The Effect of Cheese and Tofu Properties on the Expansion

Mechanism during DIC (controlled sudden decompression)

ISMAIL SULAIMAN1, 2, VACLAV SOBOLIK1, AND KARIM ALLAF1.
1University

of La Rochelle, Intensification of Transfer Phenomena on Industrial Eco-Processes,

Laboratory Engineering Science for Environment LaSIE FRE 3474 CNRS, 17042,
La Rochelle, France

2Jurusan

Teknologi Hasil Pertanian, Fakultas Pertanian, Universitas Syiah Kuala,

Banda Aceh 23111, Indonesia

Abstract
Nowadays, the expansion process in the food productions were allowed to using a DIC
method as one of new methods have being developing. In this process used a steam or
pressure with a basic transformation of material into a ready product without a
changing in the material structures and a product size. The DIC Technology to be use for
short time of treatment process with a high temperature. The phenomenon of autovaporization for water expansion and instant cooling products were held in same time.
The DIC will be improving for the drying kinetics and to obtaining in the final products
with higher quality in the texture terms, an organoleptic quality and health (full
decontamination). The evolutions of the structures function by a temperature that cause
of pressure saturated steam and material properties were never been analyzed in basic
and detail.
DIC process also performed by using a steam controlled in pressure and in a certain time
(seconds) that can produces with very big change in a product size. The mechanism of
process change into an expansion will seen produce in the products images that used a
high-speed camera (1/1000 sec); where they allows us to monitor for the structure of
materials in a DIC treatment and we could compared to the real size with the bulk
density measurements. The results have been compared and the analysis results in an
expansion will shows into best value. This experimental was conducted for two food
products; they are cheese and Tofu. Therefore, these products could be produced into
very large expansions than other food products. Finally, the study results will show how
much pressure, time and temperature needing in fatherly produces with the greatest
expansion, and who to generate and to an optimum product in the characteristics
changes.
Keywords: DIC, Expansion, Cheese, Tofu, Vacuum, image analysis

Corresponding author
Email : ismail.sulaiman@univ-lr.fr

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Nomenclature
m0

mass of a volume before (g),

m1

mass of cylinder (g)

m1,2

mass of sand (g),

m0

mass of the sample (kg),

volume of sand (cm3)

Vp

volume of product (cm3)

saturated steam pressure during heating phase of DIC treatment (MPa),

thermal treatment time of DIC treatment (s),

specific density of sand sample (kg m-3).

1. Introduction
Expansion process is phenomenon to develop energy into material, this is due to a burst
of energy from the material, the material characteristics will be change, if the pressure
or energy intake in the food quickly, then the process of change in these characteristics
will be faster as well, this is seen in the expansion process is carried out in vacuum
conditions. The expansion process of a product begins with the pre-treatment products;
pre-treatment product made by drying process.
There are many types of drying processes are carried out in reducing the moisture
content of materials in the product such a reduction of water content in food can be
combine with heat and mass transfer. In general, an elimination of the existing water is a
phenomenon of solid bonding material on the formation of the final product. In a case
study; the process of drying water contents in the material gives two stages. Firstly, the
water contents in the food can produce the result of product. However, is not a hundred
percent because a few percent will stay into the materials. Secondly, the reduction
process of water contents in food quickly leads to changes in the structure of the
characteristics of a product.
According to Louka [2004]; the principle of expansion used steam, based on a selfvaporization for the moisture contained in a piece of food; this has take place to the
influence of sudden pressures to release an atmospheric pressure. Also a product with
viscous-elastic behaviour will extend to the high temperature and the effect of the
constraints of the steam was decompression, thereby creating porous structure in the
product.
Moreover, the expansion process used the DIC has been discussed by Louka [1996 and
2004]. Indeed, the development of DIC has been used to process a product treatment
instantaneity in vacuum conditions. Whereas the textures process of food products at
DIC process has done very fast with using high pressure, while the temperature to 250
oC that has starting from initial condition vacuum and they very fast process. In addition,
this process is a new way to change the characteristics of food with quickly process
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However, the expansion by self-vaporization for the treatment cycle did not really
evolve, it was performed in a role that set a standard by under steam pressure in a quite
high temperature by following the decompression towards of an atmospheric pressure.
Like a cycle, the treatment of heat sensitive food product becomes very delicate. Thus,
this change was limited and generally, only concerned to an enhancing production
capacity or sometimes to produce for an automation and reduction of processing coast.
The structures changes made on food products that have been done in a pre-treatment a
come out to enable a steam entrant into a product and also to remove easily.
Particularly, for the technical operation of this machine can be done to control of the
food properties such as level of pressure, the temperature and the water content and
also the thickness of product as well to be analyzed. Because a thick product can be
analyzed and need a time to change the products characteristics. Hence, quality of the
product results will be investigated several response parameters: for instance the
expansion of products, the bulk density and images used.
This study, texturizing process by self evaporation within partially dried product has
been used in long studies. In the middle of 20th century, Harrington & Griffiths [1950]
used this type of treatment with vegetable. Today, the development in the textuizing
process by self vaporization; Dtente Instantaneite Controlee (DIC) by Louka [1996]
showed that this process can be used to treat biological products in the heat sensitive.
He described that the amount of steam generated by self vaporization is almost greater
when the final equilibrium temperature is low. In same study case by Louka & Allaf
[2002], cooling treatment will more intense if the final equilibrium pressure is low.
Finally, the aim of this work is to analyse the influence of pressure and time into
condition vacuum for cheese and tofu products in the final quality using DIC process.

