2.30% 2.28% 1.89% 3.21% 3.18% 2.47% Building and services 3.70% 3.73% 3.09% 5.16% 5.21% 4.04% Land and site work 3.30% 3.31% 2.75% 4.60% 4.62% 3.59% Utilities and service facilities 14.50% 14.49% 12.01% 20.22% 20.23% 15.70% Total direct costs 71.70% 71.63% 76.52% 100.00% 100.00% 100.00% Engineering, design, management 6.80% 6.83% 5.66% Construction expenses and fees 12.80% 12.84% 10.63% Total contingencies 8.70% 8.70% 7.20% Total indirect costs 28.30% 28.37% 23.49% Total project costs 100% 100% 100% 11 Ashok Dhruv, LLC. (720) 318 - 9000
  • 12.
    Ashok Dhruv, LLC.(720) 318 - 9000 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 1.67 .10 6 3.33 .10 6 5 .10 6 6.67 .10 6 8.33 .10 6 1 .10 7 1.17 .10 7 1.33 .10 7 1.5 .10 7 1.67 .10 7 1.83 .10 7 2 .10 7 Refrigeration cost Facility cost Total cost, $ Figure 1: Time for cooling, hours Capitalcost,$ 2 10 7 × 0 c r c f c t 71 t hr Services: Financial analysis – ROI, NPV, IRR Freezing tunnel - Hog Carcass Chill Room 12
  • 13.
    Ashok Dhruv, LLC.(720) 318 - 900013 Capital cost optimization - Example 80 90 100 110 120 130 140 150 160 170 180 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 Refrigeration systemcost Facility cost, @ 50 $/sq ft Total cost, FC @ 40 $/Sq.Ft. Total cost, FC @ 50 $/Sq.Ft. Total cost, FC @ 60 $/Sq.Ft. Capital cost minimization Time in chiller, minutes Installedcosts,$inMillions 2.5 0.5 RC t( ) 10 6- × FC 50 t( ) 10 6- × TC 40 t( ) 10 6- × TC 50 t( ) 10 6- × TC 60 t( ) 10 6- × 18080 t
  • 14.
    Ashok Dhruv, LLC.(720) 318 - 9000 Services: Capital Project Management 14
  • 15.
    Concept to commercializationBusiness Case Concept development Basic/ Preliminary Engineering Detailed Engineering Procurement Construction / Installation Start-Up and Commisioning Evaluation of Business opportunity: Growth – New product / Line Extension Productivity – Cost reduction Business fit – strategic / tactical Research and Development Market insights- Share / Niche / Need Technical problem solving Refine techno-economic assumptions Feasibility studies – Process definition in detail Technical / Economical Sensitivity analysis PFD / P&ID / Data sheets Cost estimate +/-: 15-30 % Engineering and documentation Drawings / Specifications Request for Proposal / Quotation Bids / Quotes – analysis Cost estimate +/-: 10-20 % Purchasing and follow Up Bid award / Purchase orders Fabrication Assembly drawing approval Inspection /Expediting / FAT Construction / Installation Mobilize trades Dry runs Electro / Mechanical completion Cost estimate +/-: 10-15 % Start Up and Commissioning Wet runs / Training / SAT Commission/Qualify/Validate Cost estimate +/-: 10 % 15 Ashok Dhruv, LLC. (720) 318 - 9000
  • 16.
    It is allabout business and finance - $$$ ……………………………………....…Under legal and ethical constraints… To all segments of the Food and Beverage Industry 35 years of experience and expertise – Comprehensive and Versatile How and Why? Mission Food Processing Maximize 16 Ashok Dhruv, LLC. (720) 318 - 9000
  • 17.
    Protect and Package Bulk Retail Raw materials Retrivaland Storage Kinetics – Reactions Microbial Enzymatic Bio-Chemistry Transport processes Heat transfer Mass transfer Momentum transfer Input Water Carbohydrates Proteins Fats and Oils Output Food product • Safety – Microbial • Shelf life • Nutrition • Sensory aspects Return on Investment Food and Beverage Processing A generic outline – the common basis 17 Ashok Dhruv, LLC. (720) 318 - 9000
  • 18.
