EPA-660/2-74-091
DECEMBER 1974
                             Environmental Protection  Technology Series
                    In-Plant  Hot-Gas
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                                             National Environmental Research Center
                                               Office of Research and Development
                                              U.S.  Environmental Protection Agency

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                      RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development,
U.S. Environmental Protection Agency, have been grouped into
five series.  These five broad categories were established to
facilitate further development and application of environmental
technology.  Elimination of traditional  grouping was consciously
planned to foster technology transfer and a maximum interface in
related fields.  The five series are:

          1.   Environmental Health Effects Research
          2.   Environmental Protection  Technology
          3.   Ecological Research
          4.   Environmental Monitoring
          5.   Socioeconomic Environmental Studies

This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY STUDIES series.  This series  describes research
performed to develop and demonstrate instrumentation, equipment
and methodology to repair or prevent environmental degradation from
point and non-point sources of pollution.  This work provides the
new or improved technology required for  the control and treatment
of pollution sources to meet environmental quality standards.

This report has been reviewed by the Office of Research and
Development, EPA, and approved for publication.  Approval  does
not signify that the contents necessarily reflect the views and
policies of the Environmental Protection Agency, nor does  mention
of trade names or commercial products constitute endorsement or
recommendation for use.

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                                  EPA-660/2-74-091
                                  December 1974
             CONTINUOUS IN-PLANT  HOT-GAS

              BLANCHING OF VEGETABLES
                         By

                  Dr. Jack W.  Rails
                Mr. Walter A.  Mercer
                 Grant No. S-800250
               Program Element  1BB037
                     21 BAB/029
                   Project Officer

                Mr. Harold W. Thompson
Pacific Northwest Environmental  Research Laboratory
      National Environmental Research Center
              Corvallis, Oregon   97330
      NATIONAL ENVIRONMENTAL RESEARCH CENTER
         OFFICE OF RESEARCH & DEVELOPMENT
       U.S.  ENVIRONMENTAL PROTECTION AGENCY
              CORVALLIS, OREGON   97330
     For sale by the Superintendent of Documents, U S Government Printing Office
             Washington, DC  20402 - Stock No' 5501-00983

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                           ABSTRACT

An experimental hot-gas blancher was operated in two food process-
ing plants using spinach, green beans, corn-on-cob, beets,  and
green peas.  A side stream of commercially prepared vegetables was
hot-gas blanched and returned to  the production line.  Wastewater
samples were collected from the  commercial blanchers and the hot-
gas blancher; these were measured for volume and analyzed for pH,
COD, BOD, and SS.  Electrical,  gas,  and steam flow meters were
used to obtain data for  cost estimates of commercial scale hot-gas
blanching.   Comparisons were made of potential reductions in volume
of wastewater, weight of BOD,  and  weight of SS generated when con-
ventional steam or hot-water blanching was replaced by hot-gas
blanching; in the case of spinach these reductions were 99. 9, 99. 8,
and 99. 5%,  respectively.  Preserved (canned or frozen) samples of
blanched vegetables were analyzed for vitamin and mineral content.
The retention of nutrients was the same for hot-gas  blanching and
commercial blanching except for  retention of ascorbic acid in spinach
and green peas where hot-gas blanched samples had higher retentions.
Evaluation of flavor, texture  and  appearance of preserved samples
demonstrated similar quality products from hot-gas blanching and
commercial blanching.  The overall quality of hot-gas blanched vege-
tables  was well within the range of commercial acceptability.  Esti-
mated  capital costs for a commercial scale hot-gas  blancher for green
beans are twice that of a hot-water  blancher.  The estimated operat-
ing costs for hot-gas blanching  of green beans are 25%  less than those
for hot-water blanching of green beans.

This report was submitted in fulfillment  of Project Number S-800Z50
under the sponsorship of the Office  of Research and  Development,
U.S. Environmental Protection Agency and the Research Foundation
of the National Canners Association.  Work was completed  as of
September 1973.
                                 -11 -

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                      TABLE OF CONTENTS
                                       '                  Page
Abstract                                                    ii

List of Tables                                              iv

Acknowledgments                                           vii

Sections
I.     Conclusions                                           1

II.    Recommendations                                     2

III.   Introduction                                           3

IV.   Experimental Plan                                    7

          General  Considerations                           7
          Blanching                                        10
          Wastewater Measurements                       13
          Product  Evaluation                               16
          Economics                                       21

V.    Experimental Results                                 23

          Blanching and Wastewater Measurements          23
          Product  Evaluation                               40
          Energy Requirements                             47

VI.   Discussion                                           49

          Blanching, Wastewater, and Product Evaluation   49
          Comparison of Costs of Blanching Systems        55
          Dehydration During Hot-Gas Blanching            59
          Overall Considerations                           60

VII.   References                                           62

VIII.  Glossary                                             64

IX.   Appendices                                           66
                              -iii-

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                              TABLES

No.                                                       Page

 1.    Schedule of Analysis for Vitamins and Minerals         18

 2.    Long Term Hot-Gas Blanching of Cut Green Beans      23

 3.    Wastewater Volume and Characteristics for Hot-Gas
      Blanching  of Green  Beans                              25

 4.    Wastewater Volume and Characteristics for Make-Up
      Water Overflow Composite Samples from Commercial
      Blancher for Cut Green Beans                          26

 5.    Long Term Hot-Gas Blanching of Corn-on-Cob          27

 6.    Wastewater Volume and Characteristics for Hot-Gas
      Blanching  of Corn-on-Cob                              29

 7.    Wastewater Volume and Characteristics for Steam
      Condensate Composite Samples from  Commercial
      Blancher for Frozen Corn-on-Cob                      29

 8.    Long Term Hot-Gas Blanching of Beets                 30

 9.    Wastewater Volume and Characteristics for Hot-Gas
      Blanching  of Beets                                     31

 10.   Wastewater Volume and Characteristics for Make-Up
      Overflow Composite Samples from Commercial
      Blancher for Beets                                     32

 11.   Long Term Hot-Gas Blanching of Washed Spinach       33

 12.   Moisture Content of Raw and Hot-Gas Blanched
      Spinach                                                35
                                - iv -

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                            TABLES

                          (continued)

No.                                                       Page

 13.   Wastewater Volume and Characteristics for Hot-
       Gas Blanching of Washed Spinach                     36

 14.   Steam Condensate  and Make-Up  Water Overflow
       Rates for Commercial Spinach Blancher              36

 15.   Characteristics  of Commercial Spinach Blancher
       Dump Water, Steam Condensate, and Make-Up
       Water Overflow                                      37

 16.   Long Term Hot-Gas Blanching of Green Peas         38

 17.   Wastewater Volume and Characteristics for Hot-
       Gas Blanching of Green Peas                         40

 18.   Characteristics  of Commercial Green Pea Pipe-
       Blancher Dump Water and Make-Up Water            41

 19.   Headspace  Gas Composition of Canned Vegetable
       Samples                                             41

 20.   Nutrient Content of Raw, Hot-Gas  Blanched,  and
       Commercially Blanched Vegetables                   42

 21.   Levels of Polynuclear Hydrocarbons in Canned Green
       Bean Samples                                        44

 22.   Results of Organoleptic Evaluation of Canned Green
       Beans One  Month After Canning                       45

 23.   Results of Organoleptic Evaluation of Canned Green
       Beans After Storage at 38  C for Three and Six        46
       Months
                              -v -

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                             TABLES

                            (continued)

No.                                                       Page

 24.   Organoleptic Panel Evaluation of Frozen Corn-on-
       Cob After Storage for One Month at -18 C             46

 25.   Taste Panel Ranking of Three Commercial and
       One Hot-Gas Blanched Sample of Canned Spinach       47

 26.   Energy Consumption During Hot-Gas Blanching
       of Vegetables                                         48

 27.   Comparison of Wastewater Volume, BOD, COD,
       and SS from Hot-Gas and Commercial  Blanching
       of Vegetables                                         50

 28.   Percentage Reduction of Wastewater Volume, BOD,
       COD,  and SS Due to Hot-Gas Blanching of Vegetables   52

 29.   Estimated Cost of Blanching Vegetables                56

 30.   Basis for Estimating First Cost of Commercial
       Scale  Hot-Gas Blanchers                              57
                                -vi-

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                        ACKNOWLEDGMENTS

We express our sincere appreciation to the EPA's Kenneth A. Dostal
and Harold W. Thompson for many helpful suggestions during plan-
ning, data collection,  and reporting of results for this project.

We thank Michael T. Soderquist and his  colleagues at Oregon State
University for the BOD,  COD, and SS determinations  on wastewater
samples collected during experimental work at Corvallis.

The  in-plant operations would not  have been possible without the
permission and constant advice and assistance of management, pro-
duction, and technical persons at two food processing plants.  Al-
though it is not possible to acknowledge by name the large number
of persons who made direct  contributions to the installation,  opera-
tion,  and product evaluation phases of the in-plant work,  a number
of key persons must be mentioned. At Tillie  Lewis Foods, Inc. in
Stockton, California, the following persons were extremely help-
ful:  Harry Rosen,  Rex Defenbaugh, Clair Weast, Max Nicholson,
Andy Dillman, Walter Hein, Hugh Gartin,  Don Krull,  Frank
Yoneshiga, Chuck Fettie, Mary Wong, Jack Mays, and Jackie
Brewer.  At  Agripac,  Inc. (Salem, Eugene, and Corvallis, Oregon),
Ed Pitkin, George Henken,  Alton McCully,  Donald Walker, Gary
Lewis,  Robert Isaac,  and Gene Parrish were instrumental in the
accomplishment of the in-plant blanching studies.

Many of the Oregon  State University faculty provided advice and
direct assistance to the  work in Corvallis, especially Darrell
Beavers,  Robert Cain, Howard Milleville, Lois McGill, and
Michael Soderquist.

We thank Magnuson  Engineers, Inc. of San Jose, California for
loaning  us pieces of ancillary equipment  during spinach blanching.

The  following temporary employees of the National Canners Asso-
ciation were  responsible for the operation of the  hot-gas blancher,
sample  collection,  and sample analysis:  Mark Zinnecker,  Rich
Lane, Douglas Hommick, James Reiman, Holly Karnath,  and
Nancy Howard.
                             -vii-

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                         SECTION I

                        CONCLUSIONS

Hot-gas blanching of thin or small piece-size vegetables (such as
spinach, cut green beans, or green peas) accomplishes the requisite
enzyme deactivation and tissue gas removal at practical loading rates
[10. 7 to 14. 6 kg/m2 (2. 2 to 3. 0 Ib/ft2)]and residence times (77 to
240 sec).

Hot-gas blanching of large  piece-size vegetables (such as  corn-on-cob
and whole beets) requires long residence times (14 to  25 min) and high
steam usage [1. 9 to 2. 9 kg  (4. 2 to 6. 3 lb)/min] to achieve adequate
blanching.

Costs for hot-gas blanching of vegetables are higher than for steam or
hot-water blanching.  The fixed costs estimated for hot-gas  blanchers
are 1. 6 to  10. 7 times higher than for  hot-water blanchers.  The
operating costs for hot-gas blanching  are 0. 75 to 5.8 times higher than
for conventional steam  or hot-water blanching.

The flavor, texture,  appearance,  nutritional content,  and  safety of
hot-gas blanched vegetables are generally equivalent to hot-water or
steam blanched vegetables.
                              -1-

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                         SECTION II

                    RECOMMENDATIONS

Food processing equipment-supply companies  should design hot-gas
blanchers of optimal performance for  each individual  commodity.

The  commercial scale hot-gas blanchers should incorporate vibratory
conveyors to move vegetable pieces and to expose fresh surfaces for
more efficient and uniform heating.

The  commercial scale hot-gas blanchers should be designed to take
advantage of natural convection currents above natural gas flames
with minimal assistance from blowers.

A commercial scale hot-gas blancher  for  cut green beans should be
installed in  a food processing plant and should be compared to current
or previous experience with hot-water blanching.

Hot-gas blanching should receive careful consideration in new plant
installations where closed loop use of water is planned.

The  overall consequence  of accepting  higher dehydration losses during
hot-gas blanching  of vegetables prior  to canning or freezing should be
more completely evaluated.
                             -2-

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                          SECTION III

                        INTRODUCTION

The food processing industry is now evaluating the economic conse-
quences of radical changes in processing equipment as one option
available to assist the industry in meeting  the national goal of zero
discharge of pollutants by 1985.  It is likely that new technology for
raw product preparation, which substantially reduces waste genera-
tion, will cost less when old equipment is replaced than the  cost of
installation or expansion of treatment facilities.  New equipment which
produces little or no liquid waste would be advantageous if total re-
cycle use of water in food processing is  shown to be possible.

Vegetables which are preserved for long-term storage by freezing,
dehydration, or canning, receive a treatment (known as blanching)
with hot-water or steam.  The purpose of blanching is to deactivate
enzymes and to  remove tissue gases.  In addition,  blanching fre-
quently accomplishes or facilitates removal of juice,  soil, insects  and
other debris from the  vegetable pieces.

It has long been known  that the blanching of vegetables is a source of
strong liquid wastes with a potential for pollution of receiving water.
For example, the blanching and peeling of  beets, carrots, and potatoes
account for 85,  65, and 89 percent, respectively, of the five-day bio-
chemical oxygen demand (BOD) generated in the  processing  of these
commodities, Weckel  et. al. 1 It has been estimated, Weckel, 2 that
the national (United States) amortized annual (1969) treatment facility
cost for liquid wastes from selected vegetable blanching is $2,400,  000
and the annual operating and maintenance cost is $3, 000, 000.

The blanching of vegetables, therefore, is  a food processing unit
operation having a high potential for substantial reduction in liquid
waste generation.  The volume of liquid waste produced from hot-
water blanching of vegetables is  10-20 times  that produced by steam
blanching.   Therefore,  the greatest opportunity for significant re-
duction of waste water  volume during vegetable processing is the re-
placement of hot-water blanching by a  system generating little or no
                              -3 -

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liquid waste.

A preliminary study of potential low-water volume methods of blanch-
ing was accomplished under U.S. Environmental Protection Agency's
Grant 12060 PAV, Rails and Mercer. ^  Comparison of the results of
blanching seven vegetables with microwave, hot-gas,  steam,  and hot-
water blancher simulators revealed exceptional promise for the new
method of hot-gas blanching.  The experimental unit used in the
laboratory study of hot-gas blanching (also called hot-air blanching
or dry-blanching) was the first  of its kind known (to the authors) to
be constructed and tested.  The unit conveyed raw vegetables through
an insulated rectangular chamber containing a natural gas furnace.
Most of the thermal energy received by the vegetable was due to the
heat content of combustion products and nitrogen.  The hot  gases
were circulated in the chamber by means  of a large blower  and by
convection currents.   The cooled combustion gases were partially re-
circulated through the blower.  Steam was injected at  the top  of the
chamber to improve heat transfer from the hot gases to the vegetables
and to  reduce dehydration losses from  the high-water  content vege-
tables.

This preliminary study indicated that the volume of wastewater,  the
pounds (Ib) of chemical oxygen demand (COD),  and suspended solids
(SS) per ton of vegetable blanched could be reduced 90 to 99 percent
when hot-water  blanching was replaced by hot-gas blanching.   There
were no significant differences  in product quality, vitamin and
mineral retention, or internal can corrosion,  among samples of
vegetables prepared with the four different blanching systems.  An
estimate for  commercial blanching using the four systems studied
led to the following total annual cost per ton of raw vegetable  blanched:
microwave, $18.47; hot-gas,  $3.39; steam, $2.21; and hot-water,
$2. 36 or $20. 30; $3. 73; $2. 43; and $2. 60  per kilo-kilogram (kkg),
respectively.

The initial study of hot-gas blanching was conducted in the National
Canners Association  (NCA) Laboratory in Berkeley, California.   The
laboratory study had  several limitations; the most serious of which
was the requirement  of long transport distances [322 to 1609 kilo-
meters (km)  (200 to 1000 miles)]and excessive holding times (8 to
                              -4-

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48 hours (hr)] before blanching the vegetables.  The long holding times
between commercial preparation of the vegetable  samples for blanch-
ing and the actual laboratory blanching were particularly serious for
green peas (shelled), cut green beans, and asparagus (trimmed).  The
changes which took place in these commodities during the holding per-
iod before blanching made the significance of some data uncertain.   The
changes in corn (shipped in husks),  beets, pumpkin (shipped whole),
and spinach (whole leaf) during Jthe holding periods were not large
enough  to influence the significance of the data collected on these
commodities.  The laboratory study was limited to short-duration
blanching runs due to raw vegetable  cost; for long-duration blanching
runs it  would have been necessary to waste  large  quantities of whole-
some food since the laboratory equipment for canning and freezing of
vegetables could not handle the blancher's output.   A third limitation
of the laboratory study was the lack  of direct measurement of electri-
cal, gas,  and steam usage for more precise cost  estimates.