2. Material and Methods

2.1. Raw Materials
This work presented into two raw materials: cheese and Tofu. We used Cheese
Emmental Francaise by Entre Mont product; the product that we use for this experiment
is originally from France. A cheese Emmental with 29% fat finished product and cutted
to some pieces with dimension 20 x 15 x 15 mm, and also we dried using conventional
drying oven with temperature 40C for 62 hours.
The Second material that we used Tofu with grains Soya natural without OGM. These
materials are contain water, calcium sulphate (E516) and cutted to some pieces with
dimension 14 x 15 x 10 mm, also we dried using conventional drying oven with
temperature 40C for 24 hours.
In this experiment, we used methodology with different expansion and this study might
be allowed for snack foods industry. In this experience, we propose to see the expansion
of characteristic with new technology DIC. In this case, the higher fat content and
thickness give the effects to process expanded.

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2.2. Procedure
The general treatment procedure is present in Figure 1. It involved preparing the
product; cleaning, partial drying, preparation product, DIC Processing and final
Expansion.
Fromage and Tofu
Cleaning and cutting
Pre-treatment by Drying

Humidity

Treatment by DIC
Reactor
Condition Vacuum
Injection air steam

Condition under pressure

Condition high Pressure

Temperature
Picture and Video
Expansion
Fig 1. Schematic diagram of global processing

Pre experiment
The products have been drying in oven with temperature 40C for 62 hours until the
water contain in the product was stable where Cheese and Tofu was stable to
temperature 40C for 62 hours.
DIC treatment includes several steps: the product was placed under vacuum; that means
this treatment under pressure until 1 bar Absolute and then exposed to high pressure
through the injection of saturated steam, which pressure (P) and time (t), those
underwent a decompression to the vacuum before the return to atmospheric pressure.
During time process, we rapidly made record images for temperature inside products,
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temperature reactor and pressure inside reactor. This treatment was followed for a final
drying in order to bring the product back to the water content that will necessary
storage.
After the experimental done, the product was calculated for the expansion and weigh. It
used to see a product lost during the process expansion. In this study, we used statgraphic for data analysis and repeated for three times.

Fig 2. Temperature and pressure history of a DIC processing cycle PA, pressure in
autoclave; PV, pressure in vacuum tank TA, temperature in autoclave; TP, temperature of
product.
This process used fast speed camera Nikon and Photron software that made for data
record which is use for all of the temperature, pressure, and time. At the same time and
we also produced for 1000 images per second.

2.3. Measurement of physical Properties

Before, measurement of physical ingredients of cheese and Tofu, we use tried and error
for some sample and we used stat-graphic to determine good point of expansion.
Products
Cheese
Tofu

Pression (MPa)
Temps (s)
Low High
Low High
3,0
5,0
40,0 50,0
5,0
6,0
40,0 50,0
Table 1. Analysis Product

