1. STERISTEP® Germ reduction for low moisture products
(spices, herbs, dehydrated vegetables, seeds, nuts…)
Process owned and worldwide patented by FCD

2. CONTENTS How was born STERISTEP® ? Process description Process control1.
How was born STERISTEP® ? 2.
Process description 3.
Process control 4.
Products treated 5.
Sum-up of the advantages

3. Overview of existing technologies

4. 1st generation: Autoclave technology Sterilizer and pasteurizer
Fluid bed technology
Continuous Autoclave system
TEMA
VENTILEX
IMTECH NAPASOL HOSOKAWA
Advantages:
Sterilization ensured
Parameters controlled
can treat powders and big particles size
can treat small lots
Limitations:
Equipment , labor and maintenance costs (moving parts, filters,
Cleaning
Batch system
Limitations:
No small lots
Cleaning time is 50% of production time.
Quantity of steam: roughly 10 times more than other technologies in continuous. So fragile products like thyme, sage or rosemary don't have any more essential oil at the outlet
Hygroscopic products like pistachios get very wet
Advantages :
Vibration: no damage to particles
Easy scale up as thickness of bed is regular, increasing capacity is increasing width.
Can treat powders of big forms
Can achieve sterilization.
Perfect for a customer treating only one product like pepper (lot of sporulated forms)

5. 2nd Generation: Pasteurizing system
3rd generation: Safesteril pasteurization system (joule effect)
Advantages:
Transport by vibration, no damage to particles
Product is heated by contact with tube, 10 times less steam than Ventillex or Tema
Can achieve pasteurization (not sterilization).
Limitations:
Minimum of quantity is 250 KG, no small lots
Cannot treat powders (due to rheologic effect)
Cannot treat too big particles like cinnamon sticks
Can only feed the tube to 1/3
Impossible to guarantee the inside is clean
Long cleaning time (8 hours for 2 people to clean the line)
Poor bacteriological results when the sizes of particles have a big range: vibrations make segregations, fines go down, big particles go up, there’s no mixing in the tube so steam cannot treat the bottom products.
REVTECH
ETIA
Advantages:
Can treat powders
heat by contact, less steam is injected.
product is heated by contact with tube, 10 times
less steam than Ventillex or Tema
can achieve pasteurization ( not sterilization).
Limitations:
Transport by screw, risk of damage the particles when big especially in the bypass section
Minimum of quantity is 250 KG, no small lots
cannot treat too big particles like cinnamon sticks
can only feed the auger to 1/3
long time to clean 8 hours for 2 people to clean the line

6. 1. How was born STERISTEP®?
Elodie Janson & Nicolas Braun Die Traumfabrik Dubai

7. How was born STERISTEP® ?
What are the key properties to have good process ?
Possibility to treat large/sensible particles ? YES Vibrations used
Possibility to treat powders ? YES Vibrations used
Possibility to treat small lots ? YES No minimum feeding grade required
Homogeneity of the treatment ? YES Steps ensure the mixing
Easy, quick and accessible cleaning ? YES <3hrs for a 3,300lbs/h unit
Low energy cost ? YES <90 kWh/ton
Low maintenance cost ? YES < $1000/year
TERP validated process ? YES 6log reduction of E. Faecium
 For the first time ever, a steam pasteurization equipment was designed in order to
meet a need, rather than adapting from an existing technology

8. 2. Process description

9. DECONTAMINATING UNIT ”DS”
2. Process description
General view of the process
CHILLER / AIR DRYER
COOLING UNIT ”CS”
HOPPER & DOSING
DECONTAMINATING UNIT ”DS”
STEAM BOILER

10. 2. Process description Hopper Vibrating dosing system
Hopper and dosing system
Hopper
Level probes indicate the remaining level of product
Possibility to control an automatic feeding system
OPTION : hopper can be placed on a weighing system
(indicates the flow of product treated in kg/h)
Vibrating dosing system
Vibration = no risk of breakage
Continuous and regular flow
Height (thickness) of the product is controlled for a homogeneous treatment
Easily accessible for cleaning and inspection

11. 2. Process description Conveying method
DS : Decontamination System (1/5)
Conveying method
“Staircase” design in stainless steel
9 steps
2 vibrating engines
Particles move from one step to another – from top to bottom
Fine powders (2 microns) or whole products (chili pods, breakable herbs)
smooth and continuous mixing of the particles
regular exposure to steam
homogeneous treatment and final product

12. 2. Process description
DS : Decontamination System (2/5)
HEAT and STEAM : two sources of energy for more flexibility and effectiveness
Direct heat
Particles heated by contact with a heated stainless steel surface
Heat comes from simple electrical resistances
= low energy consumption
4 sides heated
= condensation avoided
= high heating surface/m2
= fast rise of product temperature
= short residence time
= preserves the organoleptic properties of the product
Heating surface
Heatingsurface

