JOURNAL OF FOOD SCIENCE

ENGINEERING/PROCESSING

Heat Distribution in Industrial-scale Water Cascading (Rotary) Retort

C. SMOUT, A. VAN LOEY and M. HENDRICKX

ABSTRACT A heat distribution study was performed in an industrial-scale 4-basket water cascading rotary retort under fully loaded operating conditions. Detailed analysis of the temperature distribution basket-by-basket was followed by an evaluation of the temperature distribution throughout the retort (at 0, 4 and 7 rpm). Finally, a heating rate distribution study, using silicone elastomer food-simulants, was carried out to evaluate heat transfer uniformity throughout the retort. Results revealed that for static processes the slowest heating zone was located at the bottom of the basket at the back of the retort, whereas for rotary processes the center of this basket was heated slowest. Heating rate distribution results indicated uniform heat transfer throughout the retort. Key Words: water cascading retort, heat distribution, temperature, heating rate

ditions (heating medium) can be determined by measuring temperatures inside food products and calculating the distribution of heating rates (fh-values) among containers processed. It is a common food industry practice to limit heat distribution studies to the measurement of temperature distribution of the heating medium (Adams and Hardt-English, 1990; Park et al., 1990). Published studies (Tung et al., 1989; Tung et al., 1990; Ramaswamy et al., 1991; Campbell and Ramaswamy, 1992; Tung and Britt, 1992) have indicated that for air-overpressure retorts, heating medium temperature measurements alone were not sufficient to assure consistent heating of products at all points. Analysis of food product heating rate or lethality distribution among processed containers may be required. Nevertheless, temperature uniformity remains an important and necessary criterion for evaluation of retort performance (Ramaswamy et al., 1991). Our objective was to evaluate heat delivery to containers inside an industrial-scale 4-basket water cascading rotary retort (operating in both static and rotary modes) by measuring heating medium temperature and simulated food product heating rate distributions.

INTRODUCTION
STEAM-HEATED WATER WITH AIR-OVERPRESSURE AND STEAM/AIR mixtures are commonly used to sterilize food in glass containers and in flexible and semi-rigid plastic packages. The air-overpressure is used to promote uniform heat transfer and protect package integrity. However, such heating media exhibit lower surface heat transfer coefficients than saturated steam (Adams et al., 1983; Ramaswamy et al., 1983; Tung et al., 1984). Thermal processing of foods should result in safe and high-quality products uniformly throughout the retort. High quality retention is sought by applying minimum lethality values to guarantee product safety. Heating medium agitation (circulation), container layout, can rotation etc. will influence the heat distribution in a retort with direct effects on product safety and quality. Heat distribution and heat penetration studies are part of food process design. Heat distribution studies are performed to ensure adequate lethality at any point, especially to identify the position of lowest lethality. Heat penetration data must be collected for a product positioned in the least heated zone of the retort. Such experiments can be carried out on a pilot retort if the least heated zone of the production retort can be simulated. If the initial conditions (e.g. product and retort temperature) are uniform, the accomplished lethality in the product after processing is dependent only on the retort temperature and heat transfer to and within the product. If temperature and heat transfer rates at any point within the retort are uniform, then all products processed in the retort would receive the same degree of lethality. Such condition is not achievable in practice. Therefore, a complete heat distribution determination, including a temperature distribution study followed by assessment of uniformity of heat transfer to the containers, is required. Differences in product heating as a result of processing conThe authors are affiliated with the Laboratory of Food Technology, Dept. of Food & Microbial Technology, Faculty of Agricultural & Applied Biological Sciences, Katholieke Universiteit Leuven, Kardinaal Mercierlaan 92, B-3001 Heverlee, Belgium. Address inquiries to Dr. M. Hendrickx.

MATERIALS & METHODS

Retort system

Heat distribution was evaluated in a 1400 mm diameter industrial-scale 4-basket water cascading rotary retort (Barriquand Steriflow retort, France) (Fig. 1). Water cascading retorts are heated by a spray of superheated water showered on top layers and flowing from top to bottom. From the bottom, the water is recycled passing through a steam-supplied heat exchanger (at the back of the retort). For cooling the heat exchanger is supplied with cold water instead of steam. Pressure is regulated by introduction of pressurized air. The retort process is controlled by a microprocessor, which independently controls time, temperature and pressure. The retort was fully loaded with 400 mL cans (300405), filled with water in order to generate a high heat demand during the retort come up. Each basket (width height depth = 0.80 0.80 0.85m) contained 7 layers of 110 containers, separated by perforated pads (thickness = 4 mm, cross sectional open area = 35%).