We also created a Central composite design: 2^2 + star design which the effects of 2
factors in 13 runs. This design is to run into a single block and the order of the
experiments has been fully randomized.
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2.3.1. Expansion 3D
Calculation of expansion can be done several ways; directly and indirectly , one of them
direct expansion is expansion 3D. Direct Expansions (t) can be calculating value
dimensions directly; the calculation is done by calculating the dimensions of a product
and we can found the volume of the product.
This calculation depends on the product for example: product characteristic, thickness,
composition, dry basis and etc. We compare the product before DIC process and the
product after DIC process.
Volume = long x width x large; for material cubic, this experiment we used product in
condition cubic.
2.3.2. Expansion ratio
This expansion has been made by Louka, 2004. However, the method we will use in this
experiment will be change slightly different but the basic theory was taken from the
journal.
The expansion ratio is the method for calculated the volume of products dry expansion.
We use this method for control the volume of the products volume
Normally, this method is known by the bulk density of dry piece product, it was
measured by using a fine/sand powder; it was obtained from difference in weight
between two identical volumes; one is contained only powder and the other is contained
powder that we used under study.
The product was covered with the used of sand powder by one or a series of mechanical
shakes until the volume was reached, before being weighed. The calculation of the bulk
density of the product which involved to measuring the bulk density of packed powder.
This measurement was performed as above but without the product before. The bulk
density of dry product is expressed by formula

VP V

m m m
1, 2

In this experiment, we used sand with 400 micro.

2.3.3. Expansion 2D
We also measured the image processing expansion. We use Software application which
is adobe Photoshop. We calculate the expansion volume with image from the condition
of expansion. The method that we used in the calculation expansion is a direct measure,
the initial screen of samples up to the end point samples, which are compared with the
initial value calculation, after that we calculating the volume: height and width of the
real on-screen.

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3. Results and Discussion

3.1. The Effect of Pressure and time for expansion
Pressure and time are the combination to produce an expansion; this expansion is due to
the steam into the product. Pressure required for each different product will vary by the
characteristics of a product that will be tested., In this study, we tested the samples;
cheese and tofu, in general the same form but the cheese has a high fat content so that
the fat content should be removed before processed, therefore it done by drying. Cheese
requires high pressure to remove excess fat. As a result the time required to remove the
fat content is not fast. From some experiments and analysis of a study, required pressure
is 3-5 MPa to remove fat and we need 40-50 sec in vacuum conditions.
In this work, change the pressure when less than 3 MPa, the cheese cant be changed but
it will remain into original state with the characteristics of the cheese is stable, if given a
longer time then the burn cheese.
Parameters Volume
Volume
Volume
Cheese
Exp 3D
Exp.by sand
Exp 2D
DIC-1
2,71
2,72
3,99
DIC-2
3,30
2,05
4,49
DIC-3
2,85
2,43
3,97
DIC-4
2,68
1,99
3,65
DIC-5
3,24
2,78
4,35
DIC-6
2,79
2,53
4,17
DIC-7
2,71
2,43
3,99
DIC-8
2,06
1,82
3,61
DIC-9
1,79
1,50
2,92
DIC-10
2,17
2,01
2,48
DIC-11
2,82
2,11
3,87
DIC-12
2,54
1,58
4,09
DIC-13
2,71
1,88
3,70
Table 2. Volume expansion of cheese
The volume expansion can occur due to the movement of molecules with very fast and
also the influence of high pressure. It is looks increasingly high pressures on periods of
time and will produce a very large volume expansion.
In this experiment only requires 5 MPa pressure with a range time between 40- 45 sec
and will produce a very significant expansion.

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Standardized Pareto Chart for Volume Expansion with dimension

a
+
-

A:Pressure
AB
BB
AA
B:Heating time
0

0,5

1,5
2
Standardized effect

2,5

Standardized Pareto Chart for Volume Expansion with images

+
-

A:Pressure
AB
AA
BB
B:Heating time
0

2
3
Standardized effect

Fig 3. Standard Pareto cheese 3D (a) and 2D(b)

According to the chart, the calculation of the 3D and 2D are very influential for product
cheese.
Parameters
Tofu
DIC-1
DIC-2
DIC-3
DIC-4
DIC-5
DIC-6
DIC-7
DIC-8
DIC-9
DIC-10
DIC-11
DIC-12
DIC-13

Volume
Exp 3D

Volume
Exp 2D

Time of
Exp (s)

3,20
3,15
3,36
3,63
2,79
2,53
3,20
3,10
4,45
3,04
2,32
2,34
3,08

3,47
3,45
3,84
4,12
3,55
3,05
3,73
3,51
4,49
3,52
2,91
3,61
3,91

1,06
0,86
0,96
0,96
0,78
1,16
0,96
0,66
1,04
1,04
1,04
0,94
0,94

Table 3. Volume expansion of tofu

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The different condition with Tofu because Tofu is not content fat, because the ingredient
of tofu content very little fat which is classified into fat vegetable. The expansion of tofu
is greater than cheese; it is because tofu made from bio products and cheese from
animal products.
In this study also affect to the steam that was used as the pressure increased. The steam
used is water vapor, in principle, water and fat cant be fused, so the steam comes from
water does not easily fit into the material that the reason it will takes time to penetrate
the particle into cheese, Tofu not contain much fat then cheese. As a result, cheese is
easier to get into Tofu steam.