    Cereals • General Mills •130 MM Grassroots • Arizona • 35 MM Expansion • Cedar Rapids • 8 MM Addition • Bugles / W. Chicago Granola • Extruded corn @ F/L • Rumbles Ashok Dhruv, LLC. (720) 318 - 9000 Bakery: Experience by Industry Segments Selected examples Bakery • 20 MM Artisan Bread • 25 MM Duncan Hines • Aurora foods /Fru-con • 8 MM Gourmet Cake • Refrigerated Dough • Earthgrains • Single serve cup cakes • Sara lee / F-L • Hot Pockets - Fruit 18
  • 19.
    Bakery 19 Ashok Dhruv,LLC. (720) 318 - 9000
  • 20.
    Emulsified / Comminuted/ Restructured meats • Pizza toppings • Doskocil foods • Dim Sum items – 3I • 50 % TSP • Simulates Steaks – 3I • Pet Foods - Ashok Dhruv, LLC. (720) 318 - 9000 Meat: Experience by Industry Segments Selected examples Bulk Meat • Kill floor design – Hogs • Freezer comparisons • PSE reduction • Drip loss • Mathematical model • Myosin Kinetics 20
  • 21.
    X-101 Stun X-102 Position X-103 Stick X-104 Shackle X-105 Cold water dip X-106 Scald X-107 Dehair X-108 Gambril X-116 Headcut off X-115 Final wash X-114 Final shave Clip eye lids X-113 Hot water wash X-112 Singeing X-111 Toe-nails pinch off X-110 Manual shaving X-109 Cold water spray X-117 Open carcass X-118 Remove aitch bone X-119 Open breast bone X-120 Bung drop X-121 Eviscerate Lung, heart, liver,etc X-122 Eviscerate Thyroid X-123 Eviscerate Kidneys X-124 Eviscerate Split carcass X-132 Chilling X-131 Water spray X-130 Grading pH measure X-129 Scaling X-128 Washing Carcass / Neck X-127 Ham facing X-126 Leaf fat removal X-125 Trim Bruises and blemishes 102 From stunning 140 After leaf fat removal 138 From kidney Evisceration 134 To thyroid removal 136 To kidney removal 132 To evisceration 130 After aitch bone removal 143 To scale 146 To chilling 101 Hogs From supply pens 128 After head cut off X-133 Equilibration 147 To Equilibration 102 102 102 102 103 108 To Gambrieling 107 Hair and water 104 Fresh water 105 Scald Purge 109 Cold water supply 106 Hot water 140 F 110 111 Cold water discharge 112 115 To Singeing118 From Singeing 121 To final shave 126 From Final wash 123 To final wash 113 Shavings 114 Toe -Nails 117 Gas exhaust 116 Gas supply 119 Hot water 120 Hot water purge 122 Shavings 124 Hot water 125 Hot water purge 127 Cut Heads 129 Aitch bone 131 Bung 133 Liver, lung, heart etc. 135 Thyroid 137 Kidneys 139 Leaf fat 142 Wash water purge 145 Water discharge 141 Wash water 144 Water 148 To Fabrication 108 To Gambrieling 128 After opening carcass 130 To bung drop 138 To B&B trim 138 From B&B trim 140 After ham facing 143 From scale 143 To water spray Ashok Dhruv, LLC. (720) 318 - 9000 Experience by Industry Segments Meat Abattoir – Generic Flow Diagram 21
  • 22.
    Consumer products • Realcheese • Edam / Gouda • Cheese spreads • Processed - American • Non Dairy - Analogs • Cream cheese • Mozarella • Processed American • Soy cheese Ashok Dhruv, LLC. (720) 318 - 9000 Dairy: Experience by Industry Segments Selected examples Commodities • Milk proteins - • Casein / Caseinates • Non Fat Dry Milk • Whey solids • Soy proteins • Isolates / Concentrates • Enzyme Modified Cheese • Yogurt 22
  • 23.
    Ashok Dhruv, LLC.(720) 318 - 9000 23 Dairy – Stirred yogurt example Process improvement – P&F HX with corrugated tubes Source: Dairy Processing Handbook. Published by Tetra Pak Processing Systems AB, S-221 86 Lund, Sweden. pg. 249.
  • 24.