13. 2. Process description
DS : Decontamination System (3/5)
Steam (100 – 120°C / 220°F – 275°F) : necessary for decontamination
Injected with nozzles at the bottom of each step :
To slightly condense on the product
To increase the heat conductivity
To control the moisture of the product during
the treatment
steam injection with nozzles is controlled

14. 2. Process description
Heat and Steam Balance
Heat conduction
Heat convection
Heat and steam can be adjusted for a greater flexibility.
Plate temperature
Steam quantity
For herbs :
For pepper :
Plates
Steam

15. 2. Process description Some of the products treated
DS : Decontamination System (4/5)
Some of the products treated
Mushrooms
Pistachios
Cinnamon sticks
Rice flour

16. 2. Process description No minimal quantity required
DS : Decontamination System (5/5)
No minimal quantity required
Possibility to treat small lots (5 – 10 kg)
… and still have big capacities (20 – 40 tons)
… on the same equipment !

17. 2. Process description
Bypass section (optional)
Decontamination unit
cooling unit
bypass
Isolates the “warm” area (decontamination) and “cold” area
(cooling)
If product has not reached sufficient temperature or residence time,
it is ruled out.
Separates the treated and non-treated products
No disruption of the decontamination cycle
Run trapdoor can be adjusted with control parameters

18. 2. Process description CS : Cooling System Product inlet
Product outlet at room temperature
cold water circulating

19. 2. Process description
CS : Cooling System
Importance of the cooler : to stabilize the product and to pack it without risk of recontamination
Vibrating plate cooled by water (cross-current)
Filtered, cold and dry air injected at the input = to avoid condensation of the steam
Product reaches a room temperature (20-30°C)
No more bacterial development

20. 2. Process description
Annexes
STERISTEP® requires 3 fluids for the decontamination
Steam generator : “culinary” steam produced for the
decontamination unit (5% of the flow of treated product at 6 bars)
Air dehumidifier : injection of filtered, cold and dried air at the
input of the cooler to remove the moisture of the steam remaining
within the hot product
Water chiller : cold water (5-12°C) is circulating in the double jacket
of the cooler. Closed loop (no water consumption)

21. 2. Process description Low maintenance and spare parts
Maintenance and Online support
Low maintenance and spare parts
Main maintenance : change the fan filters
Online support : control cabinet connected to the Internet with a modem
Online troubleshooting
Software update
Assistance for the production

22. Water goes to one collecting point
2. Process description
Cleaning
The key of success for a flexible production
Designed for a quick cleaning
Complete accessibility : no “hidden” area
All parts can be visually controlled
Dry cleaning : vacuum
Wet cleaning : water and bactericides / washing soda
“Water fall” design
Water goes to one collecting point

23. 2. Process description
STERISTEP models
4 models from 550lbs/h to 2,640lbs/h are available
STERISTEP 25
STERISTEP 50
STERISTEP 75
STERISTEP 100
Units can be doubled for more capacity !

24. 2. Process description Configuration adjusted to your building layout
DS 1
Incoming product Area
CS 1
Separation wall
“clean”  area

25. 2. Process description Configuration adjusted to your building layout
DS 1
CS 1
Separation wall
“clean”  area
Incoming product Area

26. 2. Process description Configuration adjusted to your building layout
“clean”  area
CS 1
Bypass
DS 1
Separation Wall (Recommended)

27. 1,100 lbs/h unit for herbs & spices
2. Process description
Example of configurations
STERISTEP 50
1,100 lbs/h unit for herbs & spices

28. 6,600 lbs/h unit for almonds & pistachios
2. Process description
Example of configurations
STERISTEP 75
6,600 lbs/h unit for almonds & pistachios

29. 2x 1,700 lbs/h unit for herbs & spices
2. Process description
Example of configurations
DOUBLE STERISTEP 75
2x 1,700 lbs/h unit for herbs & spices

30. 2. Process description
Video of the process
Here is the link to a video showing the process :
Video Link
(or type “FCD SAS” in Youtube/Dailymotion)

31. 3. Process control

32. 3. Process control Control of the process Recipe function
Control cabinet, PLC and supervision
Control of the process
Motors, temperature probes, level probes,
steam and air exhaust, control of the annexes..
Recipe function
Parameters saved and programmable
Control panelview
Possibility to send automatically the data
per at the end of a production
Connected to Internet for E-assistance

33. 3. Process control Saves the “history” of the process Safe recording
Traceability software
Saves the “history” of the process
Temperature, alarms… are recorded
Safe recording
A new file is generated for each recording
Access by login and password for each
operator / administrator
Multiple input data for each recording
Customer name and folder, batch numbers,
order numbers, formula data…
Recall function
To review a past production’s data
Export in Excel format

34. 4. Products treated

35. 4. Products treated Pasteurization Sterilization Application
Inactivation of pathogens : E. Coli, salmonella, reduction of yeast, molds and other coliforms
Sterilization
Up to 5 logs reduction of the Total Plate Count (TPC) *
Inactivation of pathogens : E. Coli, salmonella, reduction of yeast, molds and coliforms
* FCD does not guarantee any effect on heat resistant forms such as spores, bacilli that might not be eliminated by treatment.