Fig. 1Layout of the 4-basket water cascading rotary retort (A = heat exchanger; B = water inlet; C = water outlet; D = pump; E = air inlet).

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Table 1Processing conditions Temperature distribution studies Come up Overshoot Holding Cooling Cooling 16 min to 127C 2 min to 125C 15 min at 125C 5 min to 75C ASAP to 35C Heating rate distribution studies 16 min to 127C 2 min to 125C 60 min at 125C 5 min to 75C ASAP to 35C

Product-simulants

To measure heat transfer into any container within a retort, product-simulants with thermal properties similar to foods were used in order to minimize variations in thermal properties within containers or changes in heating characteristics with repeated use. In order to minimize any change in the flow profile of the heating medium, product-simulants with the same dimensions and shape as that of the product containers were developed. Silicone elastomer (Sylgard 170, Dow Corning, CCMP, Belgium) cylinders were constructed to simulate strict conduction-heating products. The simulants were calibrated three times in a pilot steam heated retort to determine the heating response under conditions of near infinite surface heat transfer coefficients. The temperature was monitored in the center of each cylinder and the location of each cylinder in the retort was changed for each run. The calibration indicated no difference (p>0.05) in heating rates (fh-values) between calibration runs, but a difference (p<0.05) in fh-values among some simulants was observed. To correct for sample-to-sample variability heating rate measured in a heating rate distribution study was normalized by dividing by the mean heating rate in pure steam (fh,HD/fh,calibration).
Temperature measurement

tached to the sides, but not touching the containers. Based on results of the temperature distribution study basket-by-basket, the containers were located such that the thermocouple locations represented extremes in temperature to which containers may be exposed during the process cycle. In each basket, 5 thermocouples were placed as follows: in the center of the bottom layer, in the center of the middle layer, on the right of the middle layer, on the left of the middle layer and in the center of the top layer (Fig. 3a). The temperature distribution throughout the retort was determined at 0, 4 and 7 rpm and the retort was programmed as indicated (Table 1). As with the basket by basket studies, an equilibration phase at 40C was included to minimize the spread among thermocouple readings, at different positions within the retort, to 0.1C at the start of each temperature distribution test. To confirm results, each experiment was performed in triplicate (runs 1, 2 and 3).
Heating rate distribution throughout the retort

At 15 positions (Fig. 3b) within the fully loaded retort, waterfilled containers were substituted with product-simulants. The simulants were fitted with thermocouples at the geometric center. Next to each simulant the temperature of the heating medium was also recorded. These data were used to calculate the heating rates. The distribution of heating rate into product-simulants throughout the retort was investigated at 0, 4 and 7 rpm. Conditions were similar to those for temperature distribution studies (Table 1). The holding phase was extended to 60 min. to accurately estimate the heating rate (fh-value). Each experiment was carried out in duplicate (runs 1 and 2).

RESULTS & DISCUSSION

Temperature distribution basket-by-basket

Temperatures were recorded at 15 s intervals using a MDP 8250 datalogger (Mess+System - Technik GmbH). The (V-signal of the datalogger was calibrated against a thermocouple voltage calibrator (PVG77, Ellab, Denmark). The datalogger was connected to a personal computer and installed with a 30-channel thermocouple box containing the reference junction. The output had an accuracy of 0.1C. All temperature sensors were copper-constantan thermocouples (type T). We made thermocouples (Omega thermocouple wire, TT-T-24, USA) to measure the processing medium temperature in the retort. For the heat penetration in product-simulants, thermocouple probes, needle-type with rounded tip (SSA-12080-G12M-TF, Ellab, Denmark), were used. Thermocouples were calibrated in an oil bath at 90C against a calibrated quartz-thermometer (testo 781, Testoterm, Belgium; resolution = 0.001C and accuracy = 0.1C) and a performance check was carried out in a pilot water cascading retort at the processing temperature. A 32-channel slipring contact (Ecklund, USA) was used during rotary processes.
Temperature distribution basket by basket