The next step in testing the commercial utility of  hot-gas blanching
was operation of the unit under conditions which would avoid the limita-
tions of the laboratory  study.  The decision was made to test the com-
mercial utility of the new processing system at a  commercial process-
ing plant.  With an in-plant installation,  raw vegetables prepared for
commercial  and experimental blanching would be  identical and,  there-
by, eliminate the impact of blanching time differences on the signifi-
cance of data collected.  Assuming that the  experimental unit could be
operated to produce blanched vegetables having acceptable commer-
cial quality,  most of the blanched vegetables could be returned to the
commercial  production line to avoid wastage of food.  The in-plant
installation of a single  experimental blancher would make  possible,  at
reasonable cost,  the installation of electrical, gas,  and steam flow
meters. Meter readings would supply information for operational cost
estimates.  The in-plant study also would provide the opportunity for
the measurement of the volume and characteristics of waste waters
from commercial  blanchers and comparison of these values  with the
same wastewater values from the experimental blancher.

This report describes the results of a comprehensive study of hot-gas
blanching of  peas, corn,  spinach, beets and green beans at two food
processing plants.  The study was designed to develop information on
                              -5-

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all the factors which would concern potential commercial users of hot-
gas blanching.  The major considerations treated in the  study were
operational costs; wastewater generation; wastewater characteristics;
final product safety, quality,  and nutritional content; and internal can
corrosion.

One safety aspect of the final product was not recognized until  after the
study was underway.  This was the potential for the occurrence of
polynuclear hydrocarbons  in vegetables blanched by the hot-gas unit.
It is known that oxidation of any fuel can produce a  mixture of poly-
nuclear hydrocarbons  during incomplete combustion, Mukai, et. al.

Some of these compounds are known to produce cancer in experimental
animals, Bryan and Lower. -* Although there is  no  definitive evidence
that oral ingestion of trace amounts of  polynuclear  hydrocarbons causes
cancer in humans, any food shown to contain significant  amounts of
known animal carcinogens would be subject to question by the Federal
Food  and Drug Administration.   Therefore,  a study of the polynuclear
hydrocarbon content of samples of hot-water and hot-gas blanched cut
green beans was  conducted to determine if the potential for this con-
tamination existed.
                               -6-

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                           SECTION IV

                      EXPERIMENTAL PLAN

GENERAL CONSIDERATIONS

The  study of hot-gas blanching in commercial canning and/or freezing
plants was designed to collect sufficient data to  provide a basis for
management decisions on the use of this new blanching system.  To
evaluate all possible options,  a manager would need to know capital
cost, operating cost,  ease of sanitation and maintenance, product
quality,  effect on containers,  and cost of waste  management for each
blanching system under consideration.  Therefore, the hot-gas blanch-
er was operated and sampled in a way which would provide the neces-
sary data for comparison to the steam or hot-water blanchers which
are now  in use.

The  in-plant location of the hot-gas blancher provided access to a
readily available supply of vegetables prepared  for blanching under
commercial  conditions. The option of returning hot-gas blanched
vegetables to the commercial  production line was available and, if used,
demonstrated the immediate commercial utility of hot-gas  blanching.
The  opportunity for extended operation of the hot-gas blancher made it
possible to use material from all stages of the production season and
provided assurance that raw product variation would not  limit the utili-
zation of hot-gas blanching to  any specific time  span of the operating
season.  A target of forty hr of operation for each of the five vege-
tables scheduled for  study was established to provide the long term
testing period.

The  in-plant testing program provided the opportunity for sampling of
commercial  blanchers receiving lots of vegetables identical to those
being hot-gas blanced.  Volumetric measurement and analysis of
samples of wastewater from commercial blanchers provided a basis
for direct comparison of the waste  generating characteristics of hot-
gas,  steam,  and hot-water blanching.  While it  is well known that wide
variations exist in  the waste generating characteristics  of blanchers in
different plants processing the same commodity, Holdsworth",  such
comparisons should establish the approximate extent of waste reduction
                                -7-

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possible with hot-gas blanching.  The waste generation comparison
should also provide a model into which new data could be substituted
for the  reported data to allow a comparison to be made between a
specific commercial blancher  and the hot-gas blancher.

The in-plant study gave access to product samples which could be
evaluated for quality on a direct comparison basis.  The first quality
measurement planned was the  effect of the blanching treatment received
on the level of nutrients in the blanched samples of vegetables.  The
retention of nutrients during food processing is receiving considerable
attention at the present time due to intense public  concern with nutri-
tion and nutritional labeling.  The nutrient retention in vegetables
which are hot-gas blanched must be at least equivalent  to that in vege-
tables from the blanching system being considered for  replacement.
The cost of preparing labels for food producers listing nutritional in-
formation is so large that changes in nutrient content due to hot-gas
blanching would be the  basis for rejecting its use.  Therefore, for
decision making reasons it was important to determine the percentage
change  in the nutrient content of raw vegetables due to hot-gas blanch-
ing.  A comparison of nutrient retention between commercially blanch-
ed vegetables and hot-gas blanched vegetables is important as a basis
for judgements on the degree of differences to be expected.

Assuming that no  substantial differences in nutrient content are found
due to hot-gas blanching, the next product quality factors of concern
would be flavor, texture, and appearance.  The ideal basis for com-
parison of the  effect of blanching on these quality factors would be
using preserved samples from all hot-gas  blanched product compared
with regular commercial production line samples  from similar lots of
vegetables prepared on the  same  day.  The experimental plan was de-
signed to provide  these kinds of samples whenever possible.  It was
recognized that if the output of the hot-gas blancher was low, it would
be necessary to blend hot-gas  blanched product with commercially
blanched product to avoid loss of commercial production capacity.  In
the event that blending  of the two  types of blanched materials was
necessary,  consumer reaction to lots of such product would be used
for quality evaluation.  For  commodities where it was  possible to pre-
serve all hot-gas  blanched material, direct testing against an equiva-
lent commercial sample was possible.
                               -8-

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The experimental plan called for evaluation of flavor and appearance
by an organoleptic panel.  These panels are used routinely in the food
industry to establish differences in quality among food samples,
Amerine, et. al. ^  The laboratory study of hot-gas blanching had in-
dicated a weight loss in blanched material due to dehydration.   There
was also an indication that steam injection could reduce dehydration
losses.  Loss in weight by dehydration is of direct  consequence for
preservation by freezing since the product value is usually based on
weight.  The only frozen product used in this  study, corn-on-cob,  was
sold by count so weight losses due to blanching were not of critical
concern.  There is a possibility that spray cooling  of hot-gas blanched
vegetables destined for frozen preservation would cause replacement
of a substantial part of the water lost by dehydration; investigation of
this point was not part of the experimental plan.  Some loss of mois-
ture content during hot-gas blanching of vegetables could be accomo-
dated in products  to be preserved by canning.  It would be expected
that the partially dehydrated vegetables would regain water from the
packing medium.  The experimental plan called  for control of the loss
of water through dehydration by injection of steam.  In those cases
where some dehydration of vegetables took place, the experimental
plan called for  determination of the change in  moisture content and
evaluation of the degree of rehydration in the  can.

The most important function of blanching for vegetables  to be pre-
served by canning is  removal of tissue gases. If not properly  re-
moved during blanching,  gases released by the vegetable tissue can
decrease the vacuum and contribute to the  internal corrosion of the
container by increasing the oxygen content in the headspace gases.
Direct measurement  of the gas composition of vegetables is very
difficult due to  sampling and gas displacement problems.  It is
possible to determine the degree of gas  removal during blanching by
an indirect method of headspace  gas analysis.  The experimental plan
included analysis  of cans from hot-gas blanched and commercially
blanched material for composition of gases in the headspace as  an
indication of the effectiveness of hot-gas blanching in removing oxygen
from vegetable tissues.

Another indicator  of incomplete removal of gases from  vegetables  dur-
ing blanching is accelerated internal can corrosion.  Examination  of

                              -9-

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opened cans containing samples of hot-gas blanched vegetables and
commercially blanched vegetables were made as a second indirect
estimation of tissue gas removal.

Vegetables are classified as low acid foods due to observed pH values
above 4. 6.  The pH range of vegetables permits growth and toxin pro-
duction from the mesophilic anaerobic  bacterium Clostridium botuli-
num,  if any spores survive in a can due to underprocessing.

The calculation of the  thermal process is based on thermal  death time
data for anaerobic  spores and heat penetration measurement for each
product formulation.   Blanching can  influence the heat penetration
characteristics of canned vegetables, such as in chopped spinach, and
render an established  thermal process inadequate.  Blanching may
have an effect on fill weights which are another factor which must be
controlled for thermal processing adequacy.  For these reasons, the
experimental plan called for examination of the effect of hot-gas blanch-
ing on critical control points in the thermal  processing of canned
vegetables.

BLANCHING

The hot-gas blancher used for the in-plant studies  was the  experi-
mental unit described  previously by Rails and Mercer.

Figure 1 shows a photograph of the hot-gas blancher installed in one
of the food processing plants used in this study.

 The blancher was installed with three electrical meters: one for the
 large blower; one for  the combustion air supply turbine; and one for
 the conveyor drive, gas furnace ignitor, and electronic controls.  A
 gas meter was placed on the inlet side of the natural gas furnace.  A
 Fisher and Porter Model 10A1152-55EM steam flow meter  rated at
 9. 54  kg (21 lb)/  minute(min) at 100 percent  of scale was installed on
 the steam inlet line.  A FMC Syntron Model No. BF-2 electric vibra-
 tory feeder was used  to control the rate of feeding of green beans and
 beets onto the conveyor belt of the hot-gas blancher.  Corn-on-cob
 and spinach were  loaded by hand by workers  wearing food grade  rubber
                              -10-

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gloves.  Peas were delivered in a flume from storage hoppers with
partial removal of water on the conveyor belt of the hot-gas blancher.
                         Hot-gas blancher installed in
Figure 1.  Hot-gas blancher instal
          a food processing plant
Dry belt conveyors were used as much as possible to accomplish the
transfer to both raw and blanched vegetables.  Raw No. 4 sieve size
cut green beans were delivered to the hot-gas blancher in 363 kg
(800 Ib) capacity tote boxes using fork-lift trucks. Spinach was trans
ported to a feed conveyor in a Z27 kg (500 Ib) capacity wheeled cart.
Corn-on-cob and beets  were carried in  13.6 kg (30 Ib) capacity plas-
tic  pails.

After the installation and testing of the hot-gas blancher had been
                              -11-

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completed,  samples of commercially blanched vegetables were exam-
ined and the reduction in peroxidase level measured,  Dietrich, et al.

Beets, spinach and peas for canning are blanched until almost all
peroxidase activity is  destroyed.  Therefore, the target peroxidase
reduction level for hot-gas blanching of beets, spinach, and peas was
95-100 percent.  Complete destruction of peroxidase  activity is  re-
quired to retain the quality of frozen corn-on-cob.  The target perox-
idase reduction level for both kernels  and cob of hot-gas blanched
corn-on-cob was 100 percent.  The level of enzyme deactivation  dur-
ing blanching of cut green beans is a special case and requires care-
ful  control to avoid over-blanching. Cut  green beans  which are hot-
water blanched to a level of 40 percent peroxidase reduction or great-
er, frequently  show a  separation of the skin from the  bean pod in the
final canned product.  This  condition is known as "sloughing" and
when it occurs, the appearance of the  product is much less attractive
than material  consisting wholely of intact bean pods.  The target
peroxidase reduction level for hot-gas blanched  beans was 20 to  40
percent.  A large number of short duration hot-gas blanching runs
were necessary to establish consistent operating conditions yielding
canned samples showing low levels of sloughing.

The appearance,  texture and color changes in commercially blanched
samples were used, along with the peroxidase reduction values,  as
targets  for the  performance of the  hot-gas blancher.   The operating
conditions (loading rate, temperature,  residence time,  and steam
flow) were varied systematically until a set of conditions were found
which reproduced the commercial blanching effect as  closely as
possible. The  hot-gas blancher was then operated for approximately
one hr under the  conditions  found to duplicate the effect of the com-
mercial  blancher to confirm that extended operation would produce
uniformly blanched material and to provide material for preparation
of samples for  quality evaluation using the commercial  line equipment.

The canned or frozen samples  prepared for quality evaluation were
examined by routine quality control procedures used by the plant and
by a group of company management and technical persons.  The pro-
cess of sample preparation  and company  evaluation was repeated un-
til management was satisfied that material from the hot-gas blancher
                              -12-

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could be incorporated into commercial production and sold in the same
way as conventional products.

The next stage of the in-plant study was extended operation of the hot-
gas blancher up to the planned period of forty hr whenever  possible.

WASTEWATER MEASUREMENTS

The measurements made on waste-waters from the hot-gas blancher
and the  commercial blanchers were designed to provide the basis for
comparison of the waste generating characteristics of these blanching
systems.  The volume of wastewater produced during the blanching of
a measured quantity of vegetables was determined.  For the hot-gas
blancher, the total volume of condensate collected from the single
drain of the blancher, during each eight hr of operation was measured
with a plastic graduated  cylinder or a calibrated plastic pail.  The
collection of the eight hr total volume wastewater from the hot-gas
blancher was  accomplished with ice-water cooling whenever possible.

The method used for  collection  of wastewater  samples from the hot-
gas blancher, with ice-water cooling, is shown in Figure 2.

To determine the volume of wastewater generated per unit weight of
vegetable blanched, it was necessary to measure the quantity of vege-
tables hot-gas blanched  during  every two hr period of operation.

Generally the weight of vegetables hot-gas blanched was calculated
from the constant loading used  and the determination of the number
of flights of the conveyor belt loaded during different periods  of  opera-
tion.  This method of determining the weight of material hot-gas
blanched was used for corn-on-cob and beets.  In the  case of hot-gas
blanching of cut green beans and spinach, gross and tare weights of
tote boxes  or wheeled carts  containing beans or spinach were used for
the determination of the weight of material blanched.  Due to the
variability in maturity of green peas, it was necessary to  change the
residence time frequently to get complete blanching.   A constant load-
ing rate was used.   The variable residence time accounted for vari-
able through put.
                               -13-

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         Figure 2.  Collection of steam condensate sample
                    from the hot-gas blancher

The sampling of wastewater from commercial blanchers was designed
to determine the total wastewater generated during eight hr periods of
commercial operation.   The wastewater measured consisted of total
steam condensate  in the case of the corn-on-cob blancher which was
collected at four drainage points, combined,and the volume measured
in calibrated drums every two hr.

Combined make up water overflow and  dump water for the  green bean,
beet,  spinach,  and green pea blanchers were measured.. Rarely did
the dumping of commercial hot-water blanchers occur at  eight hr in-
tervals; to put wastewater data on a comparable basis, the volume of
dump water measured was divided by the number (no. ) of eight hr
periods comprising the hr of use of the blanchers  between dumpings.

The method used to determine the weight of vegetables blanched in the
commercial blancher being monitored  varied with the  commodity  under
study. The no. of cans packed in any given time period from material
blanched during that time in a specific  blancher was obtained from
                              -14-

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warehouse counts of cans after retorting.  Knowing the fill weight for
each can, the total weight of material after blanching (with the excep-
tion of material lost in hold-up and spillage)  could be computed.  This
method was used for  determining the weight  of cut green beans and
whole beets blanched commercially during specific time periods.  No
hot-gas blanched beans were mixed in  with commercially blanched
beans; the weight of beets hot-gas blanched and returned to production
was subtracted from the computed weight.  The weight of corn-on-cob
blanched in  the commercial steam blancher was determined from a
count of the no. of ears  entering the blancher/min and the weight of an
average (ave. ) ear.  The ave.  weight/ear was determined by weighing
several containers each holding a known no.  of unblanched ears  and
dividing the net weight of ears by the no.  of ears.

The weight of spinach commercially blanched was determined from
scalehouse weights (gross and tare) of trucks unloading spinach  dur-
ing the period of blancher wastewater monitoring.  These weights
were incorrect to the degree to which the raw spinach contained  debris
or unusable spinach leaves rejected during sorting or washing.   It  was
estimated that the wet  spinach presented to  the blancher weighed
about the  same as the dry, raw, spinach containing small amounts of
stones, dirt, weeds,  and overmature leaves.

The volume of wastewater added to the commercial hot-water blanch-
ers was determined by metering the make-up water line,  or by mea-
suring the blancher liquid discharge by collection in calibrated drums
for specific time periods.  Generally,  the rate of wastewater from
the commercial hot-water blanchers was determined by collection
during a period of one to five min every two hr of operation of the hot-
gas blancher.  In the  case of the pipe blancher for peas, the extensive
foaming at the make-up water  surge tank and drain made direct  mea-
surements of volume  inaccurate.  It was determined by observation of
the complete pipe blanching system that the major source of make-up
water was the rinse water at the dewatering screen which delivered
commercially blanched peas to the conveyor  belt feeding the can filler.
A measurement of the rate at  which rinse water was sprayed on the
commercially blanched peas established the make-up water feed rate.
                              -15-

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The estimate of the weight of peas blanched in the commercial blanch-
er being monitored was  made from can counts,  can size,  fill weights
of each can size, and subtraction of the weight of peas contributed by
the hot-gas blancher during the period monitored.   A check list for
recording measurements and sample collections during the operation
of the hot-gas blancher is shown as Appendix T.

The eight hr total volume wastewater discharge  from the hot-gas
blancher, two hr grab samples,  and a  composite of equal volumes of
four  consecutive two hr  grab  samples from the commercial  blancher
wastewater were analysed for BOD, COD, SS, and pH by standard
methods, Taras'.  The  wastewater samples were refrigerated  from
shortly after collection until laboratory analyses were started.