    Corrugated tube –Double tube design
  • 25.
    •Generic approach • Assumepressure drop • Derive Viscosity, Velocity, Shear profile • Predict U, Derive T Vs length profile • Pick L for T< 100. Calculate Del P • Iterate with new Del P • Add Del P for elbows • Summarize results 25 Ashok Dhruv, LLC. (720) 318 - 9000 Provide Insight Explore ideas Evaluate design alternatives Challenge: Temperature and Pressure profile Double, multi tube – Corrugated or Spiral
  • 26.
    Indian / Oriental •Dals / Sambhar • Curries • Veg. / Non- Vegetarian • Dairy (Non too) sweet dishes • Rabdi / Basundi / Ras-Malai • Liquid pre-mixes • Soups Ashok Dhruv, LLC. (720) 318 - 9000 Expertise by Industry Segments Selected examples: Thermally Processed Foods Western • Gravies • Meat a food dishes / Pet Foods • Dips - Cheese • Salsa • Soups with Particulates • Fruit fillings • Purees / Concentrates • Pie fillings 26
  • 27.
    Ashok Dhruv, LLC.(720) 318 - 9000 Thaw Blend Heat Cool FillHold Soups, Gravy, etc.: Thermally Processed Food Generic Block Flow Diagram 27
  • 28.
    Thermally Processed Foods– Soup 28 Ashok Dhruv, LLC. (720) 318 - 9000
  • 29.
    Ashok Dhruv, LLC.(720) 318 - 900029 Typical ingredients to consider: HFCS Liquid Sugar “Base – concentrate” Fruit concentrates – Mango, Guava, Banana, etc Proteins Gums and processing aids Spices Allergen containing “Beads” – formulated additives Functional aids – nutrition, specific health benefit Ethnic ingredients – flavorings, etc. Physical properties: Density, Viscosity, Specific heat, thermal conductivity and surface tension Particle size and distribution Chemical properties: Reaction rate constants and Activation Energy Microbial properties: Ni, F0 , z, D TR for target organism / range. Above corresponding values for Enzymes. Example - Peroxidases, Pectin Galacto-Uranse for fruits and veggies, etc. And / or Reaction rate constants and Activation Energy Beverages – Hot Fill, Chilled, Aseptic Ingredient properties of interest
  • 30.
    Beverages – ConceptualPFD Bulk bottles to rinsing 30 Ashok Dhruv, LLC. (720) 318 - 9000
  • 31.
    Beverages – ConceptualPFD Blend to thermal 31 Ashok Dhruv, LLC. (720) 318 - 9000 T-2100 Pre-mix tank xx ft Dia X xx ft TT xx Gal. 316 SS T-103 Balance Tank xx ft Dia. X xx ft TT 316 SS T-2110 / 2120 Blend tank xx ft Dia. X xx ft TT xx Gal 316 SS P-2101 Pre- mix pump xx gpm @ xx TDH 316 SS P-2411 Balance tank pump xx gpm @ xx TDH 316 SS P-2130/2131 Blend pump xx gpm, xx TDH 316 SS E-201 Heater xx BTUH, xx Sq. ft. E-203 Divert cooler xx BTUH, xx Sq. ft. E-202 Trim cooler xx BTUH, xx Sq. ft. 223 Feed to hold tibe 222 Blend to Thermal 222 Blend to Thermal 224 Discharge from Trim cooler xx F 220 Blend xx GPM @ xx psi xx F 210 Premix xx GPM @ xx psi xx F 203 Bev Base 220 Blend 210 Premix E-202 RO water heater xx Sq. ft, xx BTUH 304 SS tube, CS shell 231 RO Water 230 230 HX - RO Water Recirculation loop xx GPM @ xx psi xx F P-23 294 PP-2411 Product feed pump 115 GPM @ 100 ft TDH T-2430 Filler supply tank 500 Gal. xx ft Dia X xx ft TT 316 SS PP-2434 Filler feed pump 105 GPM @ 35 ft 7.5 HP 225 Filler supply T-2431 Filler return tank 250 Gal. 316 SS E-97 252 Filler return to Divert cooler 251 Filler return xx GPM @ psi 178 F 221 Recycle xx GPM @ psi 90 F 225 Filler supply xx gpm @ xx psi xx F 202 Citric Acid 204 42 % Sucrose M-121 Pallet jack xx Tons A-2110/2120 Blend tank agitator xx rpm, xx hp M-2110/2120 BTA motor A-103 Blend tank agitator xx rpm, xx hp M-103 BT motor A-2100 Pre-mix tank agitator xx rpm, xx hp M-2100 PMT motor 201 Flavor Cloud xx lbs/hr xx F, 209 RO Water xx gpm @ xx psi xx F, 208 RO Water 205 55 % HFCS 206 RO Water xx GPM @ xx psi xx F, HP Stm. Xx psi Cond. return E-201 RO water pre heater xx Sq. ft, xx BTUH 304 SS tube, CS shell Stm. Xx psi Cond. Xx gpm xx F 207 RO Water xx gpm @ xx psi xx F, 291 293 295 CTR 290 CTS xx GPM @ xx psi 78 F 292 CTS
  • 32.