The temperature distribution study revealed that for static processes the slowest heating zones were at the bottom of the baskets, while for rotary processes the slowest heating zones were located in the center. These results were expected since the spray of superheated water showered on top of the retort streams down over the containers releasing heat. No fastest heating zones were identified. The temperature-time profiles indicated that the spread of thermocouple readings during come up was remarkably wider in basket 1 (back of the retort) than in the other baskets. The mean and standard deviation of temperatures at all thermocouple locations were calculated. The standard deviation at the be-

To determine the extremes in temperature, to which containers are exposed during a process cycle, 30 thermocouples were located within one basket, attached to the sides, but not touching the containers. This basket was repositioned within the fully loaded retort at each run to determine temperature distribution at each basket-position (Fig. 2). At each basket-position, the temperature distribution within the basket was tested in the static mode as well as in the rotary mode (7 rpm). The process consisted of several stages (Table 1). An equilibration phase at 40C preceded each process so that thermocouple readings at different positions within the basket were 0.1C at the start of each test.
Temperature distribution throughout the retort
Fig.2Thermocouple layout for a temperature distribution test basket by basket.

Thermocouples (20) were distributed throughout the retort, at-

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Table 2Temperature distribution basket by basket Std dev begin HT (C) 0.84 0.18 0.26 0.13 0.69 0.25 0.28 0.26 T T after T after begin HT 1 min. HT 3 min. HT (C) (C) (C) 3.4 1.0 1.0 0.5 2.5 1.1 1.0 1.1 2.5 1.0 0.5 0.6 1.9 0.8 0.8 0.9 1.0 0.5 0.5 0.6 0.9 0.6 0.8 0.4 T after 5 min. HT (C) 0.7 0.8 0.6 0.6 0.5 0.6 0.5 0.4

Basket 0 rpm 1 2 3 4 1 2 3 4

7 rpm

water cascading static retort (1300 mm diameter, loaded with 211212 cans filled with water; Adams and Hardt-English, 1990), resulted in temperature differences between the highest-reading and lowest-reading thermocouple of 2.2C during the first minute, 1.0C by the third minute and 0.8C by the fifth minute. With the loading configuration and under the processing conditions we used, the temperature distribution of basket 1 confirmed their reported results. The temperature distribution of the other baskets was more uniform.
Temperature distribution throughout the retort

a Standard deviation (std dev) at the beginning of holding time (HT) and temperature

difference ( T) between highest-reading and lowest-reading thermocouple at the beginning of holding, and after 1, 3 and 5 min holding time.

Table 3Temperature distribution throughout the retort T after T after T after Std dev T begin HT begin HT 1 min HT 3 min HT 5 min HT (C) (C) (C) (C) (C) 0.83 0.91 0.98 0.76 0.66 0.77 0.76 0.76 0.76 3.8 4.1 4.6 3.2 2.7 3.1 2.9 3.2 3.0 2.5 2.6 3.0 3.0 2.3 2.0 1.9 2.0 2.4 1.3 1.2 1.6 1.5 1.9 1.6 0.9 0.7 1.3 0.7 0.6 0.8 0.8 1.1 0.7 0.4 0.3 0.5

Run 0 rpm 1 2 3 1 2 3 1 2 3

4 rpm

7 rpm

a Standard deviation (std dev) at the beginning of holding time (HT) and temperature

difference ( T) between highest-reading and lowest-reading thermocouple at the beginning of holding, and after 1, 3 and 5 min. holding time.

ginning of holding and the temperature difference between the highest-reading and lowest-reading thermocouple at the beginning of holding, and after 1, 3 and 5 min. holding were summarized (Table 2). Standard deviations and temperature differences were largest in basket 1 for static and rotary processes. The deviation and difference values for basket 2, basket 3 and basket 4 were slight. The reported temperature distribution in one basket of a 4-basket