The wastewater samples were not screened prior to analysis and  were
shaken before aliquot removal to give uniform suspension of insoluble
material.  No preservatives were used to stabilize the refrigerated
wastewater samples prior to  analysis.

Wastewater samples from the blanching of cut green beans,  corn-on-
cob,  and beets were analysed at a laboratory in  Corvallis, Oregon.
Wastewater samples from the blanching of spinach and green peas
were analysed  at a laboratory in Berkeley, California.

PRODUCT EVALUATION

The evaluation of the effect of hot-gas  blanching on the quality of  vege-
tables took place in several stages.  The initial  product  evaluation was
made subjectively, by blancher operators and company technical
specialists who inspected freshly blanched material from short dura-
tion exploratory experiments. Experienced observers estimated  the
adequacy of blanching by noting changes in color,  texture and flavor of
freshly blanched material.  For exploratory runs  of the  hot-gas blanch-
er, where  the blanched material passed subjective examination, a
measurement  of the  extent of reduction in peroxidase was  made.  This
objective test  of peroxidase reduction was made hourly for the  long
duration (forty hr) runs.
                              -16-

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The next product evaluation was made by examination of samples of
hot-gas blanched material which had been prepared and preserved
under commercial conditions.  It was  this examination which was the
basis of approval  by plant management for the long duration runs.
The examination was made by running routine quality control exami-
nation and additional subjective testing for color,  flavor, and texture
using commercial line samples as a basis for comparison.

Samples of raw, hot-gas blanched and commercially blanched vege-
tables were frozen using solid carbon  dioxide, shipped frozen,  and
stored frozen until vitamin and mineral  analysis could be conducted
in the  Berkeley, California and St. Louis, Missouri laboratories.
Samples were  analysed for the vitamins and minerals expected, from
published compositional data, to occur at significant levels  in each
of the five vegetables  studied.  The determinations  of vitamin and
mineral content were made according to the Eleventh Edition of the
"Official Methods  of Analysis of the Association of Official Analyti-
cal Chemist",
The  selection of vitamins and minerals for analysis was based on three
types of data:
          a)  Tabulations of vitamin and mineral content of raw
          and processed vegetables,  Watt and Merrill^,  Orr
          b)  Official tabulations  of Recommended Daily Dietary
          Allowances,  National Research Council •*• .
          c)  Per capita consumption of processed vegetables, Judge   .

In general,  a vitamin or mineral  was included in the analytical schedule
if a 100 gram (g) portion of a specified vegetable contained 10 percent
or more of the maximum recommended daily  dietary allowance,
(MRDA).  In those cases where all vitamins and minerals were below
the 10 percent figure,  a combination of the percentage contribution to
the MDRA and the per capita consumption were used to make the
selection.

The vitamin and mineral testing schedule used in this  study is tabu-
lated in Table 1.
                              -17-

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Table 1.  SCHEDULE OF ANALYSIS FOR VITAMINS AND MINERALS
                       Vitamins
                                                  Minerals
Commodity    A

Green Beans  Yes Yes Yes Yes Yes Yes
                       B,,  B.  C   Niacin      Ca   Mg   P     Fe
                        2   5         -        	  —    —     	
                                               Yes  Yes  Yes   No
Beets
              No  No  Yes No  No  Yes
No    No   Yes  No
Corn
Peas
Spinach
              No  Yes Yes Yes No  Yes
              No  Yes Yes Yes Yes Yes
              Yes No  Yes No  Yes No
No    No   Yes  No
Yes   Yes   Yes  Yes
Yes   Yes  Yes  Yes
Heads pace  gas analysis (by gas chromatography) of canned samples of
green beans, beets,  spinach and peas was made as a measure of the
removal of oxygen from the tissues of blanched vegetables, Rails and
Mercer^.  The second type of estimation of the extent of tissue oxygen
removal was subjective examination of cans of cut green beans after
various storage times and temperatures.  Canned samples of beets,
spinach, and peas were not stored long enough to  show differences in
extent  of internal can corrosion.  Samples of  green  beans  were stored
at 38 degrees Centigrade  (°C) [100 degrees Fahrenheit (°F)] (accelera-
ted storage) for six months (mo), a condition  which  approximates the
longest expected storage life (18 mo) of cans in commercial distribution
at ambient temperatures.  Results of examination of cans  of green beans
stored in a warehouse for five mo were also made available by the Re-
search Director of the canning company in whose  plant the cans were
packed.

The complete description of the method used for measuring levels of
polynuclear hydrocarbons is given in Appendix A.  For this investiga-
tion, standards  used were the polynuclear hydrocarbons: anthracene,
fluoranthene,  and pyrene.  It was not possible to introduce potentially
carcinogenic hydrocarbons  such as benzo (a) pyrene into a food re-
search laboratory due to  the extensive  monitoring and safety protocols
                                -18-

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which would have been required.  The use of potentially carcinogenic
hydrocarbons was unnecessary for this study since it had been demon-
strated by Mukai,  et. al.4 that incomplete combustion of methane, pro-
pane or isobutylene always produces a mixture of anthracene,  pyrene,
fluoranthene,  benzo (a) pyrene,  benzo (e) pyrene,  and perylene in
relatively constant proportions.  Therefore, detection of any signifi-
cant differences in the level of anthracene, fluoranthene,  and pyrene in
hot-water and hot-gas blanched  green bean samples would be presump-
tive evidence for the presence of benzo (a) pyrene.

A detailed evaluation of the quality of canned cut green bean samples
was made in the Sensory Evaluation Program of the Department of
Food Science and Technology at Oregon State University under  the
supervision of Professor Lois A.  McGill.   The samples were  tested
after storage at 38°C (100°F) for periods of one,  three, and six mo.
The procedure used for preparing samples for panel evaluation varied
slightly for each storage period.

For samples stored one mo: The separate samples were brought to
71°C (160°F) and served in random numbered coded cups.

For samples stored three mo: One Number 10  can of each sample of
canned  green beans  was removed from 38°C (100°F) storage at
10:00 a.m. and allowed to stand at room temperature until tested at
2:00 p.m.  For testing, a vacuum reading was taken on each can, the
cans opened, emptied into identical sized pans, heated to  a rolling
boil, removed from the heat then served hot to the judges.

For samples stored six mo:  One Number  10 can of each sample of green
beans was removed  from  38°C (100°F) storage  on March  12 and placed
at ambient temperature until tested at 2:30 p.m. , March 13, 1973.   For
testing, a vacuum reading was taken  on each can, the cans opened,
emptied into  identical pans,  heated to boiling at 100°C (212°F)  and held
at boiling temperature for ten min then removed from the heat and
served hot to the judges.  The ten min boil was a  precautionary mea-
sure as the vacuum  readings were 3.  0 inches (in. ) of mercury  or less
on all four samples.

The Oregon State University panel consisted of forty staff members  who
completed a ballot based on a nine point hedonic scale for appearance,
                               -19-

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texture,  flavor and overall desirability.

The samples were served in paper cups coded with three-digit random
no.  The four coded cups, randomly placed on a tray along with a
ballot and fork,  were served to the judges seated in individual testing
booths.   The judges were asked to score the appearance by viewing one-
cup samples in white bowls and finally score the overall desirability
and indicate which sample they preferred.

It should be noted that a different scoring system was used at the one
mo storage test than was employed on the three mo and  six mo storage
tests.  At the initial storage period, sample A  was used as a known
reference and also included as a coded sample  along with the other
samples and the judges scored the four coded samples in direct relation
to the reference (A) sample which was pegged at a score of five. How-
ever, even  though the scoring  system makes the absolute scores lower
on the one mo storage test, the relative differences between samples
are the  main considerations.

The Oregon State University group also evaluated  samples of hot-gas
blanched and commercially blanched frozen corn-on-cob.

Laboratory  taste panels were run in the NCA Berkeley  Laboratory on
samples of  canned spinach.  A set of three samples (two identical) of
commercially-blanched and hot-gas blanched spinach was presented  to
a panel  of sixteen persons on four occasions for determination of
difference.  A ranking  test of three commercially-canned  samples and
one hot-gas blanched canned sample was also conducted in the NCA
Berkeley Laboratory.

By following consumer reactions to samples, a,less objective, but still
highly  significant,  product evaluation was obtained on samples of green
beans, beets, corn-on-cob, spinach and peas which contained all or
partially hot-gas blanched material.  For beets, and peas,  this type of
evaluation was the only source of information on product quality as in-
fluenced by  the blanching treatment received.

The results of NCA product evaluations were subjected  to analysis  of
variance to  determine if there was a significant effect due to the blanch-
                                -20-

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ing condition used in the preparation of samples  on which the measure-
ment was made.  The analysis of variance was made using a random-
ized complete block design, Amerine, et. alJ, with the vegetables in-
volved in the analysis as blocks and the blanching conditions  as treat-
ments.   When the variance ratio (F value) calculated exceeded the
tabular F values at the one or five percent level  of significance,  mul-
tiple  range tests could be used to determine  significance due to indivi-
dual blanching for specific  vegetables.

The statistical evaluation of organoleptic evaluation of canned green
bean  samples was made by the investigators at Oregon State University
who conducted the test.  These data were analysed by analysis of vari-
ance  and the Least Significant Difference (LSD) at the five percent
probability level.  A similar statistical evaluation was made of the re-
sults of organoleptic panel  evaluation of  samples of frozen corn-on-cob.

ECONOMICS

The cost of blanching using a new system such as hot-gas is a critical
factor in any decision to replace currently used equipment.  Therefore,
a serious attempt was made in this  study to gather information on which
to base cost estimates  of commercial scale equipment for hot-gas,
steam,  and hot-water blanching. The information on  capital costs and
space requirements was obtained from suppliers or potential suppliers
of commercial scale equipment.  The first  cost ($) and  space require-
ments (m^) for commercial steam and hot-water blanchers were:
25, 000,  46. 65; 15, 000, 46. 40; 20, 000, 45. 13; 30, 000, 55. 14; and
8685,  15. 50 for green beans,  corn-on-cob, beets,  spinach,  and green
peas, respectively.

The operating costs were estimated from power usage,  steam usage,
water consumption,  and public utility fee schedules for a commodity be-
ing blanched in a unit of approximately five kkg or  5. 5 ton/hr  capacity.
Actual measured energy use during hot-gas blanching was one basis for
part of the estimate using appropriate scale-up factors.

Annual fixed costs were the sum of  amortized first cost,  space rent,
taxes, insurance and maintenance.  Amortization was defined as the
capital recovery factor (erf) with 7  per-cent interest for  a five year (yr)
                                -21-

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period and allowing no salvage value.  Space rent was set at $129/m .
Boiler space requirements were ignored since all units require steam.
Taxes were set at $5. 00/$100 of assessed value based on 25 percent of
first cost.  Insurance cost was  computed on the basis of 0. 2 percent of
assessed value.  Maintenance cost was calculated as 1. 0 percent of
first cost/yr.

In calculating operational  costs, actual energy usage for the experi-
mental hot-gas blancher was  multiplied by a scale-up factor (5 kkg
divided by  the ave. feed rate  in kkg) and an  energy  cost factor.   For
commercial blanchers, part of  the estimated operational costs were
based  on the  no.  of drive motors and their ratings,  measured water
consumption,  and measured BOD and SS content of  wastewaters.  Cost
of electrical  power was based on $0. 035/kilowatt hr (kwh).   Steam
costs were computed at a  rate of $2. 20/kkg.  Water costs were com-
puted based on $0. 10/3785 liters (1) [1000 gallons (gal. )].  Waste dis-
posal was based on $0. 023/kg (0. 05/lb) for BOD and SS removal during
treatment.   Cost of natural gas  was computed on the basis of $0. 76
/28. 3m3(1000 ft3).  Labor costs were based on $4.  00/hr plus $1. 20 in
benefits.  Each blancher was  assigned a half-time  worker for operation.
Cost of operating the pipe  blancher was based on water cost, heating
cost,  power cost for  circulation pumps, and dewatering screen-drive
motors.

The uncertainties of estimation made the cost estimate useful only as a
rough  screening of economic  practicability of a new blanching system
before more  extensive collection of cost factors for specific application
are made.
                               -22-

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                            SECTION V

                      EXPERIMENTAL RESULTS

BLANCHING AND WASTEWATER MEASUREMENTS

Green Beans

The results of short duration hot-gas blanching runs for cut green beans
are tabulated in Appendix B.  The conditions used to prepare canned
samples of hot-gas blanched green beans for evaluation by management
prior to long duration runs are tabulated in Appendix C.  The samples
prepared in Runs No. GB-41, GB-42,  GB-44 were judged to be of
commercial quality and conditions used  in these runs were established
for the  forty hr  of long duration operation.  The conditions used for the
long  duration hot-gas blanching of No. 4 sieve  size, cut,  green beans
were: a loading  of 14.6 kg/m^ (3 lb/ft^), a feed rate of  526-911 kg
(1160-2000 lb)/hr, an 80-96°C (176-205°F) operating temperature,  a
77 sec residence time, and a 3 percent gauge setting on the  meter
which gave 0. 30 kg (0. 66  lb)/min of steam flow. The results from  long-
term hot-gas blanching of cut green beans are  tabulated in Table  2.

Table 2.  LONG TERM HOT-GAS BLANCHING OF CUT GREEN BEANS

Date

8-15-72








8-16-72

Hour of
operation3-
0
1
2
3
4
5
6
7
8
9
10
Feed rate,
kg/hr
0
737
730
--
669

567

628

671
Temp,
°C

85
87
92
82
91
91
93
83
87
84
Peroxidase
reduction, %

17
17
28
33
20
18
55
51
19
27
                               -23-

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Table 2 (Continued).  LONG TERM HOT-GAS BLANCHING OF CUT
                     GREEN BEANS

Date Hour of
operation3-
11
12
13
14
15
16
8-17-72 17
18
19
20
21
22
23
24
8-18-72 25
26
27
28
29
30
31
8-19-72 32
33
34
35
36
37
38
39
40
41
Feed rate,
kg/hr

835
--

725

709
709
763


758
--
780
--
763



911
763
--
526


763


681

653
Temp,
°C
95
83
80
81
86
84
83
96
82
83
80
83
90
83
83
80
92
83
87
84
83
80
83
86
82
83
82
89
82
84
83
Peroxidase
reduction, %
54
40
83
17
43
42
51
44
35
23
19
26
54
45
37
0
40
44
32
39
30
27
70
42
33
37
62
23
33
27
37
a Total volume wastewater samples collected from
to 32,  and 32 to 40 hr of operation were 0. 473,  0. 1
0. 246 1.  respectively,   The  16 to 24 hr sample was
                                -24-
 0 to 8,  11 to 16, 24
13,  0. 620, and
 spilled and lost.

-------
 The wastewater volume and characteristics for hot-gas blanching of
 cut green beans are tabulated in Table 3.

 Table 3.  WASTEWATER VOLUME AND CHARACTERISTICS FOR
           HOT-GAS BLANCHING OF GREEN BEANS

Sampling
date

8-15-72
8-16-72
8-17-72
8-18-72
8-19-72
Wastewater
volume, 1

0.473a
0. 113b
c
0.620
0. 246
Weight
blanched,
kkg
5.33
3.90b
5.95
6.49
6.85
BOD,
mg/1

1170
6380

3530
6840
COD,
mg/1

2670
15500

7260
17400
SS,
mg/1

140
450

180
550
PH


7.2
6.8

--d
6.7
 a Eight hr collection periods.
   For period of 11 to 16 hr of  operation.
 c Sample spilled
 " Data not recorded.
 The commercial green bean blancher was a cylindrical tank,  partially
 filled with  1133 1 (300 gal. ) of hot water.  The blancher water was
 drained about every eight hr.  The wastewater  volume and character-
 istics of the make-up water overflow from the commercial cut green
 bean hot-water blancher are tabulated in Table 4.   The composite
 samples were prepared from equal volumes of  each of four grab samples
 taken at 2 hr intervals.

The volume of make-up water overflow was highly variable as shown by
the data in Table 4.   The variability was due to  the use of different set-
tings  of control valves for the make-up line and non-uniform practice in
turning off valves when the complete canning line was not operating due
to mechanical failures or rest periods.  See Appendix D for additional
data.
                                -25-

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Table 4.  WASTEWATER VOLUME AND CHARACTERISTICS FOR
          MAKE-UP WATER OVERFLOW COMPOSITE SAMPLES
          FROM COMMERCIAL BLANCHER  FOR CUT GREEN BEANS

Sampling
date


8-15-72
8-16-72
8-17-72
8-18-72
8-19-72
Total
weight
blanched,
kkg
12. 9
14.2
17.6
9.8
11.3
Total
volume,
1

882
406
339
303
272
BOD,
mg/1


8510
7070
3850
2870
4580
COD,
mg/1


13900
11800
6600
5280
7720
SS, pH
mg/1


1810 6.5
1520
530
470
810
Corn
The  results of short duration experiments on hot-gas blanching of corn-
on-cob are tabulated in Appendix E.  Corn-on-cob was  the only com-
modity studied in this project which was marketed as a frozen product.

