Introduction to Micvac June 2013 Micvac Founded year 2000 by Dr Joel Haamer, Chalmers University, Gothenburg 2000-2004 • Patent, Product & Process development 2005 • First two customers Today • 10 Micvac customers • 12 commercial lines and 4 pilot production plants in operation • Cooperation partner for Japan and South Korea with Dai Nippon Printing • Cooperation partner for North and South Americas with Curwood / Bemis • Agents in UK/IE, Spain/Portugal, Poland, Italy, Turkey, South Africa, Baltics/Russia • Micvac ambassadors worldwide Chilled ready meals • A complete ready meal • Fish, meat, chicken • Rice, potatoes, vegetables • Sauce • Distributed chilled • Size for one person up to family • Pasteurised product • Reheated, consumed warm A growing category Chilled ready meals per country %, annual growth in volume, 2007-12 New product launches Key words 1. Convenience • Microwavable 28% 2. Natural • No additives / no presevative 15% 3. Healthy eating Patented solutions Process (worldwide) • Microwave cooking of food in package with re-closable valve Valves (worldwide) • Designed to open and close at specific pressure and temperature FlexTray (worldwide) • Container with controlled deformation One small valve, one big innovation One innovative solution A fresh way to cook ready meals Fill Seal Heat Cool One continous process Sealing Filling Heating Cooling …with a consumer experience Cook Listen Eat Micvac value chain benefits • Continuous and cost efficient production • Unique yet market proven • A longer shelf life yet no preservatives • Less store-waste due to longer shelf life • Easy to transport, easy to display packaging • Potential for increased range availability • Fresh and convenient • Fast and healthy • Tasty and easy Technology benefits June, 2013 The unique combination Micvac Quality Safety Shelf life Technology benefits Oxygen removal • Minimise oxidization processes – longer shelf life • Less need of preservatives – more natural/clean label Short cooking time • Better texture, keep vitamins & colours In-pack cooking • Less pre-cooking steps – gain high quality & product yield • No risk of recontamination – safe product Continuous • Gain high quality & production flow Why removal of oxygen? • Vitamins are antioxidants Antioxidants protect other components Antioxidants are good for your health Inhibit bacterial growth Break down by heat and light • • Short cooking time keeps vitamins Protection from light keeps vitamins E C Oxidization • • Vitamin concentration Avoid break down of vitamins and other components The evidence – Vitamins stay over time Analysis of Vitamin C in potatoes (mg/100g) Products stored at +8°C (46°F) Colour remain Week 0 Week 4 Week 8 Concept development & equipment June 2013 Our customers have a wide recipe range Type Total 2011 Total 2012 Trend 27 31 -7% 23 35 +3% 4 12 +7% Indian 8 9 -2% Mexican 2 4 +1% Side dish 3 3 -2% Total 67 74 Traditional Italian (pasta) Asian Recipe development with Micvac lab kit Budget price € 2000 Delivery time 2-3 weeks • • • • Microwave oven Panasonic Inverter Traysealer (hand) with tool for Flextray ~1000 MicVac Flextrays ~1000 Valves pre-applied on film Recipe development with Micvac lab kit 1. Find out recipe and process parameters • • • • • Recipe composition Inlet temperatures Temperature in coldest spot, 98C, to get full pasteurisation Weight loss Find process time PU equivalents Tref = 90C z =10 (constant) 90C, 10 min 98C, 2 min Pasteurisation 120 40 35 100 30 80 60 20 PU Temp (C) 25 10 mm from bottom 15 17 mm from bottom 40 Enter heating zone 10 Out from heating zone 20 Out from 5 tunnel PU90 0 0 0 2 4 6 8 Time (min) 10 12 14 Clostridum botulinum Proteolytic (A, B or F) • All spores are NOT killed in the heating process (D121=0,1-0,25 min) • Growth above 10°C Non-proteolytic (B, E or F) • All spores are killed in the heating process (D80=0,6-3,3 min) • Growth above 3,3°C • Generally inhibited at pH 5,0-5,2 Conclusions: A temperature below 10°C must be maintained during storage to avoid growth of Clostridium botulinum. Recipe development with Micvac lab kit 1. Find out recipe and process parameters • • • • • Recipe composition Inlet temperatures Temperature in coldest spot, 98C, to get full pasteurisation Weight loss Find process time Base to decide size of tunnel 2. Storage tests Sensorical approval 3. Internal tests e.g. reference group Micvac rental equipment Microwave tunnel 3.0 pilot, 12kW 1-3 months, €4,500/month 4-6 months, €3,750/month Micvac microwave tunnel 3.0 Features Product quality improvements • Microwaves from below – • Decreased edge heating maximized bottom heating • PC based control system • Easy opening for cleaning • Decreased weight loss • Decreased lane variation Micvac microwave tunnel 3.0 Approx. 3400 mm Approx. 2000 mm Approx. 3200 mm Micvac microwave tunnel 3.0 Easy opening for cleaning Capacities Micvac microwave tunnel 3.0 Capacity at 100% usage & yield Production outcome in 1000pcs at 85% efficiency and 99% yield Together with leading suppliers Equipment partners Packaging material partners Micvac flextray range • • • • • Tray design is patented Controlled deformation Shape optimal for microwave heating PP copolymer (Polypropylene) or modified PP (with 15% chalk) Colours such as black, white and opaque Single: 200, 330, 400, 600 gr (also 2 pers.) Family: 1000 gr Our product range is business case driven New concept Micvac pouch Opportunity: High quality chilled dinner components “Pick and Mix”-concept • • • • • • High quality (color, texture, taste and nutrition) Products with pieces Sensitive products e.g. seafood, vegetables Premium components/ingredients Smaller meal i.e. “snack pot”, in between meals Internal project ongoing Concept development and NPD Brand dynamics Market dynamics Consumer trends Concept idea Packaging development (tray, valve, sleeve, etc) MicVac concept creation Reference group Consumer tests Market tests Recipe development Trials in household microwave oven Cost calculation Samples evaluated over time - Sensorical - Microbiological Production criteria Greatest Opportunity • Microwaveable • Natural /No additives • Health/Wellness • Quality • Convenience – time saving Scope of supply and line designs Equipment; Order and installation Implementation of recipes, training & start-up Possible next steps Visit at Micvac • Demonstration in pilot plant • Training with lab kit (also possible at your place) Visit a reference plant Concept development