    Beverages – ConceptualPFD Filling to bottle cooling 32 Ashok Dhruv, LLC. (720) 318 - 9000
  • 33.
    Beverages – ConceptualPFD Labeling to Warehouse 33 Ashok Dhruv, LLC. (720) 318 - 9000 W-401 Shrink Wrapper Case Packer VarioPack or Hi-Cone L-401 A/C Labeller Case Former A-401 Labeled Bottles Accumulator xx ft X xx ft, xx min 304 SS P-401 Palletizer 412 Formed cases 404 Labeled bottles 403 Labeled bottles 402 Label roll P-52 406 Pallets 405 Filled Cases P-55 401 Cooled bottles 500 BPM 90 F, 411 Case stock
  • 34.
    Beverage Processing Equipment AshokDhruv, LLC. (720) 318 - 900034 •Ingredient storage environments – Atmospheric, refrigerated, controlled atm. •Mixers / Blenders – •Surge tanks – Blend, Balance, Filler Supply •Rinsing - Air only, Water – with conservation •De-Aerator - “Versator” type – Mono layer film under vacuum, Coalescing type •Convective diffusion type – pressure differential / Vacuum •Disk centrifuges •Evaporator - TASTE •Homogenizers - Piston type – perforated disk, Colloid mill, Shear pump •Heat exchangers – “Pasteurizer”, Trim Cooler, Divert cooler, Regen’s, Recoverer’s, Plate and Frame, Double tube – tube in tube, Multi – tube •Thermal microbial processors - Hold tube •“Warmers” – tunnel pasteurizers •Inverter / Side layer, Alternates •Filter •For small bottles – filler, capper •Bottle cooler
  • 35.
    Ashok Dhruv, LLC.(720) 318 - 900035 Unit Operations:  Dissolution, Dispersion, Suspension  Hydration / Size reduction  Shearing – • Pipe flow, Pumps, Agitators, Filler inner tube, Valves, accessories  Homogenization / Emulsification • Desirable – Cloud - oil in water Un- desirable – foaming - air in water  De-aeration – Coalescence  Coagulation – gum thro  Diffusion – Oxygen control  Heating / Cooling / Regeneration / Heat recovery  Centrifugation  Evaporation Unit processes: HRM control – Hold tube Target organism – Bottle HF Target organism – Caps – inversion Product / process / package combinations for all other products Oxidation – Unsaturated fats and Oils rancidity Citric Acid Oxidation in Juices Enzymatic hydrolysis Enzyme de-naturation – pectinase Beverage Processing Unit Operations and Unit Processes
  • 36.
    It is allabout business and finance - $$$ ……………………………………....…Under legal and ethical constraints… By maximizing economic as well as consumer needs A distinctive approach – Competitive Advantage with Confidence How and Why? Mission Food Processing Maximize 36 Ashok Dhruv, LLC. (720) 318 - 9000
  • 37.
    Ashok Dhruv, LLC.(720) 318 - 9000 37
  • 38.
    Ashok Dhruv, LLC.(720) 318 - 9000 Increase profitability Yield Hog Carcass chilling and drip loss 38
  • 39.