A dozen ears  of corn from Run Number COC-20 were tagged and  frozen.
The  following day these ears were tested (with  subjective examination)
by a group of  Agripac, Inc. quality control specialists and compared
with commercially-blanched frozen ears of corn.  The  consensus of the
evaluation group was that the hot-gas blanched  corn would be  commer-
cially  acceptable but had a distinctly different flavor.  A decision was
made by Agripac,  Inc. management that the forty hr run of hot-gas
blanching of corn-on-cob should proceed but that all product produced
must be tagged and segregated after freezing for further quality evalu-
ation after three mo of storage.  A further condition was that the ears
of hot-gas blanched corn be cooled to a temperature as  low as the
water-cooled  corn on the commercial line before they were put into the
freezer.   This latter condition was met by installing a  second cooling
water  spray manifold and using five min of spray cooling, five min of
draining,  and a second five min  of spray cooling.  The  internal temper-
ature in the cob of hot-gas blanched corn, under  conditions of Runs 20-
22,  was 66-71°C (150-l60°F).   After the cooling sequence described

                                -26-

-------
above was used, the internal temperature of the cob ranged from 32-
43° C (90-110°F);  a commercial line sample taken at the end of the
water spray cooling had a cob temperature of 51°C (124°F).  In the
initial tests,  the bottom of the ears after the first five min of spray
cooling  were distinctly warmer than the tops.   In the long duration runs
the ears were rotated 180 degrees as they were held in the five min
draining station to achieve more uniform cooling.

The conditions  used for hot-gas blanching of corn-on-cob were: a load-
ing rate  of 22 kg/m2 (4. 5 lb/ft2),  a feed rate of 109 kg (240 lb)/hr, a
temperature range  of 99-110°C (210-230°F),  a residence time of 14
min, and steam injection at a rate of 2. 9 kg (6.4 lb)/min.  No pH deter-
minations were made on the corn-on-cob wastewater samples.

The results of  observations recorded and analyses made on product
samples collected during the long term hot-gas blanching of corn-on-
cob are tabulated in Table 5.

Table 5. LONG TERM HOT-GAS BLANCHING OF CORN-ON-COB

Date


9-18-72 a. m.








9-18-72 p.m.




Hour of
ope ration a

0
1
2
3
4
5
6
7
8
9
10
11
12
13
Temp,
°C

	
104
104
106
99
100
102
104
102
103
102
103
104
104
Kernel
peroxidase
reduction, %
—
98
100
92
100
100
98
90
97
100
100
87
97
97
                                -27-

-------
Table 5. (continued).  LONG TERM HOT-GAS BLANCHING OF CORN-
                      ON-COB

Date





9-19-72 a.m.







9-19-72 p. m.







9-20-72 a. m.




Hour of
operation3-

14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Temp,
°C

102
104
104
104
106
103
102
107
107
105
107
110
	
	
	
	
108
106
107
104
103
107
107
105
Kernel
peroxidase
reduction, %
100
97
93
98
98
99
98
92
100
100
100
100
100
100
100
100
100
91
100
100
100
100
100
100
    Total volume wastewater samples collected after 0 to 8, 8 to 16,
    16 to 24,  24 to 32 and 32 to 37 hr of operation were, 26. 4,  60. 5,
    52. 9,  52. 9 and 37. 8 1 respectively.

The wastewater volume and characteristic of samples collected during
hot-gas blanching of corn-on-cob are tabulated in Table 6.   The water
                                -28-

-------
used to cool the hot-gas blanched corn was not collected and, therefore,
its contribution to wastewater volume and BOD content was unknown.

Table 6.  WASTEWATER VOLUME AND CHARACTERISTICS FOR
          HOT-GAS BLANCHING OF CORN-ON-COB

Sampling
date
Wastewater
volume, 1
Weight
blanched,
BOD,
mg/1
COD,
mg/1
SS,
mg/1
kkg
9
9
9
9
9
-18-72
-18-72
-19-72
-19-72
-20-74
a.
P.
a.
P-
a.
m.
m.
m.
m.
m.
26.
60.
52.
52.
37.
4
5
9
9
8
a
a
a
a
b
0.
0.
0.
0.
0.
872
872
872
872
545
13500
14200
15100
16500
14200
24900
23700
24500
26400
23000
2640
2920
2350
2680
1200
a  Collected during eight hr of operation.
   Collected during five hr of operation.

The wastewater volume and characteristics for steam condensate from
commercial corn-on-cob blancher are tabulated in Table 7; additional
data are tabulated in Appendix F.

Table 7.  WASTEWATER VOLUME AND CHARACTERISTICS FOR
          STEAM CONDENSATE COMPOSITE SAMPLES FROM
          COMMERCIAL BLANCHER FOR FROZEN CORN ON-COB

Sampling
date


9-18-72 a. m.
9-18-72 p.m.
9-19-72 a.m.
9-19-72 p.m.
9-20-72 a.m.
^3 	 : 	 ' 	
Average
feed rate,
earsa/min

69
66
66
76
98
Total
weight
blanched,
kkg
9.95
9.69
9. 56
11. 0
15. 5
Total
volume,
1

960
677
919
1058
1150
BOD,
mg/1


15600
13800
13100
14200
13800
COD,
mg/1


21700
20600
20100
22700
21800
SS,
mg/1


2000
740
1300
1880
3190
   Ave. weight of corn ear before blanching was 0. 303 kg (0. 667 Ib).
Composite samples prepared from equal volumes  of each of four grab

                                -29-

-------
samples taken at 2 hr intervals.

Beets

It was possible to develop hot-gas blanching conditions for beets which
gave raw product which peeled satisfactorily and yielded canned pro-
duct judged by cannery personnel as commercially acceptable.  The
results of short-term experiments on hot-gas blanching of beets are
tabulated in Appendix G.  Due to an unexpectedly short processing
season for beets, it was possible to complete only nineteen hr of long-
duration operation.  The shortened operating season also limited col-
lection of commercial blancher wastewater data by NCA personnel, in
particular,  the volume and composition of blancher discharge water.

The  conditions used for the nineteen hr of hot-gas blanching of beets
were:  a loading  rate of 29 kg/m  (6 Ib/ft ),  a feed rate of 73-136 kg
(160-300 lb)/hr,  a 106-124°C (223-255°F) operating temperature, a
25 min residence time, and a steam injection of 1.9 kg (4. 2 lb)/min.
The  data collected during the nineteen hr of  hot-gas blanching of beets
are tabulated in Table 8.

Table  8.  LONG  TERM HOT-GAS BLANCHING OF BEETS

Date

10-5-72








10-6-72


Hour of
operation3-
0
1
2
3
4
5
6
7
8
9
10
11
Feed rate,
kg/hr
0
91
--
--
--
--
--
--
136
136
--
136
Temp,
°C
_ — —
106
122
118
116
122
124
119
117
116
120
118
Peroxidase
reduction, %
— — —
100
98
98
100
98
98
98
96
97
99
98
                                -30-

-------
 Table 8.  (Continued).  LONG TERM HOT-GAS BLANCHING OF BEETS

Date


10-10-72



10-11-72


Hour of
operation3"
12
13
14
15
16
17
18
19
Feed rate,
kg/hr
—
--
73
--
--
91
--
—
Temp,
°C
117
122
119
119
123
120
121
116
Peroxidase
reduction, %
98
98
98
97
98
98
96
100
    Total volume wastewater  samples collected at 0 to 4, 4 to 8,  8 to 12,
    12 to 16, and 16 to  19 hr of operation were 37. 9, 18. 9, 25. 5, 35. 2,
    and  35. 0 1, respectively.

 The wastewater volume and characteristics for hot-gas blanching of
 beets are tabulated in  Table  9.  No measurements of pH were made  on
 wastewater samples from hot-gas blanching of beets.  Additional data
 are tabulated in Appendix H.

 Table 9.  WASTEWATER VOLUME AND CHARACTERISTICS FOR
          HOT-GAS BLANCHING OF BEETS

Sampling
date

10-5-72
10-6-72
10-10-72
10-11-72
Wastewater
volume, 1

56. 8a
25. 5b
35. 2b
35. Oc
Weight
blanched,
kkg
0. 773
0. 544
0.292
0. 271
BOD,
mg/1

5360
	
7140
d
COD,
mg/1

8050
	
10900
d
SS,
mg/1

300
_ _
150
d
a  Eight hr of operation.
   Four  hr of operation.
c  Three hr of operation
   Sample  lost.
                                -31-

-------
The commercial beet blancher which was monitored was a rectangular
tank 1. 22 m (4 ft) by 0. 71 m (2 ft 4 in. ) by 9. 18 m (30 ft), partially
filled with approximately 7560 1 (2000 gal. ) of hot water.  The  blancher
was drained weekly  after five days of operation during which time 273-
364 kkg (300-400 tons) of beets were blanched.  The blancher was sit-
uated outdoors and it was observed that more steam was required on
cold days than on hot days.   The steam condensate formed the addi-
tional water which was  discharged from the  overflow pipe.  No water
was supplied to the blancher when it was  in operation.   The volume of
overflow from the blancher receiving the smallest sized beets was
measured on two days.   The results of volumetric measurements and
wastewater characterization of the make-up water overflow (steam con-
densate) of the commercial hot-water blancher for beets are tabulated
in Table 10.   Due to scheduling problems and the short processing
season  for beets,  it was not possible for NCA to directly sample blanch-
er dump water.  For purposes of calculation,  the values found for the
eight hr  composite sample  of 10-5-72 (BOD = 19,600  mg/1; and SS = 340
mg/1) were used for the blancher dump water composition.   The volume
of water corresponding to eight hr of beet blanching  on  10-5-72 was
21.8/(319) x  7560 or 517 1.
Table 10.  WASTEWATER VOLUME AND CHARACTERISTICS FOR
           MAKE-UP OVERFLOW COMPOSITE SAMPLES FROM
           COMMERCIAL BLANCHER FOR BEETS

Sampling
date

10-5-72
10-6-72
Weight
blanched,
kkg
21. 8
11. 1
Volume,
1

1999a
484b
BOD,
mg/1

14000
11400
COD,
mg/1

19600
16500
SS,
mg/1

340
230
a  Composite sample prepared from equal volumes of each of the four
   grab samples.
   Composite sample made up of equal volumes of the 2 and 4 hr grab
   samples.
                               -32-

-------
Spinach

A partial study of hot-gas blanching of spinach was made in March, 1972;
a more detailed study was made during the 1973 canning season.

The results of short duration runs with washed spinach are tabulated in
Appendix I.  These runs were sufficient to prepare enough samples for
quality evaluations  and  to receive approval of the cannery management
to make long-duration runs and return hot-gas blanched spinach to com-
mercial production.

The conditions used for the long-term hot-gas blanching of spinach
were:  a loading rate of 10. 7  to 14. 6 kg/m2 (2. 2 to 3. 0 lb/ft2), a feed
rate of 113-202 kg (248-444 lb)/hr,  operating temperatures of 99-
118°C (210-245°F),  a residence time of 108 sec and an average steam
flow of 0. 91 kg (2. 0 lb)/min.  The results of the long-duration hot-gas
blanching of spinach  are tabulated in Table 11.

Table  11.  LONG TERM HOT-GAS BLANCHING OF WASHED SPINACH

Date
3-28-72








3-29-72





Hour of
operationa
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Feed rate,
kg/hr
	
--
--
202
--
--
--

120

154
--
113
--
154
Temp,
°C
_ _
110
118
104
106
107
110
106
113
110
104
99
104
104
110
Peroxidase
reduction, %
_ _
97
97

99

99
99

99

99

99
—
                               -33-

-------
Table 11 (Continued).   LONG TERM HOT-GAS BLANCHING OF
                       WASHED SPINACH

Date



4-12-73






4-13-73







4-14-73









Hour of
operation3-
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Feed rate,
kg/hr
- -
173

154
--
136
--
--
132
--
144
--
--
158
--
132
--
144
158
144
122
--
144
--
144

156
Temp,
°C
104
110
104
104
99
113
110
104
102
107
104
107
107
104
107
104
107
110
107
104
107
110
107
104
102
104
107
Peroxidase
reduction, %
_ _
--


99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
99
a  Total volume wastewater samples collected from 0 to 8,  8 to 16,
   16 to 24, 24 to 32, and 32 to 40 hr of operation were 1. 8, 0. 74,
   0.42,  0.58,  and 0.511, respectively.

The presence of free water on the washed spinach loaded on the feed

                                -34-

-------
conveyor of the hot-gas blancher made direct weighings of samples of
washed and blanched spinach of questionable significance in determin-
ing actual weight changes due to blanching.  During the long-term  runs
in 1973, three samples each  of raw and of hot-gas  blanched spinach
were taken and moisture determinations made;  the results are tabu-
lated in Table 12.

Table 12.  MOISTURE  CONTENT OF RAW AND HOT-GAS BLANCHED
           SPINACH
Sample                                        Moisture content, a %
Raw
   1                                                    91. 7
   2                                                    91. 7
   3                                                    91. 5
Ave.                                                    91.6

Hot-gas blanched
   1                                                    90. 1
   2                                                    89. 7
   3                                                    90. 5
Ave.                                                    90. 1

a  Calculated on a wet weight basis.

The volume and characteristics of wastewater collected from the hot-
gas blancher during long term operation with washed spinach are tabu-
lated  in Table 13.  Additional date collected during the  1972  season are
tabulated in Appendix J.

The commercial spinach blancher monitored was a combination steam
and hot-water unit.  The blancher had a 1. 52 m  (5 ft) wide wire mesh
belt which  conveyed washed spinach through a steam section 3. 05 m
(10 ft) long and a hot-water section  12.2 m (40 ft) long and 0. 914 m
(3 ft)  deep.  The blancher had a rated capacity of 9. 09 kkg (10 tons)/hr.
For three 22. 5 hr operating periods in 1972, the weight of spinach
loaded into the blancher was 149,  174,  and 164 kkg, respectively.   The

                                -35-

-------
blancher had two continuous liquid waste discharge lines,  one for steam
condensate and one for water overflow.  Single measurements of the
flow rates of these lines in 1972 gave a volume of 221 1 (60 gal. )/min
for the overflow line and 113 1 (30 gal. )/min for the steam condensate
line.  The volume of these lines were measured frequently in 1973 and
the results are tabulated in Table  14.
Table 13.  WASTEWATER VOLUME AND CHARACTERISTICS FOR
           HOT-GAS BLANCHING OF WASHED SPINACH

Sampling
date

3-28-72
3-29-72
4-12-73
4-13-73
4-14-73
Wastewater^
volume, 1

1. 8
0. 74
0.42
0. 58
0. 51
Weight
blanched,
kkg
1.35
1. 18
1. 12
1. 14
1. 12
BOD,
mg/1

a
a
28600
15600
3700
COD,
mg/1

49900
13200
41300
24100
5400
SS,
mg/1

3400
2600
4700
1200
250
PH


7.4
7.7
7.0
7.3
5.9
a  BOD determinations were not made for wastewater samples collected
   in 1972.
   Total volume collected during eight hr of operation.

Table  14.  STEAM CONDENSATE AND  MAKE-UP WATER OVERFLOW
           RATES FOR COMMERCIAL  SPINACH BLANCHER

Sampling dates



4
4



4
and times


-9-73 1 pm
-12-73 10 am
12 pm
2 pm
4 pm
-13-73 8 am
Weight
blanched,
kkg/hr

8. 7
8. 6
7. 8
8. 0
8.4
8. 0
Steam
condensate
discharge rate,
1/min
68
110
76
110
110
110
Water
overflow
discharge rate,
1/min
565
604
572
572
545
588
                                -36-

-------
Table 14 (continued).
STEAM CONDENSATE AND MAKE-UP WATER
OVERFLOW RATES FOR COMMERCIAL
SPINACH BLANCHER

Sampling
dates
and times


4-16-73

4-18-73


4-19-73




1 pm
3 pm
12 pm
2 pm
4 pm
10 am
12 pm
2 pm
Weight
blanched,
kkg/hr

8. 8
8.4
8.2
7.8
8.6
8.4
8. 2
8.8
Steam
condensate
discharge rate,
1/min
102
110
117
76
102
102
110
114
Water
overflow
discharge rate,
1 /min
527
585
545
604
545
481
572
604
The hot water in the blancher tank was drained three times each day;
it had a volume  of 16980 1 (4480 gal. ).  The characteristics of the
blanch water are tabulated in Table 15 along with the results from ana-
lysis of samples of steam condensate  and water overflow discharge
lines.  Additional data collected during the 1972 season are tabulated in
Appendix K.

Table 15.   CHARACTERISTICS OF COMMERCIAL SPINACH BLANCHER
           DUMP WATER,  STEAM CONDENSATE, AND MAKE-UP
           WATER OVERFLOW

Sampling
date
4-12-73


4-13-73


Sample
type
DWa
sc-cb
WO-CC
DW
SC-C

BOD,
mg/1
3860
2840
70
3540
3070
-37-
COD,
mg/1
4630
4030
140
5050
3740

SS,
mg/1
160
170
75
190
230

PH

6. 2
6.0
7. 5
5. 8
5.9


-------
Table 15 (continued).  CHARACTERISTICS OF COMMERCIAL SPINACH
                      BLANCHES DUMP WATER, STEAM CONDEN-
                      SATE,  AND MAKE-UP WATER OVERFLOW

Sampling
date
4-13-74
4-19-73


Sample
type
WO-C
DW
SC-C
WO-C
BOD,
mg/1
80
3390
Z740
70
COD,
mg/1
140
4050
3160
120
SS,
mg/1
12
150
130
20
PH

7. 7
6. 8
6.7
7. 5
a  DW Single sample of dump water
   SC-C  Composite of equal volumes of steam condensate grab sam-
         ple collected at 2,4,6 and 8 hr.
c  WO-C  Composite of equal volumes of make-up water overflow grab
          samples collected at 2,4,6 and 8 hr.