The temperature-time data for the retort indicated that for static processes, the thermocouple at the bottom of basket 1 (back of the retort) was heating (and cooling) slowest. For rotary processes the thermocouple in the center of basket 1 was heating (and cooling) the slowest. These results seemed to reflect the water and/or air inlet. Superheated water was brought into the retort through a distribution manifold near basket 1 in the direction of the front of the retort. Because of this arrangement basket 1 could partly miss the water spray. Cold air was also injected into the retort near basket 1. The standard deviations of temperature for all thermocouple locations and the spread of the thermocouple readings at each time interval were used to evaluate the temperature distribution throughout the retort. The standard deviation at the beginning of holding and the temperature difference between the highest-reading and lowest-reading thermocouple at the beginning of holding, and after 1, 3 and 5 min. holding were compared (Table 3). Rotation slightly improved temperature distribution: the standard deviations and temperature differences at the beginning of the holding phase were not different (p>0.05). We concluded that the standard deviation and temperature differences calculated for basket 1 (Table 2) were the same order of magnitude as the standard deviation and temperature differences calculated for the whole retort (Table 3). NFPA (1985) advises that all points in a steam retort should be at or above the desired process temperature within one minute after the retort reaches the process temperature and the holding phase is started. In addition, all thermocouple readings after the first minute should have a maximum range 1.7C and should be within 0.8C of the reference temperature device. The loading configuration and the dif-

Fig. 3Thermocouple (and simulant) layout for (a) temperature distribution test and (b) heating rate distribution test throughout the retort. Side-view of positioning of baskets in the retort.

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Table 4Temperature distribution throughout the retort Spread mean Ta (C) 0.8 0.7 0.9 1.1 1.1 1.2 0.5 0.7 0.8 Overall mean T (C) 125.5 125.5 125.4 125.7 125.3 125.3 125.5 125.0 125.1 Overall std dev (C) 0.16 0.15 0.19 0.23 0.31 0.32 0.14 0.20 0.19

Run 0 rpm 1 2 3 1 2 3 1 2 3

4 rpm

7 rpm

a Spread of mean temperatures at different locations during holding and overall mean

temperature and standard deviation during holding.

ferent processing conditions used in the test showed that temperatures of the retort did not meet NFPA recommendations. For each thermocouple location, the mean and standard deviation of the temperature during holding were calculated to enable detection of cold spots and measurement of temperature stability at each location. For static processes (Fig. 4a) the coldest zone was situated at position 1, the center of the bottom layer of basket 1. For rotary processes (Fig. 4b) the coldest zone was situated at position 2, the center of the middle layer of basket 1. This trend was exhibited for all runs. The temperature stability seemed to be better (smaller standard deviations) for the static process than for the rotary process. This could be attributed to small temperature fluctuations at each thermocouple location as a result of periodical interruptions of the continuous water flow by rotation. The spread of mean temperatures at the different locations during holding (15 min) and the overall mean temperatures and standard deviations during holding were compared (Table 4). The spread varied between 0.5C and 1.2C and the overall standard deviation ranged from 0.14C to 0.32C. A temperature distribution study was reported for a standard 1basket (0.810.810.81m) water cascading retort (Ramaswamy et al., 1991). The maximum spread of mean temperatures at various locations during holding (27 min. at 121C) was 0.6C. The maximum overall standard deviation in retort temperature during holding was 0.71C.
Heating rate distribution throughout the retort

The resulting fh-values at each position for each experimental run were calculated and compared (Table 5). The fh,HD/fh,calibrationvalues were only slightly higher than 1, indicating that the fh-values in a water cascading retort were only slightly higher than those for a condensing steam retort. There were almost no limiting heat transfer conditions when superheated water was used as heating medium. The difference in fh-values was <5%. Thus, heat transfer from the heating medium to the containers was uniform throughout the retort. Once the least heated zone of the retort has been identified, heat penetration data could be collected by locating heat penetration samples in that zone. Also the least heated zone could be simulated in a pilot retort in order to determine the heating and cooling characteristics of the product. Those characteristics would then enable the design of an effective process.

CONCLUSION
THE BASKET-BY-BASKET TEMPERATURE DISTRIBUTION INDICATed that in the static mode, the slowest heating zones were at the bottom of the baskets, while in the rotary mode they were at the center of the baskets. Temperature distribution revealed that in the static mode the slowest heating zone was at the bottom of basket 1, while in the rotary mode it was in th\e center of basket 1. Temperature stability at the different locations within the retort was decreased by rotation. Heating rate distribution showed that heat transfer was uniform throughout the retort. Thus temperature distribution would be

Fig. 4Temperature stability and variability during holding in a water cascading retort: (a) static mode and (b) rotary mode at 7 rpm. The horizontal line represents the overall mean holding temperature.