    Ashok Dhruv, LLC.(720) 318 - 9000 39 Yield - Hog Carcass chilling – Myosin denaturation in chilling , PSE and drip loss tc 0 5 300..Pdrip Percent drip lossPdrip 4 60 FractionMyoDe× FractionMyoDe FractionMyoDe 1 Convratio-  Convratio Convratio e LnConv LnConv LnConv 0 160 tcKrate tc -    d min× Conv 160  Conv tc  0 160 tcKrate tc -    d Krate 7  min 1- Krate tc  K0 e E Rgas TAvg tc ×       - × 10 1.3- pH tc × × TAvgF 45  RExpExp E Rgas TAvg 5 ×  E 43500 454× cal mole ×K0 2.13 10 34 × 60× min 1- ×pH 160  pH tc  7.0 .01 min tc× min×- Calculation of Myosin denaturation :
  • 40.
    Ashok Dhruv, LLC.(720) 318 - 9000 40 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 0 10 20 30 40 50 60 70 Temp, Firmness and PG Conc. of peaches Time, minutes TempF,Firmness,N,PGConcentartion 70 0 T MW q( ) R Firm q( ) PG q( ) 100× 10 q Sensory perception - Texture – Peach firmness Combine time – temperature with Enzymatic Kinetics
  • 41.
    Safety: F0 –Pasteurization and Microbial kill Ashok Dhruv, LLC. (720) 318 - 9000 LogRedClB 1.044 10 4- ´LogRedClB log e 10( ) LncitocfClB× CitoCfClB 1.00024CitoCfClB e LncitocfClB  LncitocfClB 2.403 10 4- ´LncitocfClB 0 t min qKClB q      d min× KClB 7( ) 3.534 10 3- ´ min 1- KClB q  K0ClB e EClB Rgas TAvg q( ) 460 R× × é ê ë ù ú û - × TAvg 8( ) 196.762 RExp 101.745Exp EClB Rgas TAvg 15( ) 460 R× ×  EClB Rgas 3.73 10 4 ´ KEClB 3.73 10 4 × Rgas× K×K0ClB 2 10 40 × s 1- × Calculation of Microbial kill : FTPast 37.228 sFTPast 0 t min q10 TAvg q( ) TRef- z     d min× t 4.359 min z 10 R×TRef 180 R× Calculation of extent of Pasteurization : Measure of Safety 41
  • 42.
    Ashok Dhruv, LLC.(720) 318 - 9000 0 1 2 3 4 5 0 20 40 60 80 100 120 140 160 180 200 Peroxidase activity drop in heat period Time in heating MC tube, minutes Activityratio,;AvgTempdegF 200 00 Ratio POD q( ) % T Avg q( ) R 50 t min q Extend shelf life – Enzyme deactivation Prevent enzymatic degradation with time 42
  • 43.
    Nutrition Vitamin B1 –Thiamin kinetics Ashok Dhruv, LLC. (720) 318 - 9000 Calculation of Nutrition destruction : Based on Vitamin B1 - Thiamin, Kinetics K0B1 2.19 10 9 × s 1- × EB1 1.18 10 4 × Rgas× K× EB1 Rgas 1.18 10 4 ´ K Exp EB1 Rgas TAvg 15( ) 460 R× ×  Exp 32.187 TAvg 8( ) 196.762 R KB1 q  K0B1 e EB1 Rgas TAvg q( ) 460 R× × é ê ë ù ú û - × KB1 7( ) 1.074 10 3- ´ min 1-  LncitocfB1 0 t min qKB1 q      d min× LncitocfB1 7.046 10 4- ´ CitoCfB1 e LncitocfB1  CitoCfB1 1.000705 LogRedB1 log e 10( ) LncitocfB1× LogRedB1 3.06 10 4- ´ 43
  • 44.
    It is allabout business and finance - $$$ ……………………………………....…Under legal and ethical constraints… With technical rigor appropriate to challenge First principle, statistical or empirical analysis – Robust decisions How and Why? Mission Food Processing Maximize 44 Ashok Dhruv, LLC. (720) 318 - 9000
  • 45.
    Ashok Dhruv, LLC.(720) 318 - 9000 45 Microbiology Enzymes Bio-Chemistry Organic Chemistry Heat transfer Mass transfer Momentum transfer Kinetics Why and How – Application of sound Science and Engineering Chemical engineering analysis Apply tenets of chemistry
  • 46.