Standardized Pareto Chart for Expansion with dimension

+
-

AB
A:Pressure
B:Heating time
AA
BB
0

2
Standardized effect

Standardized Pareto Chart for Expansion with images

+
-

A:Pressure
AA
B:Heating time
AB
BB
0

4
Standardized effect

Fig 4. Standard Pareto tofu 3D (a) and 2D (b)

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3.2. Modification structure during DIC

During the process of DIC a phenomenon that is expected in this process. This change
occurs because of the process that occurs very quickly, and speed is making the products
to be surprised and products result cant be trepaired.
These structural changes occur when the molecules of the product is open to large and
bulky, because the pressure of steam, and the breakdown of cell walls are change in the
structure of the material, during the process of DIC occurs. Furthermore this can be done
in vacuum conditions, and cant be done under normal conditions, therefore controlling
the temperature and pressures greatly affect the DIC results.
In some products are change in the structure of the product could occur, this reversible
and depend on the content of products material, in this experiment, cheese and Tofu was
reversible phenomenon.

3.3. Condition temperature inside product vacuum

The temperature of product in vacuum conditions is usually lower than surrounding
conditions, because the condition is of the product formerly colder. Rapid changes that
occur in this expansion can cause the temperature changes in food and also affect the
rate of change of a characteristic of a material. These changes can be seen through some
of the phenomena that occur in the following graphic that shows the temperature levels
which occur in the process of DIC.
The resulting temperature at the end of this process can be analyzed also by using a DSC
that is seem good under temperature conditions to storage products, this can be seen by
the experiments performed by using a DSC that is using 30 C to 300 C with a speed of
2 C and will produce the desired value of TG. In general, the resulting value of TG is
under temperature 38 C to 40 C, these results have also been demonstrated through a
journal written by the U.S. Pajok, 2002. Value of these conditions can be done as a
reference or value for the storage of these food products.
From the observation, the products were analyzed by using the DIC, the storage period
could be longer, than the initial product which is dried and then stored in the same
condition. Analysis obtained from the use of DIC and DSC analysis can see the value of
the perfect storage on cheese and Tofu.

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Parametre
Tofu
DIC-1
DIC-2
DIC-3
DIC-4
DIC-5
DIC-6
DIC-7
DIC-8
DIC-9
DIC-10
DIC-11
DIC-12
DIC-13

Tmax Product
C
172,8
166,4
171,3
164,1
157,8
163,1
158,2
167,9
168,8
161,8
155,0
164,5
169,9

TMin Product
C
25,1
29,6
40,4
42,4
37,5
36,5
37,5
40,7
48,7
51,0
80,0
40,8
49,8

TFinal Product
C
52,0
60,8
56,8
53,0
51,6
56,0
55,0
58,7
53,4
57,6
85,0
55,0
56,5

Table 4. Products, DIC parameter, temperature product doing expansion

Interaction Plot for Expansion with dimension

3,1
Expansion with dimension

a.

Heating time=40,0

Heating time=50,0
2,8

Heating time=50,0
2,5
2,2
1,9
1,6

Heating time=40,0
3,0

5,0
Pressure

b.

Volume Expansion with dimension

Interaction Plot for Volume Expansion with dimension

4,1
Heating time=40,0
3,7
3,3
Heating time=50,0
Heating time=50,0

2,9
2,5
2,1

Heating time=40,0
5,0

6,0
Pressure

Fig 5. Interaction plot tofu (a) and cheese (b)

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3.4. Phenomena Expansion after vacuum

DIC process always done in a vacuum state, the expansion phenomenon occurs during
the process of DIC, but changes may occur at the time of the product under normal
conditions (atmospheric) but the changes are not significant. This occurs because the
process in vacuum conditions can be adjusted in accordance with the wishes, and under
normal conditions
From the research results and calculations using stat graphic, the optimum value in the
cheese is produced at point 5 MPa with a time 40 seconds, and the optimum expansion
that produced 3-fold from the original form.
Factor
Cheese Pressure
Temps
Tofu Pressure
Temps