Green Peas

The results of short-duration hot-gas blanching runs for green peas are
tabulated in Appendix L.  The conditions used for the long-duration hot-
gas blanching of peas were:  a loading rate of 14. 6 kg/m  (3 Ib/ft ), a
feed rate of 182-490 kg (400-1080 lb)/hr. 99-132°C (210-270°F) oper-
ating  temperature with an ave. steam flow  rate of . 94 kg (2. 08 lb)/min.
Due to the differences in size and maturity of peas available for hot-
gas blanching, the residence time was varied between 108 and 240 sec.
The variation in residence times accounts for the wide variation in
feed rates.  The results of  30 hr of hot-gas blanching of peas are tab-
ulated in Table 16.

Table  16.  LONG TERM HOT-GAS BLANCHING OF GREEN PEAS
Date                Hour of      Feed rate,    Temp,    Peroxidase
	                operationa     kg/hr         °C      reduction, %

5-11-73                 0
                        1           288          121          99
                                -38-

-------
Table  16 (continued).  LONG TERM HOT-GAS BLANCHING OF GREEN
                      PEAS

Date Hour of
operation3-
2
3
4
5
6
7
8
5-12-73 9
10
11
12
13
14
15
5-14-73 16
17
18
19
20
21
22
23
24
25
26
27
28
29
30b
Feed rate,
kg/hr
233
288
232
259
273
268
277
490
286
232
182
182
182
440
375
280
238
263
450
186
184
273
248
408
182
477
279
284
277
Temp,
°C
107
107
99
107
99
99
99
132
116
113
107
110
107
113
121
101
99
104
132
107
107
110
116
113
110
132
113
110
107
Peroxidase
reduction, %
99
99
99
99
99
99
99
99
99

99

99
99
--
99
--
--
99
--
99

99

99
99

99
99
a  The total volume of waste water  collected (corrected for the volume
   contributed by residual fluming water) at 0 to 8,  8 to 16,  16 to 24,
   and 24 to 29 hr of operation was  30. 5,  33. 1,  32. 6,  and 18. 1 1,
   respectively.
                                -39-

-------
   Ice supply exhausted,  no sample collected.

 The characteristics of wastewater collected from the steam condensate
 line of the hot-gas blancher during three  eight-hr periods and one five-
 hr period are tabulated in Table 17.

 Table 17. WASTEWATER VOLUME AND CHARACTERISTICS FOR
           HOT-GAS BLANCHING OF GREEN PEAS

Sampling
date

5
5
5
5

-11
-12
-14
-14

-73
-73
-73 a. m.
-73 p. m.
Wastewater
volume,

30.
33.
32.
18.
1

5
1
6
1
Weight
blanched,
kkg
2. 12
2.37
2. 12
1.63
BOD,
mg/1

3100
13800
10100
7330
COD,
mg/1

4070
31800
18100
14400
SS,
mg/1

100
340
440
—
PH


7. 2
7. 0
6. 0
—
 The commercial pea blanchers consisted of three pipes through which
 the peas were pumped in hot water.  The rated capacity for the three
 pipe blanchers was 9. 09 kkg (10 ton)/hr.  The commercial pea blancher
 which was monitored  was a stainless steel pipe 10 centimeters (cm)
 (4 in. ) in diameter, approximately 34. 1 m (112 ft) long, with a capacity
 of approximately 380  1 (100 gal. ).   The source of make-up water for the
 pipe blancher was  a water manifold (3 spray lines) used to rinse  and
 partially cool peas  after separation from the recirculated hot-water.
 The flow rate of the rinse water which returned to the pipe blancher
 surge tank was 9.51 (2. 5 gal. )/min based on the  average  of six mea-
 surements.  The hot-water in the  pipe blancher system was discharged
 about every  8 hr of operation.  The results obtained on analysis of grab
 samples collected  every 2 hr from the surge tank are tabulated in
 Appendix M.  Characteristics of the commercial  blancher's wastewater
 samples are  summarized in Table 18.

PRODUCT EVALUATION

The results of analysis of single canned samples prepared from hot-gas
or commercially-blanched material for  headspace gas composition are
                                -40-

-------
tabulated in Table 19.

Table 18.   CHARACTERISTICS OF COMMERCIAL GREEN PEA PIPE-
           BLANCHER DUMP WATER AND MAKE-UP WATER

Sampling
date

5-8-73

5-9-73

5-10-73

5-11-73

5-12-73

5-14-73
Weight
blanched,
kkg
20.4

21.2

20. 1

20. 5

20. 6

20. 7
Sampling
typea

DW
WO-C
DW
WO-C
DW
WO-C
DW
WO-C
DW
WO-C
WO-C
BOD,
mg/1

6920
4820
8250
5800
8890
4650
4650
6180
4060
6500
7410
COD,
mg/1

9800
7040
11800
7040
13100
7710
8170
10700
5000
10400
13600
SS,
mg/1

470
210
410
290
390
230
220
210
210
310
190
PH


8.4
8.4
7. 1
8.2
6. 8
7. 2
7.4
7. 0
8. 8
8. 1
8. 1
a See footnotes a,  c of Table 15.

Table 19.  HEADSPACE GAS COMPOSITION OF CANNED VEGETABLE
           SAMPLES

Commodity
(blancher )
Green beans
(commercial)
(hot-gas)
Beets
( commercial)
(hot-gas)
Headspace
volume, ml

119
117

a
a


N2

90.
86.

87.
93.

3
4

4
8


co2

1.
5.

7.
5.

1
0

6
0
Percent of



Argon+02 H2

8.
5.

1.
1.

6
2

9
2

0.
3.

3.
0.

0
4

1
0
                              -41-

-------
Table 19 (continued).  HEADSPACE GAS COMPOSITION OF CANNED
                      VEGETABLE SAMPLES

Commodity
(blancher)
Spinach
(commercial)
(hot-gas)
Peas
(commercial)
(hot-gas)
Headspace
volume, ml

40
146

10. 9
13.4
Percent of
N2

88. 5
87.6

89.8
92.5
C02

4.3
10. 7

7.4
5. 1
Argon+02

5. 3
1.7

2.8
2.4
HZ

1.9
0.0

0. 0
0. 0
a  Data not recorded.

The results of replicate analyses for vitamin content of raw, hot-gas
blanched, and commercially blanched vegetable samples are tabulated
in Appendix N.

The results of replicate analyses for mineral content of raw, hot-gas
blanched, and commercially-blanched vegetable samples are tabulated
in Appendix O.  The average values  found for nutrient content of vege-
table  samples are tabulated in Table 20.

Table 20.  NUTRIENT CONTENT OF RAW, HOT-GAS BLANCHED,
           AND COMMERCIALLY BLANCHED VEGETABLES
                              (mg/100  g wet weight)
Commodity     Nutrient        Raw      Hot-gas     Commercially
                                          blanched      blanched
Green beans    Vitamin Aa     --         0.34            0.32
                Vitamin Bj      0.08      0.06            0.07
                Vitamin B2      0.07      0.06            0.06
                Vitamin B6      0.03      0.03            0.05
                Vitamin C        7.3       2. 2             1.3

                               -42-

-------
Table 20 (Continued).
NUTRIENT CONTENT OF RAW,  HOT-GAS
BLANCHED, AND COMMERCIALLY BLANCHED
VEGETABLES (mg/100 g wet weight)

Commodity





Corn




Beets



Spinach






Peas








Nutrient

Niacin
Calcium
Magnesium
Phosphorus
Vitamin B }
Vitamin BZ
Vitamin B£
Niacin
Phosphorus
Vitamin B2a
Vitamin C a
Niacina
Phosphorus
Vitamin A
Vitamin B£
Vitamin C
Calcium
Magnesium
Phosphorus
Iron
Vitamin B j
Vitamin ~S>2
Vitamin B&
Vitamin C
Niacin
Calcium
Magnesium
Phosphorus
Iron
Raw

0.46
32
19
20
0. 12
0. 04
0.20
1.9
92
--
--


2.41
0. 15
0
47
55
33
2.6
0.31
0. 12
0. 19
15.4
2. 13
25
34
89
2.0
Hot-gas
blanched
0. 36
31
17
18
0. 18
0. 04
0. 20
1.9
90
0. 03
2. 7
0. 06
110
4.41
0. 13
12. 2
66
66
33
3. 1
0. 39
0. 13
0. 23
22. 5
2. 27
23
36
93
3. 0
Commercially
blanched
0.51
38
23
21
Oo 16
0. 04
0.20
1.9
86
0.05
3,0
0.09
97
4. 14
0. 10
7. 0
66
45
40
2.5
0.40
0. 09
0. 16
11.4
1. 94
20
29
79
1.9
  Analysis conducted on canned samples.
                               -43-

-------
 The results  of analyses for polynuclear hydrocarbon content of canned
 green bean samples are tabulated in Table 21.

 Table 21.  LEVELS OF POLYNUCLEAR HYDROCARBONS IN  CANNED
           GREEN BEAN SAMPLES

Sample

Hot-water blanched
Hot-gas
Hot-water
Hot-water
Hot-gas
Hot-gas
Hot-water
Hot-gas
Hot-water
Hot-water
Hot-gas
Fortification
level, ppb
100
0
0
0
0
0
0
0
10
10
0
Polynuclear hydrocarbon
content, ppb
87
12
8. 7
8. 7
5.6
4. 3
3. 7
2.4
6.3
7.2
2. 0
The  sequence of results are tabulated in the order in which each analy-
sis was made.  The same set of glassware was used to saponify and ex-
tract each sample.  See Appendix A.  The downward trend in results
indicated contamination of the glassware  by the high-level fortified [100
parts per billion (ppb)] sample.  As subsequent analyses were run,
material was  slowly released from adsorption on glass surfaces to give
values higher than actually present.  The glassware was rinsed with
hot nitric acid prior to the last analysis and the result was below the
sensitivity level of 2 ppb.

A maturity determination was made with  canned pea samples.  A large
part of the score (50 of 100 maximum points) in the quality grading of
canned peas is the maturity and tenderness factor.   The maturity fac-
tor is derived from a flotation test of peas in sodium chloride brines of
11, 13, and 15 percent concentration.  Eleven cans from the commer-
cial  line packed on 5-12-73,  one can packed from all hot-gas blanched
peas on 5-12-73, and 12 cans from all hot-gas blanched peas  packed on

                                -44-

-------
5-12-73 were measured for vacuum, headspace, net weight, total
count,  and no. of peas which sank in three different concentrations of
brine.   These tests were made on 5-16-73.  The results of the exam-
ination of 24 cans  of peas are tabulated in Appendix P.

The evaluation of hot-gas blanched bean samples for consumer accept-
ance was an important part of this project.  It was possible to arrange
for the evaluation, by food appraisal specialists at Oregon State Univer-
sity, of samples of canned, cut green beans after various periods of
accelerated storage  at 38°C (100°F).

The results obtained on  samples one mo after canning are tabulated in
Table 22.

Table 22.  RESULTS OF ORGANOLEPTIC EVALUATION OF CANNED
           GREEN BEANS ONE MONTH AFTER CANNING

Mean Score
Factor
evaluated
Appearance
Texture
Flavor
Overall
Desirability
Sample A
(hot-water)
4. 82
4.75
4.95

4. 85
Sample B
(hot-water)
4. 07
5. 05
4. 77

4. 80
Sample C
(hot-gas)
4. 70
4.60
4.32

4.35
Sample D
(hot-gas
4. 55
5. 15
4. 77

4. 80
LSDa
(0. 05)
0.53
0.49
0.60

0. 52
a  Least significant difference at 5 percent probability level.  When the
  difference in mean scores of two samples exceeds the LSD the differ-
  ence in scores is significant.

The results of testing samples of canned beans stored at 38°C (100°F)
for periods of 3 and 6 mo are tabulated in Table 23.

Samples of frozen corn-on-cob prepared with hot-gas blanching and
steam blanching (commercial) were evaluated by a 50-member panel
at Oregon State University after storage for one mo.  The results from
this examination are  tabulated in Table 24.
                                -45-

-------
Table 23.  RESULTS OF ORGANOLEPTIC EVALUATION OF CANNED
           GREEN BEANS AFTER STORAGE AT  38° FOR THREE AND
           SIX MONTHS
Factor
evaluated
                                   Mean Score
             Sample A   Sample B    Sample C   Sample D   LSDa
             (hot-water) (hot-water)  (hot-gas)   (hot-gas)   (0.05)
                    6b
                               6b
 3b   6b    3b    6b  3b   6b
Appearance  6.40  6.45 5.92  5.82
Texture
Flavor
Overall
6.40  6. 90 j 7. 45  7. 12
                                                            .46 .43
             6.22  6. 25 j 7. 02  6.82   6.77  6. 37 ' 7. 00  6.72  .49 .56
             5.65  6. 10 I 6. 75  6.35  j 6. 30  5. 71 j 6. 05  5. 92 ' . 54 .56
Overall      ^ 65  ^. 27 : 6. 52  6.12  16.30  6. 00 ! 6. 40  6.501.49 .51
Desirability            <             i           •            ;
aSee footnote a of Table 22.
 Storage times in mo.

Table 24.  ORGANOLEPTIC  PANEL EVALUATION OF FROZEN  CORN-
           ON-COB AFTER STORAGE FOR  ONE MONTH AT  -18°C

Factor
evaluated
Appearance
Texture
Flavor
Overall

Desirability
Sample A
( steam)
7. 18
5. 80
6.40

6. 08

Sample Ba
(hot-gas)
6.40
5.26
5. 52

5. 12

Sample C
(hot-gas)
6. 50
5. 80
6. 32

6. 02

Sample D
(steam)
7. 08
6. 12
5. 78

5. 72

LSD
(0.05)b
0. 55
0. 53
0. 60

0. 55

  It was noted that Sample B was a more mature,  starchy corn than
  the other three samples and this is reflected in the lower texture and
  overall desirability score.
  See footnote a of Table 22.
A triangular set of commercially-blanched and hot-gas blanched spin-
ach from the 1972 season was presented to a panel of sixteen persons
(four  replicates) after the cans had been stored for 10 weeks at room
temperature.  In a total of 57 judgments obtained in four sessions (us-
ing a  randomized presentation of the  samples), 29 were correct (sig-
                               -46-

-------
nificant at the p=0. 01 level) matchings of two identical samples.

In a second type of evaluation, a ranking test of flavor preference using
three commercially-canned samples and hot-gas blanched spinach
(canned under commercial conditions) gave the results tabulated in
Table 25.

Table 25.  TASTE PANEL RANKING  OF THREE COMMERCIAL AND
           ONE HOT-GAS BLANCHED SAMPLE OF CANNED SPINACH

Sample
Commercial A
Commercial B
Commercial C
Hot-gas
Brine salt content, %
1. 16
0.85
0.94
0.96
Taste panel rankinga
3. 04
2.62
2. 04
2. 38
a  1 = Best flavor;  4 = Worst flavor;  56 judgments.

In addition to the laboratory organoleptic evaluations,  very substantial
quantities of commercial production of green beans, corn, beets,
spinach, and green peas containing material from hot-gas blanching
were sold.  No adverse consumer reaction was recorded,up to the
time of this report about any of these  production lots,  which could be
attributed to the blanching used.

ENERGY REQUIREMENTS

Electrical,  gas and steam flow meters on the hot-gas blancher were
used to develop information on power  requirements.  The energy con-
sumption values obtained during hot-gas blanching of green beans, corn-
on-cob, beets,  spinach and peas are tabulated in Table 26.
                               -47-

-------
Table 26.  ENERGY CONSUMPTION DURING HOT-GAS BLANCHING
          OF VEGETABLES

Cumulative
Cumulative
operational
hr

Green Beans
8. 6
16.6
24.4
32.2
41. 1
Corn
8. 5
16.0
23.3
32. 1
37. 0
Beets
7.9
14.4
19. 0
Spinach
7. 0
15. 0
22. 0
Peas
8. 0
16. 0
24. 0
30. 0
electrical
blower



33
59
90
120
150

12
29
40
57
64

14
25
23

88
180
280

40
81
120
140
energy
turbine



6
12
17
22
28

4
8
13
17
21

6
11
18

19
33
43

29
58
87
110
used, kwh
conveyor
controls


3
5
7
10
13

1
2
3
4
4

1
2
5

4
7
15

2
3
4
4

Cumulative
steam use,
kkg

0. 15
0.29
0.42
0. 56
0. 71

1.5
2.7
4. 0
5.5
6.4

0.9
1.6
2. 2

0. 38
0.82
1.2

0.46
0. 73
1.2
1.7

Cumulative
gas use,
m3

4.25
7. 65
11. 3
14. 7
17. 8

7. 09
8. 21
11. 3
18.5
20.4

11. 3
13.6
15.9

3. 96
4. 82
6. 23

4. 53
8. 78
12. 8
16.4
                             -48-

-------
                           SECTION VI

                           DISCUSSION
BLANCHING, WASTEWATER, AND PRODUCT EVALUATION

Any modification in food processing equipment must be  rigorously
evaluated in terms of reliability, safety,  ease of sanitation,  mainten-
ance, and cost per unit of material processed.  In recent years,  the
rate of  generation of gaseous, liquid,  and solid by-products as poten-
tial  contributors to  air, water, and soil pollution has become an im-
portant food processing equipment design criteria.  The final product
which results from  use of modified processing equipment must be at
least equivalent in wholesomeness, texture, flavor,  appearance,  and
nutritive value to the product prepared with current equipment.   During
the course of this investigation of in-plant, hot-gas blanching of vege-
tables,  all of the above outlined criteria were evaluated albeit at vari-
ous  degrees of completeness.