    Ashok Dhruv, LLC.(720) 318 - 900046 Physical / Chemical Process Equipment Mathematical Constitutive Eqn. Ini. & Boundary cond. Physical laws Laws of Math Product By-products Waste streams Raw materials Utilities Labor Physical properties Operating conditions Assumptions Microbial log cycle reduction Enzyme deactivation. amount Objective sensory quality Physical form Mathematical form Why and How – Mathematical modeling Application of sound Science and Engineering
  • 47.
    Ashok Dhruv, LLC.(720) 318 - 900047 q tc x0 y0 z0  p q r Ax p Ay q × Az r × Bx tc p× By tc q× Bz tc r× Cx x0 p× Cy y0 q× Cz z0 r×        Tf tc x0 y0 z0  ta Ti ta-  q tc x0 y0 z0 × 460 R×- T Avg q  t fwall T fi t fwall-  e 4- U cal× D× q× min× d 2  f× C Pf× × Why and How – Time – Temperature Profile
  • 48.
    Ashok Dhruv, LLC.(720) 318 - 9000 48 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 30 50 70 90 110 130 150 170 190 210 Time to heat fruit piece in puree Time of heating,minutes Temperature,degF 130 175 Tf tc 0 0 0  R 1- × Tf tc x in  y in  z in     R 1- × TAvgF tc  R 1- × 3 5 tc Why and How – Time – Temperature Profile in a particle
  • 49.
    tc 0 5300..Pdrip Percent drip lossPdrip 4 60 FractionMyoDe× FractionMyoDe FractionMyoDe 1 Convratio-  Convratio Convratio e LnConv LnConv LnConv 0 160 tcKrate tc -    d min× Conv 160  Conv tc  0 160 tcKrate tc -    d Krate 7  min 1- Krate tc  K0 e E Rgas TAvg tc ×       - × 10 1.3- pH tc × × TAvgF 45  RExpExp E Rgas TAvg 5 ×  E 43500 454× cal mole ×K0 2.13 10 34 × 60× min 1- ×pH 160  pH tc  7.0 .01 min tc× min×- Calculation of Myosin denaturation : Ashok Dhruv, LLC. (720) 318 - 9000 Why and How – Myosin denaturation – drip loss and PSE 49
  • 50.
    Why and How– Application of Statistics Probability of Failure and Sample size ICMSF – International Committee on Microbial Safety in Foods Ashok Dhruv, LLC. (720) 318 - 900050
  • 51.
    ICMSF – Enrichmentimplications and constraints Ashok Dhruv, LLC. (720) 318 - 9000 Why and How – Application of Statistics Probability of Failure, Sample size and Enrichment 51
  • 52.
    Microbial death kinetics– Salmonella and Listeria Ashok Dhruv, LLC. (720) 318 - 9000 Why and How – Safety: Salmonella and Listeria Combining Heat transfer with Microbial death Kinetics 52
  • 53.
    Ashok Dhruv, LLC.(720) 318 - 9000 0.015 0.01 0.005 0 0.005 0.01 0.015 0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 trace 1 Velocity in z direction Radial distance, in Velocity,ft/sec 3 0 v z r( ) ft s R iR i- r Required for Kinetics of Conversions Why and How: Non-Newtonian flow Velocity profile in a tube - 53
  • 54.
    Ashok Dhruv, LLC.(720) 318 - 9000 Measure of Mechanical Damage 1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 110 60 10 40 90 140 190 240 Shear rate, radially Shear rate, axially Shear rate as afunction of radius,SSHE Radial distance, inches Shearrateinpersecond 240 110- g q r in×( ) s× g z r in×( ) s× 10× 31.5 r Why and How: Scarped Surface Heat Exchanger Shear rate in radial and axial direction 54
  • 55.
    Ashok Dhruv, LLC.(720) 318 - 900055 Why and How – Disk Centrifugation Application of sound Science and Engineering
  • 56.
    Beverage Processing –Unit operations: Evaporation Ashok Dhruv, LLC. (720) 318 - 900056 Why and How – Evaporation Flavor and Aroma loss in Juice Processing
  • 57.