Table 5Heating rate distribution throughout the retort fh,HD/fh,calibration Position 1 0 rpm 4 rpm 7 rpm Run 1 2 Run 1 2 Run 1 2 1.057 1.060 1.051 1.063 1.031 1.032 2 1.025 1.038 1.063 1.066 1.043 1.036 3 1.029 1.038 1.037 1.055 1.036 1.036 4 1.019 1.039 1.032 1.050 1.044 1.030 5 1.040 1.044 1.043 1.058 1.027 1.031 6 1.037 1.045 1.036 1.030 7 1.024 1.034 1.041 1.045 1.054 1.018 8 1.046 1.053 1.048 1.060 1.044 1.035 9 b 1.050 10 1.026 1.030 1.024 1.019 1.026 1.026 11 1.038 1.030 1.038 1.038 1.013 12 1.033 1.048 1.039 1.064 1.039 1.027 13 1.046 1.045 1.043 1.060 1.046 1.039 14 1.027 1.030 1.032 1.053 1.031 1.026 15 1.041 1.035

a f -value measured in the heat distribution test (f h h,HD) divided by the mean fh-value of the calibration in steam (f h,calibration). b Missing values are indicated by .

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an appropriate measure to detect the lowest lethality zone. These results describe a protocol for testing retort systems to assure minimum lethality. Although such data may vary from one retort to another, it provides a guide as to where to expect the slowest heating zones and the extent of variations that might be expected.
Ramaswamy, H.S., Tung, M.A. and Stark, R. 1983. A method to measure surface heat transfer from steam/air mixtures in batch retorts. J. Food Sci. 48: 900-904. Ramaswamy, H., Campbell, S. and Passey, C. 1991. Temperature distribution in a standard 1-basket water-cascade retort. Can. Inst. Food Sci. Technol. J. 24(1/2): 19-26. Tung, M.A. and Britt, I.J. 1992. Heat transfer efficacy of overpressure media in rotational thermal processes for shelf stable foods in plastic packages. Ch. 12 in Advances in Food Engineering, R.P. Singh and M.A. Wirakartakusumah (Ed.), p. 207220. CRC Press, Boca Raton, Ann Arbor, London and Tokyo. Tung, M.A., Ramaswamy, H.S., Smith, T. and Stark, R. 1984. Surface heat transfer coefficients for steam/air mixtures in two pilot scale retorts. J. Food Sci. 49: 939943. Tung, M.A., Morello, G.F. and Ramaswamy, H.S. 1989. Food properties, heat transfer conditions and sterilization considerations in retort processes. In Food Properties and Computer-aided Engineering of Food Processing Systems, R.P. Singh and A.G. Medina (Ed.), p. 49-70. Kluwer Academic Publishers. Tung, M.A., Britt, I.J. and Ramaswamy, H.S. 1990. Food sterilization in steam/air retorts. Food Technol. 44(12): 105-109. Ms received 7/29/97; revised 3/30/98; accepted 4/23/98.
This research has been supported by the European Commission, Project AIR2-CT94-1017.

REFERENCES
Adams, H.W. and Hardt-English, P.K. 1990. Determining temperature distribution in cascading water retorts. Food Technol. 44(12): 110-112. Adams, J.P., Peterson, W.R. and Otwell, W.S. 1983. Processing of seafood institutional-sized retort pouches. Food Technol. 37(4): 123-127. Campbell, S. and Ramaswamy, H.S. 1992. Distribution of heat transfer rate and lethality in a single basket water cascade retort. J. Food Process Eng. 15: 31-48. NFPA. 1985. Guidelines for thermal process development for foods packaged in flexible containers. National Food Processors Association, Washington, DC. Park, D.J., Cabes, L.J. Jr. and Collins, K.M. 1990. Determining temperature distribution in rotary, full-immersion, hot-water sterilizers. Food Technol. 44(12): 113-118.

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