36. Dehydrated vegetables
4. Products treated
Family of products : NO LIMIT OF SIZE
Spices
Herbs & Tea cuts
Dehydrated fruits
Seeds & Nuts
Dehydrated vegetables
… and more !

37. 4. Products treated MUSHROOMS Other products RAW TEST 1 TEST 2 TEST 3
TPC
11 000
1 000
Enterobacteriaceae
41 000
350 10
Yeast
Molds
600

38. 4. Products treated PARSLEY GARLIC SLICES Other products RAW TEST 1
TPC
1 000
Enterobacteriaceae
27 000
<10
Yeast
Molds
280
RAW
TEST 1
TPC
710
Enterobacteriaceae
<10
Yeast
Molds

39. 4. Products treated CHILI PODS CINNAMON STICKS Other products RAW
TEST 1
TPC
<100
Enterobacteriaceae
<10
Yeast
>
Molds
CINNAMON STICKS
RAW
TEST 1
TPC
120
Enterobacteriaceae
110
<10
Yeast
1 200
Molds
7 300

40. 4. Products treated PEPPERMINT LEAVES SAGE Other products RAW TEST 1
TPC
2 100
Enterobacteriaceae
1 200
<10
Yeast
Molds
<40
RAW
TEST 1
TPC
140
Enterobacteriaceae
29 000
<10
Yeast
<100
Molds
18 000

41. 4. Products treated PISTACHIOS WALNUTS Other products RAW TEST 1 TPC
<40
Enterobacteriaceae
210
<10
Yeast
Molds
WALNUTS
RAW
TEST 2
TPC
<10
Enterobacteriaceae 80
Yeast
Molds
2 400
<40

42. 4. Products treated ALMONDS Other products RAW TEST 2 TPC 330 000 120
Enterobacteriaceae 70
<10
Yeast
Molds
59 000

43. 4. Products treated CINNAMON POWDER CHILI POWDER Other products RAW
TEST 1
TPC
380
Enterobacteriaceae
27 000
<10
Yeast
260
Molds
RAW
TEST 1
TPC
46 000
Enterobacteriaceae
2 100
<10
Yeast
Molds
150

44. 4. Products treated BLUE POPPY SEEDS WHITE PEPPER Other products RAW
TEST 1
TPC
1 800
Enterobacteriaceae
3 600
<10
Yeast
Molds
WHITE PEPPER
RAW
TEST 1
TPC
26 000
Enterobacteriaceae
1 600
<10
Yeast
Molds
7 500

45. 4. Products treated CORIANDER SEEDS GINGER SLICES Other products RAW
TEST 2
TPC
850
Enterobacteriaceae
1 400
<10
Yeast
Molds
GINGER SLICES
RAW
TEST 1
TPC
10 000
Enterobacteriaceae
160
<10
Yeast
Molds

46. 4. Products treated TURMERIC POWDER FENNEL SWEET WHOLE Other products
RAW
TEST 2
TPC
23 000
Enterobacteriaceae
<10
Yeast
Molds
<40
FENNEL SWEET WHOLE
RAW
TEST 2
TPC
9 300
Enterobacteriaceae
<10
Yeast
Molds
6 600
<40

47. 5. Summary of the main advantages

48. 5. Sum-up of the advantages
‘Conti-batch’: possibility to treat small lots (<10kg) even though system is continuous
Vibrations are used to convey the product
= possibility to treat all sizes of product (30cm cinnamon sticks…)
= no breakage of sensible products (tea, leafs…)
= possibility to treat powders
Quick cleaning and product changeover (<3hrs for the complete line)
Low electrical consumption (= 90 kWh/ton)
Low maintenance (< 1,000€/year)
Validated process – complete pasteurization guaranteed
1-5 TPC log reduction guaranteed

49. NEW CONTINUOUS ROASTING/DRYING PROCESS !!
6. Other equipments proposed
NEW CONTINUOUS ROASTING/DRYING PROCESS !!
for dried fruits, cocoa, coffee…

50. ZA sycala cahors sud enteste 2
ZA sycala cahors sud enteste 2
46230 Fontanes - FRANCE