    Hot fill VsAseptic Process - Beverages in PETWhy and How – Heat recovery in HF Application of sound Science and Engineering 57 Ashok Dhruv, LLC. (720) 318 - 9000
  • 58.
    Hot fill VsAseptic Process - Beverages in PETWhy and How – Temperature profile in HF – Bottle cooling comparisons 58 Ashok Dhruv, LLC. (720) 318 - 9000
  • 59.
    Hot fill VsAseptic Process - Beverages in PETWhy and How – Hot Fill Vs Aseptic comparison 59 Ashok Dhruv, LLC. (720) 318 - 9000
  • 60.
    Open Innovation –Evolution Research and Develop Acquire and Develop Connect and Develop 60 Ashok Dhruv, LLC. (720) 318 - 9000
  • 61.
    What is OpenInnovation Anyway – Really? The exact opposite of NIH – Not Invented Here Syndrome Ashok Dhruv, LLC. (720) 318 - 900061
  • 62.
    What is OpenInnovation Anyway? Open Innovation is a term promoted by Henry Chesbrough, a professor and executive director at the Center for Open Innovation at Berkeley. The central idea behind open innovation is that in a world of widely distributed knowledge, companies cannot afford to rely entirely on their own research, but should instead buy or license processes or inventions (i.e. patents) from other companies. In addition, internal inventions not being used in a firm's business should be taken outside the company (e.g., through licensing, joint ventures, spin-offs). In contrast, closed innovation refers to processes that limit the use of internal knowledge within a company and make little or no use of external knowledge. Some companies promoting open innovation include Procter & Gamble, Innovation Exchange, NineSigma, InnoCentive, yet2.com, and IBM. Prior to World War II, closed innovation was the paradigm in which most firms operated. Most innovating companies kept their discoveries highly secret and made no attempt to assimilate information from outside their own R&D labs. However, in recent years the world has seen major advances in technology and society which have facilitated the diffusion of information. Not the least of these advances are electronic communication systems, including the internet. Today information can be transferred so easily that it seems impossible to prevent. Thus, the open innovation model states that since firms cannot stop this phenomenon, they must learn to take advantage of it. It is the business model of the firm that determines what external information to bring inside, and what internal information to take outside. Ashok Dhruv, LLC. (720) 318 - 900062
  • 63.
    Our current market Our new market Otherfirm´s market Open innovation External technology insourcing Internal technology base External technology base Henry Chesbrough, 2004 Internal/external venture handling Licence, spin out, divest Ashok Dhruv, LLC. (720) 318 - 900063
  • 64.
    Ashok Dhruv, LLC.(720) 318 - 900064
  • 65.
    Ashok Dhruv, LLC.(720) 318 - 900065
  • 66.
    Ashok Dhruv, LLC.(720) 318 - 9000 Ashok Dhruv Acumen @ Business Sound Technically Highly Motivated Out of the Box Keen on Results Dedicated to team Hands on Robust @ Financials Universal Approach Varied Experience 66
  • 67.
    9958 E. MaplewoodAve., Englewood, CO 80111 [email protected] http://www.productivityandgrowth08.com Ashok Dhruv, LLC (720) 949 – 6498 (Off) (720) 318 – 9000 (Mob) 67 Ashok Dhruv, LLC. (720) 318 - 9000

Editor's Notes

  • #62 A working definition is that open innovation is the inverse video of NIH – Not Invented Here Syndrome. And as this colloquial definition implies, the challenge in pursuing open innovation has much to do with entrenched attitudes and reward structures of internal staff.Despite these challenges, the promise of propelling innovation, achieving competitive differentiation, driving sales, and thus building shareholder value has made open innovation a mantra for many big companies.
  • #63 For those who may be new to the concept of Open Innovations, I would invite you to see wikipedia for a comprehensive definition and discussion of the theoretical concept. You’ll notice that much of the thought leadership on the topic comes from Henry Chesbrough, a professor at Berkley, who wrote a very influential book on the subject. In summation, the concept states that a firm should not rely solely on its internal staff and resources to produce innovations, it should look outside for other sources of innovation. And, it should seek to exploit innovations that it produces by licesing/selling it to outsiders.