The prime motivation of this study was the attempt to demonstrate
commercial feasibility of a new blanching system which would sub-
stantially reduce the volume of liquid wastes now produced during
steam or hot-water blanching  of vegetables.  Therefore, much atten-
tion was devoted to  measurement of wastewater generation from  both
the hot-gas  blancher and the commercial  blanchers.   As the  critical
evaluation centered on reduction of waste treatment costs possible with
the new blanching system,  wastewater measurements were made for
volume, BOD, COD, SS, and pH.  Table 27 gives a summary of the
comparisons of wastewater volume,  BOD, COD, and SS for hot-gas  and
commercial blanching of five vegetables.   The values tabulated in Table
27 are expressed in percentages in Table 28.

It must  be emphasized that the percentage reductions shown,  apply to
only one location and it is  well known that water usage and waste gen-
eration  vary over a wide range for different plants processing the same
commodity, (Holdsworth ). In any consideration of the  commercial
application  of hot-gas blanching,  it would be necessary  to use data on
wastewater  generation from each individual operation to calculate ex-
pected percentage reductions.

It was not possible to evaluate completely the factors of equipment
reliability,  maintenance, ease of sanitation, and safety  because the
                                 -49-

-------




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            -51-

-------
a Dividing by 4. 17 will convert 1/kkg to gal. /ton.
  Dividing by 0. 5 will  convert kg/kkg to Ib/ton.
c Values for commercial blanchers included water overflow,  steam
  condensate,  and dump  water.
  See Appendix Q for example of calculation.

Table 28. PERCENTAGE REDUCTION OF WASTEWATER VOLUME,
          BOD, COD,  AND SS DUE TO HOT-GAS BLANCHING OF
          VEGETABLES

Commodity
Green beans
Corn
Beets
Spinach
Green peas

Percentage
Wastewater volume
99.
33.
(2.
99.
94.
9
3
2)a
9
2
reduction
BOD
99. 9
28. 3
47. 5
99.8
91.4
COD
99.9
22.2
56.5
99.2
90.0
SS
99.9
18.7
37. 0
99.5
93.0
a  Value in parenthesis is percentage increase.

hot-gas blancher used was an experimental design possibly quite diff-
erent from any future commercial unit.

The experimental hot-gas blancher was operated safely during a total
of approximately 300 hr of in-plant work.  The natural gas furnace had
elaborate safety controls and the accumulation of  gas, which would
represent the major hazard, was highly improbable.  The combustion
of the natural gas was complete so  the formation of  carbon monoxide  in
toxic amounts was highly unlikely.

There was no overt evidence of difficulty in sanitizing the hot-gas
blancher.  The blancher was operated at a temperature above those
tolerant to the growth of microorganisms.   There was  some sticking
to the conveyor belt surface of small pieces of vegetables or their

                               -52-

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parts (beet-hair roots, beet stems, corn silk,  etc. ).  These sticking
pieces tended to stay on the belt and gradually  dry out and caramelize
as the belt recycled through the  heated zone.  The sticking pieces did
not fall off the belt to  contaminate freshly blanched vegetables.  There
was no difficulty experienced in  cleaning the wire mesh conveyor belt
with small volumes of water after several  hr of continuous operation.
The hot-gas blancher did not present any unusual maintenance problems
during the period of operation.

The quality of final products from hot-gas blanched vegetables was a
major concern in this  study.  The quality evaluation of products  from
hot-gas blanching was made at three stages. The first stage was sub-
jective examination of freshly blanched material by experienced  indus-
try persons.   A combination of appearance, feel, taste,  and color
change was used to decide if a sample was  adequately blanched.  After
passing this first screening test, blanched  samples were preserved,
by use of commercial  equipment, as canned or frozen final products.
The preserved samples were given a complete  quality control  exam-
ination using objective tests and  were also  evaluated  subjectively for
color, flavor, and  texture differences by a group of technical and
management persons employed by the cannery.  This evaluation  was
the basis for approval to  conduct long term  runs with hot-gas
material returning  to the production line.   The third  stage of evalua-
tion was controlled laboratory organoleptic panel comparison of  sam-
ples and/or the sale of products  through ordinary commercial chan-
nels.   This latter form of evaluation was the only possible method for
spinach, beets,  and peas where hot-gas blanched material was mixed
with commercially  blanched material.  For frozen corn-on-cob and
canned green  beans, the hot-gas blanched portion was kept separate
and identified.

The very fact  that every commodity studied was accepted for return to
production after hot-gas blanching demonstrated the utility of this
method with a considerable degree of confidence.  The sale of beets,
spinach, and peas  containing mixtures of hot-gas blanched and com-
mercially blanched material has resulted in no adverse consumer re-
sponse.

The organoleptic evaluation of green beans  made by Oregon State Univ-
ersity, and tabulated in Table 23,  indicates  that there is no significant

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difference in overall desirability between hot-gas and hot-water blanch-
ed samples.  Similar evaluation of frozen corn-on-cob (Table 24) was
complicated by maturity difference in the samples.  The significantly
lower preference for hot-gas blanched corn-on-cob due to difference in
appearance may be a deterrent to use of hot-gas blanching of this com-
modity.

The  results of the taste panel ranking of canned spinach samples (Table
25) demonstrated no  significant preferences among three commercial
and one hot-gas blanched samples.  However, a triangle test in differ-
ences in canned spinach samples from the 1972  season did demonstrate
a significant flavor difference between hot-water blanched and hot-gas
blanched spinach.

One  of the expectations for hot-gas blanching, when it was first con-
sidered, was improved retention of water soluble vitamins and min-
erals due to reduced water leaching of soluble components.  The pro-
duction of a more  nutritious food with hot-gas blanching would justify
part of the expense of shifting to this new method.  For this  reason,
and due to the need for information on nutrient retention, considerable
effort has been devoted to measuring vitamin and mineral content as a
function of the type of blanching used.

The  results of nutrient retention measurements were tested for signi-
ficance in those cases where results were available for three or more
commodities.  The results of nutrient analysis  of thiamin (Vitamin B^),
riboflavin, (Vitamin  B£),  ascorbic acid (Vitamin C), Vitamin B^, nia-
cin,  phosphorus, calcium, and magnesium were subject to randomized
complete-block tests using the commodities as  blocks and the blanch-
ing conditions as treatments.  None of the computations produced F-
values larger than the tabulated F-values for the appropriate degrees
of freedom of the variance ratios.  The over-all data available to date,
with the exception of ascorbic acid retention in  canned spinach (see
Appendix N),  strongly suggests that there is no  significant difference in
vitamin and mineral  retention when hot-gas blanching is compared to
steam or  hot-water  blanching.  The higher level of retention of ascor-
bic acid in canned spinach from hot-gas  blanching is significant and is
supported by a higher level in blanched samples compared to raw and
hot-water blanched samples.

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An observation made by technicians at Oregon State University, who
were preparing taste-panel samples of canned green beans held at
38°C (100°F) for three mo, has led to a more detailed study of the ex-
tent  of internal can corrosion by Agripac, Inc.  and their container
supply company.  Sets  of ten No.  10 cans each of hot-water and hot-
gas blanched green beans were opened at 12°C (54°F) after five mo of
warehouse storage.   The extent of  corrosion was rated from visual
inspection by experienced persons from a container supply company
on a scale of 1 = no corrosion  and 10  = detined completely.  The set
of hot-water blanched bean cans showed an average  corrosion number
of 4. 5 compared to a corrosion number of 2. 3 for cans used for hot-
gas blanched beans.

If the extent of corrosion continues to be lower in hot-gas blanched
green bean cans, a considerable saving in container costs  could help
to justify commercial use of hot-gas blanching.

Examination of cans used to store hot-gas and hot-water blanched
green beans for six mo at 38°C (100°F) was made by Oregon State
University with the following results:

           "When examined immediately after opening, there
           appeared to be very little difference in the black
           film on the insides of the cans. Some people thought
           that the hot-gas cans were not quite so black,  but
           the difference was so small as to  be questionable.
           Close examination of the surface of the cans showed
           that the control cans appeared to be quite extensively
           detined.  After setting in the laboratory for a few
           days, the  control cans  showed quite extensive inter-
           nal rusting,  and the  hot-gas cans  only a small amount
           of rusting, indicating that there was more detinning  on
           on the controls than in the hot-gas cans." (Beavers  ->)

COMPARISON OF COSTS OF BLANCHING SYSTEMS

In any consideration of new processing technology,  the cost of  opera-
tion  per unit of production is one of the most important factors in de-
cision-making.  It was  possible to get exact operating costs for the
experimental hot-gas blancher by metering power and steam use.

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Table 29 tabulates the dollar cost per kkg (2200 Ib) of vegetable blanch-
ed for hot-gas,  steam, and hot-water blanching of five  vegetables.
Examples of detailed calculations are tabulated in Appendices Q,  R,
and S.

Table 29.  ESTIMATED COST OF BLANCHING VEGETABLES
                           ($/kkg blanched)
Commodity
                                  Blanching System
Hot-gas
Steam
Hot-water
Green Beans
Fixed costs
Operating cost
Total cost
Corn-on-cob
Fixed cost
Operating cost
Total cost
Beets
Fixed cost
Operating cost
Total cost
Spinach
Fixed cost
Operating cost
Total cost
Green Peas
Fixed cost
Operating cost =
Total cost

2. 19
0. 75
2. 94

11. 70
5. 20
16. 90

13.28
5. 90
19. 18
8. 26
2. 30
10. 56

4. 35
1. 83
6. 18

1.41
0.99
2.40

1.11
1.40
2.51

1.24
1.01
2.26
1.68
1.21
2.89

0.88
1.51
2.39
This estimate for steam and hot-water blanching was made using pub-
lished steam requirements for blanchers (Lopez  ), cost of operation

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of conveyor-drive motors,  cost of make-up water, and estimates of
wastewater disposal costs.

The estimates of first cost for commercial scale blanchers was  ob-
tained from commercial suppliers or potential suppliers.  The first-
cost of hot-gas blanchers was based on cost of modules which could
be arranged in series  to provide blanching conditions for each com-
modity.  The required number of modules was computed from feed
rates observed during experimental hot-gas blanching.   Table 30
summarizes the basis of computing first-cost of hot-gas blanchers
for various commodities.

Table  30.  BASIS FOR ESTIMATING FIRST COST OF COMMERCIAL
           SCALE HOT-GAS BLANCHERS

Commodity Average feed Scale-up Relative
ratea, kkg/hr factor scale-up
factor
Green beans 0. 720 7 1
Corn-on-cob 0. 109 46 6
Beets 0. 105 48 7
Spinach 0. 158 31 4
Green peas 0. 336 15 2
No. of First
modules0 cost,
$
2 50,000
12 255,000
14 285,000
8 185,000
4 100,000
a  For experimental data,  see Tables for long term blanching of each
   commodity.
k  See Experimental Plan (Economics) for basis of calculating scale-
   up factors.
c  Estimated cost/module:  1  to 5 @ $25, 000/each;  5 - 10 @ $20, OOO/
   each; 10 - 20 @ $15, 000/each.

Only in the case of  green bean blanching is the operation cost of hot-
gas blanching competitive  with commercial blanching costs.  The high

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operational costs for corn-on-cob and beet blanching are due to the
light loading,  long residence time, and high steam-injection require-
ments.  The operational cost for hot-gas blanching of spinach is a
factor of two higher than hot-water blanching and the increased cost
could only be justified by offsetting savings in waste disposal costs.
It is expected that some reduction of cost for hot-gas blanching would
result from increased efficiency of a commercial-scale unit compared
to  the experimental unit.

The most significantly different cost factor in comparing hot-gas
blanching with steam and hot-water blanching is in waste management
Hot-gas blanching may be  more attractive  economically in the next
few years as waste treatment costs increase as the national  goal of
zero discharge of pollutants by 1985 is approached.  The very small
volume of liquid effluent produced during the hot-gas blanching makes
it an excellent choice as part of closed-loop technology if this is
proven possible.

The cost of treatment will increase as the percent removal of BOD
and SS increases,  For those processors discharging into municipal
treatment systems,  an increase in treatment level will increase the
surcharges paid by the industrial discharger.   It is likely that waste
management costs will increase substantially;  this will make hot-
gas blanching economically more competitive with steam or  hot-
water blanching for additional  vegetable commodities.

There has  been much publicity recently about the "energy crisis".
There seems to be  little doubt that fossil fuel energy sources will be
in  short supply for  the period of 1974  to 1980.  The reasons  for the
potential shortage of such fossil fuels as natural gas  are the high-
rate growth of energy consumption (4  percent per  year)  and reduction
in  the U.S.  reserves-to-production ratio.  The reasons for the latter
fact are complex, but deliverable supplies  of natural gas are shrink-
ing and in a number of areas potential customers have been unable to
obtain supply commitments.

The predicted shortage of natural gas may  cause potential users of
hot-gas blanching to postpone use of this new blanching system.  For-
tunately, the hot-gas blancher  operates with liquified propane as a
fuel.  Under the allocation program in effect since May,  1974, food
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processing is one of the categories listed as "priority customers"
(some others are residential uses,  agricultural production and mass
transit vehicles).  Therefore, it is highly likely that vegetable pro-
cessors using hot-gas blanching could get adequate supplies of pro-
pane.  For the longer term future,  use of liquified natural  gas and
new sources such as  the Siberian production area and gasification of
coal should provide ample supplies up to the end of this century.

DEHYDRATION DURING HOT-GAS BLANCHING

A major reduction in operational cost would result if dehydration of
the hot-gas  blanched  material were accepted, as this would lower
steam cost.  It is likely that partially dehydrated  beets would recover
their water  content after canning.   Partially dehydrated corn-on-cob
may recover water during spray cooling.  Neither of these possibil-
ities have been examined as yet.  If it were possible to accept par-
tial dehydration of vegetables during hot-gas blanching, both opera-
tional costs and cost  of wastewater treatment would be substantially
reduced.

The 1. 5 percent  difference in moisture content between raw and  hot-
gas blanched spinach represents an 18 percent increase in  solids con-
tent or approximately 2 percent actual weight loss due to  the dehy-
drating effect of  hot-gas blanching.  This level of dehydration would
be of concern to  a freezer of spinach,  but for canned spinach a 2  per-
cent reduction in fill  weight would provide the proper fill  of container
for processing and standard of identity specifications.  It is expected
that spray cooling of  hot-gas  blanched spinach prior to preservation
by freezing would accomplish a partial rehydration and lead to reas-
onable weight recovery.

The data shown in Appendix P confirm the observations made about
weight loss and cooling of  hot-gas peas as they were conveyed approx-
imately 34 m (110 ft)  from the blancher to the filler.  The  lower
vacuum found is  due to a lower temperature of can contents at the
time of closing of the cans.  There is no significant difference in
headspace.   The  net weight of hot-gas blanched peas  was  5. 6  g
[0.2 ounces  (oz)] higher due to filling of more peas having  a higher
average solids content.  The  count of peas from hot-gas blanched
samples was 2.8 percent higher than the hot-water (commercial)

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blanched samples.  The observed count difference indicates about a
3 percent weight loss due to hot-gas blanching of peas.  The short
duration runs TLFP-5 and TLFP-15 (see Appendix L) were made
under conditions similar to the long duration runs and 14-15 percent
weight losses were recorded.  The weighing of partially dewatered
peas and losses in collecting blanched peas  from the conveyor belt
made these values uncertain.

The higher no. of peas  sinking in each of the three different salt solu-
tions from hot-gas  blanched peas indicates that rehydration was not
complete even after 9 days  of storage.   Peas were quality graded
within a few hr of retorting and the data clearly confirm the cannery
quality  control records showing lower grading of samples containing
hot-gas blanched peas.   If hot-gas blanching of peas ever  becomes  a
common commercial practice, it will be necessary to amend  the
maturity test  ranges in the  USDA Standards of Cuality regulations to
more accurately reflect the  storage equilibrium conditions rather than
apparent maturity immediately after retorting.

Hot-gas blanching of peas for frozen preparation would  require  a water
application during cooling.   The  peas could  recover most  of the 3 per-
cent dehydration loss.

