Introduction to Micvac
June 2013
Micvac
Founded year 2000 by Dr Joel Haamer,
Chalmers University, Gothenburg
2000-2004
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Patent, Product & Process development
2005
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First two customers
Today
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10 Micvac customers
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12 commercial lines and 4 pilot production plants in operation
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Cooperation partner for Japan and South Korea with Dai Nippon Printing
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Cooperation partner for North and South Americas with Curwood / Bemis
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Agents in UK/IE, Spain/Portugal, Poland, Italy, Turkey, South Africa, Baltics/Russia
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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)
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Designed to open and close at
specific pressure and temperature
FlexTray (worldwide)
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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
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•
Short cooking time keeps vitamins
Protection from light keeps vitamins
E
C
Oxidization
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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
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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
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Recipe composition
Inlet temperatures
Temperature in coldest spot, 98C, to get full pasteurisation
Weight loss
Find process time
PU equivalents
Tref = 90C
z =10 (constant)
90C, 10 min  98C, 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
•
•
•
•
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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
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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
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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