Low
2,58579
37,9289
4,79289
37,9289

High
5,41421
52,0711
6,20711
52,0711

Optimum
5,35028
40,2862
6,20711
37,9289

Table 5. Factor Cheese and tofu

This table shows the combination of factor levels which maximize the desirability
function over the indicated region. It also shows the combination of the factors at which
that optimum is achieved. Use the Analysis Options dialog box to indicate the region
over which the optimization is to be performed.
Main Effects Plot for Expansion with dimension

Expansion with dimension

3,1

2,9

2,7

2,5

2,3
3,0

5,0
Pressure

40,0

50,0
Heating time

Fig 6. Effect plot for expansion

According to the estimated of response surface, influence of pressure and time is impact
on the results that found in this expansion, which is seen in the following graph, the
changes that occur due to the expansion of the energy that goes into a very large
material and energy transfer that occurs are very fast.
Similarly, with tofu products, the required optimum value of 6 MPa for the pressure with
a time of 38 seconds, the resulting expansion is greater than the value of cheese, nearly
four times compare to the previous value.
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Expansion with dimension

Estimated Response Surface

3,1
2,8
2,5
2,2
1,9
1,6
3

3,4

3,8

4,2

4,6

40

42

44

46

48

50

Heating time

Pressure

Fig 7. Estimated response surface cheese

This table shows the combination of factor levels which maximize the desirability
function over the indicated region. It also shows the combination at which that
optimum is achieved.

Volume Expansion with dimension

Estimated Response Surface

4,1
3,7
3,3
2,9
2,5
2,1
5

5,2

5,4

5,6

5,8

40

42

44

46

48

50

Heating time

Pressure

Fig 8. Estimated response surface tofu

Response surface also proved that the resulting time need not be too long with a high
pressure, he will produce a very large expansion rate.

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Volume Expansion with dimension

Main Effects Plot for Volume Expansion with dimension

3,8
3,6
3,4
3,2
3
2,8
5,0

6,0
Pressure

40,0

50,0
Heating time

Fig 9. Effect plot for expansion tofu

The higher pressure generated would be better, but it takes more and more inefficient
and the results are not optimum. This phenomenon can be seen in the following graph.
To make the process of expansion, can be done in various ways, but the process that
uses DIC for process is very new and does not alter the taste of the product. This process
can also be done quickly and does not require a long time to produce a product.

3.5. Scanning Electron Microscope

We observe the microstructure is carried out using a scanning electron microscope
(SEM), FEI Quanta model 200FEG Common Center Analysis (CCA), the University of La
Rochelle. The samples are placed on a stand covered by the carbon tape, under a partial
vacuum with an acceleration voltage of 20 kV.

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Tofu
Tofu sample analyzes, we observed surface and cut surface, the first sample directly
observed on the surface of the product in the following analysis do composition in the
product.
a

Fig 10. Images tofu (a) before DIC (b) after DIC
Surface in Tofu very tight before DIC and after DIC such as rubber, particle tofu couloirs
becomes enlarged and an expansion.
This phenomenon occurs because of the steam that goes into the product particles are
blown up like a balloon and then enlarged; in these phenomena is a condition of
expansion
Cheese
a.

Fig 11. Images cheese (a) before DIC (b) after DIC

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The same thing happened on the cheese, before DIC the particles are very tight and after
DIC particles become large and fragile. The composition of the fat in cheese is very
influential on the development of the product. This is due to the drying or heating in the
DIC longer doing compared to other products.

Conclusion
The saturated vapor pressure and process DIC and the thermo-rheological with cheese
and tofu are the main parameters that affecting the rate of expansion. Among the
different methods of measuring the expansion rate, we chose the method of measuring
the specific volume as the primary response parameter.
The time and pressure during processing DIC have a direct impact on the loss of density
and hence the expansions rate the cheeses and tofu.
During heat treatment by DIC the product passes through a state rheoplastic, this state
that it must retain until the end of the expansion. The transition to the glassy state
allows preserving the new expanded structure. By measuring the temperature within
the material we can compare the timing of the transition during the operation of DIC.
The glass transition temperature normally can be identified by DSC.
The very short duration of expansion should not allow materials to pass the amorphous
glassy state despite of the passage or exceeding the level of the glass transition
temperature, which is looking at thermodynamic equilibrium later, than the glass
transition process has time to intervene.

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