OVERALL CONSIDERATIONS

The experiences with in-plant hot-gas blanching of vegetables has
demonstrated that this new  system is technologically feasible for
certain  vegetables (such as cut green beans, peas, and  spinach).  The
hot-gas blanching of larger piece size vegetables (such  as corn-on-
cob and beets) is not feasible due to the long residence times  necessary
for achieving  requisite  blanching temperature in the center of the veg-
etable.  The reduction in wastewater generation during  hot-gas  blanch-
ing of corn-on-cob  and  beets is  not large enough to justify the high
estimated capital costs of commercial  scale blanchers.  The  use of
hot-gas blanching looks most promising for canned or frozen  cut green
beans.  Although not demonstrated as yet,  the use of hot-gas  blanch-
ing of vegetables (such  as diced carrots) destined for preservation  in
a dehydrated state appears  to have considerable promise.  It  is likely
that hot-gas blanching will first be used on a commercial  scale  in
unique situations.   The factors which will promote commercial  use  of
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hot-gas blanching are:  (1) shortage of potable water, (2) good supply
of natural gas or propane, (3) high costs of liquid waste disposal and,
(4) a commodity which  regains dehydration losses readily.

For the long term future,  as food processing operations move toward
total in-plant recycle of reconditioned water, the use of hot-gas
blanching will increase due to its potential for adequate blanching
with minimum generation  of liquid waste.
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                          SECTION VII

                          REFERENCES

1.    Weckel, K. G. ,  Rambo, R. S. , Veloso, H. ,  and von Elbe,
      J.  H. ,  "Vegetable Canning Process Wastes," Research Report
      38, College of Agriculture and Life Sciences, University of
      Wisconsin (1968).

2.    Weckel, K. G. ,  unpublished data (1970).

3.    Rails,  J. W. ,  and Mercer,  W. A. ,  "Low Water Volume En-
      zyme Deactivation of Vegetables before Preservation,"  EPA
      Technology Series, EPA-R2-73-193 (May 1973).

4.    Mukai, M. ,  Tebbens,  B.  D. , Thomas, J.  F. ,  "Multidimen-
      tional Chromatography of Areanes Produced During Combus-
      tion,"   Anal.  Chem. ,  36:1126-1130 (May 1964).

5.    Bryan, G. T. ,  and Lower,  G. M. , Jr. , "Diverse Origins of
      Ubiquitous Environmental Carcinogenic Hazards and the Im-
      portance of Safety Testing, " J. of Milk and Food  Technology,
      33_, 506-515 (1970).

6.    Holdsworth, S. D. ,  "Effluents from Fruit and Vegetable Pro-
      cessing,  "Process Biochem. ,  3:27-31 (June 1968).

7.    Amerine,  M. A.,  Pangborn,  R. M. , and Roesslar,  E.  B. ,
      "Principles of Sensory Evaluation of Food, " Academic Press,
      New York  (1965).

8.    Dietrich, W.  C. , Huxsoll, C.  C. ,  Wagner,  J.  R. , and Guadagni,
      D. G. , "Comparison of Microwave with Steam or Water Blanch-
      ing of Corn-on-the-Cob:  2.  Peroxidase Inactivation and Flavor
      Retention," Food Technology,  24:293-296 (March 1970).

9.    Taras, M.  J. ,  Chairman, "Standard Methods for the Investi-
      gation of Water and Wastewater",  13th Edition.  American
      Public  Health Association, Washington, D. C. (1971).

                                -62-

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10.     Horwitz, W. ,  "Official Methods of Analysis of the Association
       of Official Analytical Chemists, " llth Edition, Association of
       Official Analytical Chemists, Washington,  D. C.  (1970).

11.     Watt, B. K. ,  and Merrill,  A.  L. , "Composition of Foods, "
       Agriculture Handbook No. 8, Agricultural  Research Service,
       U. S. Department of Agriculture, Washington, D. C. (1963).

12.     Orr, M. L. , "Pantothenic Acid,  Vitamin B/ and Vitamin B, ->
       in Foods, " Home Economics Research Report No.  36,  Agri-
       cultural Research Service,  U,  S. Department of Agriculture,
       Washington, D. C. (1969).

13.     National Research Council,  "Recommended Daily Dietary
       Allowances, "  Food and Nutrition News, 40, No.  2(1968).

14.     Judge,  E. E. , "The Almanac of the Canning,  Freezing, Pre-
       serving Industries, "  Edward E.  Judge & Sons, Inc. , West-
       minster, Maryland (1972).

15.     Private communication with Darrell Beavers of Oregon State
       University  (April 1973).

16.     Lopez, A. , "A Complete  Course in Canning, " 9th Edition,
       pp.  105-111, Canning Trade, Baltimore, Maryland  (1969).

17.     Howard,  J.  W. , Turicchi,  E.  W. , White,  R.  H. , and  Fazio,
       T. ,  "Extraction and Estimation of Polycyclic  Hydrocarbons
       in Vegetable Oils," J. Ass.  Qffic. Anal. Chem. , 49:1236-
       1244 (December 1966).

 18.    Fazio,  T. , White, R. H.  , and Howard, H. W. ,  "Collabora-
       tive Study of the Multicomponent Method for Polycyclic Aro-
       matic Hydrocarbons in Foods," J. Ass. Offic. Anal. Chem. ,
       56:68-70 (January 1973).
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                          SECTION VIII

                            GLOSSARY

Acceptance - (1) An experience or feature of experience, charact-
erized by a positive (approach in a pleasant) attitude.  (2) Actual
utilization (purchase,  eating).  May be measured by preferences or
liking for specific food item.

Analysis of Variance - A method of determining the significance of
differences in a group of averages of experimental observations by
partitioning of the total sum of  squares  and  degrees of freedom, and
estimation of the standard deviation of the population by two or more
methods and a comparison of these estimates.

Appearance -  The visual properties of a food, including size,  shape,
color  and conformation.

BOD - Abbreviation for biochemical oxygen demand.  The quantity
of oxygen used in the biochemical oxidation  of organic matter in a
specified time,  at a specified temperature,  and under specified con-
ditions.

COD - Abbreviation for chemical oxygen demand.   A measure of the
oxygen-consuming  capacity of inorganic and organic matter present
in water or wastewater.

Blanching  - Heating a food to a temperature high enough to inacti-
vate enzymes  present and to remove undesirable occluded gases and
contaminants.

Coding - Assignment of symbols, usually letters and/or numbers,
to test samples  so  that they may be presented to a  subject without
identification.

Consumer - An  individual who obtains or uses a commodity.

Enzyme  - A catalyst produced by living cells which is protein  in
nature.

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Flavor - An attribute of foods,  beverages, and seasonings resulting
from stimulation of the sense ends that are grouped together at the
entrance of the alimentary and  respiratory tracts -- especially odor
and taste.

Make-up water - Water added to circulating water in a system to re-
place water lost by evaporation, leakage, or blowdown.

Panel - A group of people (observers,  subjects,  judges) comprising
a test population which has been especially selected or designated in
some manner.

Peroxidase - A  class of enzymes which catalyze  the reaction of mole-
cular oxygen with  a substrate to produce a peroxide link in the altered
molecule.

Protein - Any of the complex nitrogeneous compounds formed in liv-
ing organisms which consist of  amino acids bound together by peptide
linkages.

Quality  - The composite of the  characteristics that differentiate  among
individual units of the product and have significance in determining
the degree of acceptability of the unit by the user.

Ranking - A procedure of arranging food products in order according
to some criterion  and assigning consecutive integers (ranks) corres-
ponding to the order.

Sample  - A specimen or aliquot presented for inspection.

Score - A value assigned to a specific  response made to a test item.

Suspended Solids (SS) - Solids that either float on the surface of, or
are in suspension  in, water, wastewater, or other liquids.

Taste - One of the senses  usually limited to four  qualities: saline,
sweet, sour, and bitter.
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                         SECTION IX

                        APPENDICES
                                                           Page
A.    Procedure for Determination of Polynuclear Hydro-
      carbons in Canned Green Beans                         68

B.    Short Duration Hot-Gas Blanching of Cut Green Beans    71

C.    Preparation Conditions and Quality Evaluation of
      Canned Samples of Hot-Gas Blanched Green Beans        76

D.    Wastewater  Volume and Characteristics  For Make-
      up Water Overflow Grab Samples From Commercial
      Blancher For Cut Green Beans                          77

E.    Short Duration Hot-Gas Blanching of Corn-on-Cob        79

F.    Wastewater  Volume and Characteristics  For Steam
      Condensate Grab Samples From Commercial Blancher
      For Frozen  Corn-on-Cob                                82

G.    Short Duration Hot-Gas Blanching of Beets               83

H.    Wastewater  Volume and Characteristics  For Make-
      up Overflow Grab Samples From  Commercial
      Blancher For Beets                                     84

I.     Short Duration Hot-Gas Blanching of Spinach             84

J.    Volume and  Characteristics of Wastewater Samples
      Collected From Hot-Gas Blancher for Spinach (1972)      85

K.    Characteristics of Wastewater From  Commercial
      Spinach Blancher (1972)                                 86

L.    Short Duration Hot-Gas Blanching of Green Peas         87

M.    Grab Sample Characteristics for  Make-up  Water
      From Commercial Blancher for Green Peas              88

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                                                             Page
N.    Vitamin Content of Raw,  Hot-Gas Blanched,  and
      Commercially Blanched Vegetables                       90

O.    Mineral Content of Raw,  Hot-Gas Blanched,  and
      Commercially Blanched Vegetables                       94

P.    Vacuum, Headspace,  Net Weight,  Count,  and Matur-
      ity of Canned Green Peas                                95

Q.    Calculations for Commercial Spinach Blancher
      Wastewater                                              96

R.    Cost Estimate for Commercial Pipe Blancher and
      Hot-Gas Blancher for Green Peas                        102

S.    Calculation  of Cost of Hot-Gas Blanching of Peas        104

T.    Checklist for Measurements Necessary for Hot-Gas
      Blanching Operation                                     105
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APPENDIX A

PROCEDURE FOR DETERMINATION OF POLYNUCLEAR HYDRO-
CARBONS IN CANNED GREEN BEANS

Introduction

The following procedure for extraction and determination of polycyclic
aromatic hydrocarbons was adapted from the publications  of J. W.
Howard et. al.  (17, 18) of the Division of Food Chemistry, Federal
Food and Drug Administration, Washington, D. C.  Using an alco-
holic potassium hydroxide solution, the vegetable sample was  digest-
ed by refluxing for 2. 5 hr.   The hydrocarbons were extracted  into
iso-octane, loaded onto a Florisil column, and eluted with benzene.
The eluate was concentrated and chromatographed using reverse
phase partition thin-layer chromatography.  The hydrocarbons were
then extracted from the plate absorbent, and the fluorescence  mea-
sured quantitatively.

Extraction

To  a one 1 round-botomed flask were added 200  g of homogenized
sample,  400 ml of 95 percent ethanol,  50 g of KOH pellets, and
boiling chips.  The flask was fitted with a condenser in the reflux
position,  and the digestion  was allowed  to continue for 2. 5 hr, re-
fluxing at a rapid rate.

At the end of the digestion, the contents of the flask were filtered,
while still hot, through glass wool into a one 1 separatory  funnel.
The flask was  then rinsed with two 50 ml portions of warm,  dis-
tilled water (about 120°F),  followed by two 50 ml portions of 95  per-
cent ethanol,  and finally with 50 ml of iso-octane.  Each washing
was poured through the glass wool into the separatory funnel.

The funnel was shaken for three min, the layers allowed to separate,
and the lower aqueous layer drawn off into a second sepatatory
funnel.   This aqueous layer was then extracted a second time with
100 ml of iso-octane,  and the aqueous layer drawn off as before  into
a third separatory funnel.  Following a  third extraction with 100 ml

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of iso-octane,  the aqueous layer was discarded.

Each of the three iso-octane extracts was then washed with four
100 ml portions of warm,  distilled water by pouring through the
water, followed by gentle swirling action.  The aqueous layer was
drawn off and discarded after each washing.

Column Chromatography

A chromatographic column was prepared by packing with a 60 g of
Florisil which had been washed three times with methanol and acti-
vated for  16 hr in an oven at 100°C.  The  column should also contain
about 50 g of anhydrous sodium sulfate packed  above the Florisil,
and the entire  column should be prewetted with about 100 ml of iso-
octane.  The iso-octane was passed in the first separatory funnel
through the column and the eluate was collected in a 500 ml beaker.
The first  separatory funnel was then rinsed with the contents of the
second separatory funnel,  and the iso-octane poured into the column.
The first  and second separatory funnels were then rinsed consecu-
tively with the  third iso-octane extract, and then poured into the
column.   All of the eluate was collected in the  same beaker.  The
drip rate  for the column should be about 20-25  drops/min.

The three separatory funnels  were then washed consecutively with
50 ml of benzene,  which was then poured into the column and the
eluate was collected in a separate beaker.  The column was then
eluted with three 100 ml portions  of benzene.

Both the iso-octane and benzene eluate •were evaporated down to a
volume of 2-3 ml using warm air  steam to increase the evaporation
rate.   These solutions  should not  be allowed to evaporate to dryness
as this results in significant losses of hydrocarbons.

Thin Layer Chromatography (TLC)

Prepare five 20 x 20 cm TLC plates as follows: Homogenize 20  g
cellulose  and about lOO'ml water in a Waring Blender at high speed
for about  three minutes.  Using Kensco applicator, apply to plates
(500 u thickness) and allow to air-dry completely.   Before use,
plates should be washed in a TLC tank with iso-octane and stored in
                                -69-

-------
a desiccator.

Two TLC tanks  should be prepared and allowed to equilibrate for
about one hr before use, one with iso-octane (mobile phase solvent),
and another with 20 percent dimethyl formamide (DMF) in ethyl
ether (immobile phase solvent).

The two  concentrated extracts were now applied to the cellulose
plate  in a streak (about 0. 5 cm x  10 cm) about 1. 5  cm from the
bottom of the plate. Both extracts were applied to the same streak,
and the beakers rinsed with three small portions of benzene,  which
were  also applied to the  same  streak.  A standard  solution of pyrene
and fluoranthene in iso-octane was also applied in a streak adjacent
to the extract.

The plate was inverted and placed in immobile  solvent tank,  allow-
ing solvent to wet to within 0. 5 cm of applied streaks.  The plate
was removed from tank and excess solvent was allowed to drain  from
plate  (about 15-20 sec).  Then plate was re-inverted and placed in
iso-octane tank  and allowed to develop in dark until solvent reached
top of plate  (about 1 hr).

When development was complete,  plate was removed from tank and
viewed under short-wave UV light, outlining pyrene-fluoranthene
band.  It was scraped and collected in  a small Erlenmyer flask.
Hydrocarbons •were extracted with three 5-10 ml portions of hot
methanol, and filtered through Whatman No. 1 filter paper into a
small beaker.  Methanol was evaporated down to less than 10 ml
and transferred to a 10 ml volumetric  flask. Beaker was rinsed
with methanol and flask made up to 10  ml.

Quantitative Analysis

Fluorescence of the extract was measured in a fluorometer at the
10-times sensitivity setting using a 7-60 primary and 2A-12 secon-
dary filter.  This filter combination was  experimentally found to
yield  the most satisfactory results with pyrene and fluoranthese.  A
methanol blank should always be run.   The standard solution used
contained 1  ug/ml each of fluoranthene and anthracene in iso-octane,
giving a  2 ug hydrocarbon/ml solution.  An  equal ratio of pyrene to
                               -70-

-------
fluoranthene was used arbitrarily as they ratio in the green bean sam-
ples could not be determined.  Pyrene and fluoranthese being isomers,
they cannot  be readily separated by thin-layer chromatography.  One
ml of this standard solution was diluted to 10 ml and used as the fluoro-
meter standard.

APPENDIX  B

SHORT DURATION HOT-GAS BLANCHING OF CUT GREEN BEANS

Run
no.
GB
1
GB
2
GB
3
GB
4
GB
5
GB
6
GB
7
GB
8
Kg/flight
total feed
wt,kg
0.9
5. 0
0.9
5. 3
0.9
5.3
0.9
5. 5
0.9
8. 8
0.9
9. 5
0.9
8.6
0.9
5.9
Product
wt/kg
4. 1
4. 1
2.7
4.9
9.3
9.5
8. 5
5. 7
Temp,
121
121
121
114-
119
110-
117
116-
118
113-
121
113-
121
Residence Peroxidase
time, sec reduction, %
183 66
183 80
330 96
144 100
82 96
82 98
82 99
92 96
Steam
meter, %
oa
25a
50a
(70 psig)b
(70psig)b
(70 psig)b
(70 psig)b
(70psig)b
                                 -71-

-------
APPENDIX B  (continued).





SHORT DURATION HOT-GAS BLANCHING OF CUT GREEN BEANS

Run
no.
GB
9
GB
10
GB
11
GB
12
GB
13
GB
14
GB
15
GB
16
GB
17
GB
18
Kg/flight
total feed
wt, kg
0.9
9.6
0. 45
8. 5
0.9
8.9
1.4
9.0
1. 8
9.5
1. 8
12. 3
1. 8
9. 1
1. 8
10. 2
1. 8
9. 3
1.4
10. 5
Product
wt/kg
9.4
8.4
8.6
8.9
9. 5
11.3
9.0
10. 0
9.2
10. 5
Temp
°C
103-
107
110-
116
110-
118
110-
116
110 -
116
107-
113
116-
118
113-
116
110-
116
110-
116
Residence
time, sec
82
73
73
73
73
73
73
73
73
73
Peroxidase
reduction, %
98
99
98
98
96
97
96
99
98
99
Steam
meter, %
(85 psig)b
(80 psig)b
(80 psig)b
(80 psig)b
(80 psig)b
(60 psig)b
(50 psig)b
(70 psig)b
(40 psig)b
(40 psig)b
                                -72-

-------
APPENDIX B (continued).





SHORT DURATION HOT-GAS BLANCHING OF CUT GREEN BEANS

Run
no.
GB
19
GB
20
GB
21
GB
22
GB
23
GB
24
GB
25
GB
26
GB
27
GB
28
Kg /flight
total feed
wt/kg
1. 8
10. 5
1.8
10. 3
1. 8
9. 7
1. 8
10. 5
1. 8
9.9
1. 8
8. 3
2. 8
9. 7
2. 8
10. 2
2. 8
9.9
2. 8
9. 1
Product Temp,
wt/kg °C
10.5 107
10.4 110
10.2 110
104-
10.4 110
116-
10.7 121
116-
8.4 127
104-
10.2 107
104-
10. 1 107
104-
10.0 107
9.6 107
Residence Peroxidase Steam
time, sec reduction, % meter, %
73 98 (40 psig)b
77 95 (40 psig)b
77 -- (40 psig)b
77 80 (40 psig)b
77 87 (40psig)b
77 86 (40 psig)b
77 87 (30 psig)b
77 -- (30 psig)t>
77 63 (20 psig)b
77 0 (10 psig)b
                                -73-

-------
APPENDIX B (continued).





SHORT DURATION HOT-GAS BLANCHING OF CUT GREEN BEANS

Run
no.
GB
29
GB
30
GB
31
GB
32
GB
33
GB
34
GB
35
GB
36
GB
37
GB
38
Kg/flight
total feed
wt/kg
1. 8
10. 0
1.8
9. 1
1. 8
9.0
2. 1
9. 1
2. 1
9. 5
2. 1
9. 3
1.4
10. 3
1.4
10. 0
1.4
10. 5
1.4
8.4
Product Temp, Residence Peroxidase Steam
wt/kg °C time, s c reduction, % meter, %
107-
11. 1 110 77 61 (20 psig)b
107-
9.3 110 77 -- (20 psig)b
9. 3 107 77 -- (10 psig)b
9.5 110 77 0 4C
9.6 121 77 9 4C
9.5 110 77 19 4C
106-
10.0 107 77 59 4C
93-
10.1 94 77 21 4C
80-
10.6 82 77 0 4C
74-
8. 5 77 77 0 4C
                               -74-

-------
APPENDIX B (continued).

SHORT DURATION HOT-GAS BLANCHING OF CUT GREEN BEANS

Run
no.

GB
39
GB
40
GB
41
GB
42
GB
43
GB
44
Kg/flight
total feed
wt/kg
1.6
11. 7
1. 5
12. 0
1.4
13. 2
1.4
12. 5
1.4
12. 0
1.4
12.6
Product Temp Residence Peroxidase Steam
wt, kg °C time, sec reduction, % meter, %


12.0 85 77 22 3C
90-
12.1 91 77 -- 3C
83-
13.0 91 77 34 3C
84-
12.9 88 77 0 3°
85-
12.2 88 77 7 3C
87-
12.7 91 77 12 3C
 a  Steam flow meter rated at 0. 95  kg (2. 1 lb)/min at 100 percent of
   scale.
 b  Steam pressure gauge reading made during temporary closing of
   inlet steam valve.
 c  Steam flow meter rated at 9. 5 kg (21 lb)/min at  100 percent of
   scale.
                                  -75-

-------
APPENDIX C

PREPARATION CONDITIONS AND QUALITY EVALUATION OF
CANNED SAMPLES OF HOT-GAS BLANCHED GREEN BEANS

Run Can Brine Exhaust Headspace
no. size temp, box temp, vacuum,
°C °C cm, Hg
GB 303a 88 85 17.8
18
GB 303 82 80 15.3
26
GB 303 88 -- 12.7
29
GB 303 88 -- 12.7
30
GB 303 86 -- 15.3
31
GB 303 85 -- 12.7
34
GB 303 82 74 12.7
36
GB 10b 77 74 12.7
39

GB 10 60 74 10.2
40

Quality
evaluation

Excessive
sloughing
Excessive
sloughing
Moderate
sloughing
Moderate
sloughing
Moderate
sloughing
Good flavor,
little sloughing
No
sloughing
Too long
hold before
retorting
Good flavor
but under -
blanched
                               -76-

-------
APPENDIX C (continued)

PREPARATION CONDITIONS AND QUALITY EVALUATION OF
CANNED SAMPLES OF HOT-GAS BLANCHED GREEN BEANS

Run Can
no. size

GB 10
41
GB 10
42
GB 10
43
GB 10
44
Brine
temp,
°C
88

88

85

88

Exhaust Headspace
box temp, vacuum,
°C cm.Hg
74 12.7

74 17.8

71 12.7

74 15.3

Quality
evaluation

Over blanched,
soft texture
Good flavor,
no sloughing
Good flavor,
no sloughing
Good flavor,
no sloughing
a  Can 8. 09 cm in diameter and 11. 02 cm high (3 3/16 x 4 3/8 in. ).
   Can 15. 71 cm in diameter and 17-76 cm high (6 3/16 x 7 in. ).

APPENDIX D
WASTEWATER VOLUME AND CHARACTERISTICS FOR MAKE-UP
WATER OVERFLOW GRAB SAMPLES FROM COMMERCIAL
BLANCHER FOR CUT GREEN BEANS

Sampling Volume,
date 1
(operating
time)
8-15-72
(0-2 hr) 458

BOD,
mg/1



6790
-77-
COD,
mg/1



11600

SS, pH
mg/1



1490 5.9


-------
APPENDIX D (continued)

WASTE WATER VOLUME AND CHARACTERISTICS FOR MAKE-UP
WATER OVERFLOW GRAB SAMPLES FROM COMMERCIAL
BLANCHER FOR CUT GREEN BEANS

Sampling
date
(operating
time)
(2-4 hr)
(4-6 hr)
(6-8 hr)
8-16-72
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
8-17-72
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
8-18-72
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
8-19-72
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
Volume,
1


227
133
64

133
72
57
144

91
104
76
68

91
64
68
80

83
64
49
76
BOD,
mg/1


7760
7610
10500

7500
7820
7660
4940

1820
2610
2040
6630

2390
4530
1300
	

4430
4020
4790
4300
COD,
mg/1


15500
15500
13400

13000
13300
13100
8320

3120
4780
3720
11000

4470
8380
2500
	

7390
6780
8080
7000
SS,
mg/1


1560
1820
1870

1640
1680
1840
910

140
550
870
610

390
670
210


650
800
1020
820
PH



5.6
5. 0
5. 3

5. 1
5.4
5.2
5.4

6.4
6. 5
6. 2
6.1

6.2
6. 0
6.2
--

6. 0
6. 1
5.9
6. 1
                                -78-

-------
APPENDIX E





SHORT DURATION HOT-GAS BLANCHING OF CORN-ON-COB

Run Kg/flight Product Temp, Residence Peroxidase Steam
no. total feed wt, kg °C time,min reduction, % meter, ^
wt/kg
COC-1
COC-2
COC-3
COG -4
COC-5
COC-6
COC-7
COC-8
COC-9
COC-10
2. 1
8.9 8.8 129 8 -- 3a
2. 1
9.5 9.3 138 8 53 3
2. 1
9.2 9.0 154 10 -- 5
2. 1
9.0 8.5 121 19 -- 10
2. 1
9.4 9.0 113 19 100 10
2. 1
9.8 8.9 99 37 96 4
2. 1
9.6 9.4 104 13 90 10
2. 1
9.2 9.3 97 13 96 10
2. 1
9.0 8.9 99 16.5 92 8
2. 1
                                     16.5        100        10
                               -79-

-------
APPENDIX E (continued)





SHORT DURATION HOT-GAS BLANCHING OF CORN-ON-COB

Run Kg/flight Product Temp, Residence
no. total feed wt ,kg °C time.min
wt,kg
COC-11
COC-12
COC-13
COC-14
COC-15
COC-16
COC-17
COC-18
COC-19
COC-20
2.
9.
2.
10.
2.
9.
2.
9.
2.
10.
2.
9.
2.
8.
2.
9.
2.
9.
2.
1
2 9.0 102 16.5
1
0 9.6 104 16.5
1
7 9.3 104 16.5
1
8 9.5 107 15
1
0 9.9 107 15
1
8 9.5 110 17
1
1 9. 5C 102 12.8
1
0 9. 3C 102 10
1
1 9.7C 102 11.3
1
Peroxidase Steam
reduction, % meter, %
83 13
95 10
95 10
97 15
96b 25
b 23
92b 30
82b 30
95b 30
           9. 5      10. Oc     102      12. 5         78         30
                                 -80-

-------
APPENDIX E (continued)
SHORT DURATION HOT-GAS BLANCHING OF CORN-ON-COB
Run     Kg/flight  Product   Temp,  Residence  Peroxidase  Steam
no.      total feed   wt, kg    °C     time.min  reduction, %  meter, %
	      wt,kg	   	 	  	
COC-21
2. 1
9.5
                     10.
104
12. 5
97
30
COC-22     2. 1
                      9.4C
                   104
          12. 5
             93
          30
a  Steam flow meter rated at 9. 5 kg (21 lb)/min at 100 percent of scale.
   Catalase test negative.
c  After cooling with water sprays.
APPENDIX F
WASTEWATER VOLUME AND CHARACTERISTICS FOR STEAM
CONSENSATE GRAB SAMPLES FROM COMMERCIAL BLANCHER
FOR FROZEN CORN-ON-COB

Sampling Feed rate
date

9-18-72
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
9-18-72
(0-2 hr)
(2-4 hr)
ears/min

a. m.
65
78
92
41
p. m.
69
62
Weight Volume,
blanched,
kkg

2. 32
2. 83
3. 31
1.49

2. 51
2. 35
1


210
190
290
270

201
213
BOD,
mg/1


12500
14400
16800
14200

12800
14800
COD,
mg/1


19000
22100
24700
20100

19000
21100
SS,
mg/1


370
733
533
620

610
630
                                  -81-

-------
APPENDIX F (continued)

WASTEWATEJR VOLUME AND CHARACTERISTICS FOR STEAM
CONSENSATE GRAB SAMPLES FROM COMMERCIAL BLANCHER
FOR FROZEN CORN-ON-COB

Sampling Feed rate Weight
date ears/min blanched,

(4-6 hr)
(6-8 hr)
9-19-72 a.m.
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
9-19-72 p.m.
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
9-20-72 a. m.
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)

79
54

61
48
91
63

85
77
64
78

93
141
79
79
kkg
2. 87
1. 96

2. 22
1. 74
3. 31
2. 29

3. 08
2. 80
2. 32
2. 83

3. 38
5. 12
4. 14
2. 87
Volume,
1

129
134

166
254
247
252

312
306
213
227

242
321
312
275
BOD,
mg/1

13600
16600

10500
10700
15400
16200

12800
14800
12500
15500

14500
13400
13100
13800
COD,
mg/1

20700
24800

15700
14000
23100
24200

20900
23400
19600
24600

23100
21400
20800
21700
SS,
mg/1

980
980

490
590
1500
1700

1450
1780
1980
2120

770
830
890
940
                                -82-

-------
APPENDIX G
SHORT DURATION HOT-GAS BLANCHING OF BEETS

Run
no.

B-l
B-2
B-3
B-4

B-5

B-6

B-7
B-8
B-9
B-10
B-ll
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23C
Feed
wt,kg

9. 1
9. 1
9. 1
9. 1

9. la

6.4

10. 0
9.2
9.4
22. 3
21.4
20. 0
22. 5
18.4
9.6
11. 0
8. 4
9. 7
9.2
10. 1
100 7
9.2
20. 0
Product
wt, kg

8.4
7. 5
8.9
8. 1

8.4

5. 0

8. 0
7. 8
7. 5
19.3
21. 1
17.9
21.4
17. 5
8.9
10. 0
18. 0
8.6
8. 2
8. 9
9. 5
8. 2
18. 6
Temp, Residence
°C time, min

121-132
124-138
124-132
124-132

121-128

118-123

113-122
110-117
102-112
79-87
133-138
83-88
81-82
80-82
110-115
111-118
113-115
118-121
121
114-122
113-121
118-124
113-121

5. 5
6.5
2.4
6.5

18. 5

14

14
14
14
21
1
30
20
20
8
14
14
16
20
23
26
25
26
Steam
flow,
kg /min
70b
40b
40b
100b

80b

1. 0

1. 8
4. 5
4.4
1. 0
1. 0
0. 5
0. 5
0. 5
0.4
0.4
1. 0
2. 2
2. 2
2. 2
1. 9
1. 9
1.9
Peroxidase
reduction, %

Under blanched
Under blanched
Under blanched
Good peel,
loosening
Under blanched,
soft peel
Good peel,
loosening
99o 9
	
	
100
0
95
	
95
73
99
Under blanched
91
96
100
99
99
	
a  Large beets used.
b  Steam pressure gauge reading made during temporary closing of in-
  let steam valve in Ib/in.  .
c  Beets put through peeling line during plant lunch break,  canned for
  evaluation.
                                  -83-

-------
APPENDIX H

WASTEWATER VOLUME AND CHARACTERISTICS FOR MAKE-UP
OVERFLOW GRAB SAMPLES FROM COMMERCIAL BLANCHER FOR
BEETS

Sampling
date
(operating
time)
10-5-72
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
10-6-72
(0-2 hr)
(2-4 hr)
Weight
blanched,
kkg


5. 55
5.36
5.42
5.45

5.47
5. 58
Volume,
1



489
511
515
484

257
227
BOD,
mg/1



13800
13500
13200
14500

12100
11700
COD,
mg/1



20000
19400
19000
21800

16900
16300
SS,
mg/1



520
220
170
270

290
240
APPENDIX I
SHORT DURATION HOT-GAS BLANCHING OF SPINACH (1972)

Run
no.
TLSP-1
TLSP-2
TLSP-3
TLSP-4
TLSP-5
TLSP-6
TLSP-7
TLSP-8
Feed
wt,
4.
4.
3.
4.
4.
4.
3.
90.
kg
5
1
9
0
8
8
9
9
Product Temp,
wt.kg
2.
2.
2.
2.
3.
3.
2.
81.
7
3
0
2
0
0
3
8
°C
1
1
1
1
1
1
1
1
16-
16-
13-
16-
18-
13-
16-
04-
12
Residence
time, sec
1
121
118
12
12
12
12
12
1
1
1
1
1
1
1
2
54
83
10
330
144

1
1
83
08
08
Perosidase
inactivation, %
99
99
99
99
99
94
99
99
                                -84-

-------
APPENDIX J

VOLUME AND CHARACTERISTICS OF WASTEWATER SAMPLES
COLLECTED FROM HOT-GAS BLANCHER FOR SPINACH (1972)

Date/time

3-27-72
11:40
12:40 p. m.
1:40
2:40
3:55
4:35
5:10
3-28-72
10:00
11:00
12:50
1:35
2:35
3:35
3-19-72
8:30
9:30
10:30
12:00
1:00
2:00
3:00
Volume
1

	
0.472
0.238
0. 238
0. 238
0. 238
0. 238

	
0. 026
0. 15
0. 02
0. 005
0.472

	
0. Oil
0. 026
0. 034
0. 12
0. 053
0. 083
COD,
mg/1

	
30500
31800
52400
69000
68500
67000

	
194200
201000
146900
275800
104000

6200
3300
179500
26900
226900
42400
259500
SS,
mg/1

	
5990
2090
7920
6340
5590
870

	
12340
4360
5860
10440
1430

360
810
10620
1700
6230
2530
6670
PH


	
7.6
7.7
7.4
7.6
7.4
7.2

	
7. 7
7.6
7.9
7.8
7.6

7.4
7.4
7.6
7.4
7.6
7. 7
7. 5
                                -85-

-------
APPENDIX K

CHARACTERISTICS OF WASTEWATER FROM COMMERCIAL
SPINACH BLANCHER (1972)

Date Sample type

3-27-72 WO-OHa
WO-1H
WO-2H
WO-3H
WO-4H
SC-OH
SC-lHb
SC-2H
SC-3H
SC-4H
3-28-72 WO-OH
WO - 1 . 5H
WO-2H
WO-4H
WO-5.6H
WO-6H
SC-OH
SC-1. 54H
SC-2H
SC-4H
SC-5. 6H
SC-6H
3-29-72 WO-OH
WO-1H
WO -3. 5H
WO -4. 5H
WO -5. 5H
WO -6. 5H
SC-OH
SC-1H
COD,
mg/1
260
160
270
230
240
4040
4120
4370
4330
4450
510
300
480
330
250
300
4120
4080
4080
3880
3960
3960
270
290
340
270
430
340
4410
4690
SS,
mg/1
50
70
50
40
30
140
120
120
130
80
70
70
170
140
90
90
110
70
120
100
60
80
60
70
130
60
170
100
140
110
PH

7. 8
7. 7
7. 7
7. 7
7. 7
7. 0
7. 0
7. 0
7. 0
7. 0
7. 5
7.6
7.6
7.6
7. 7
7.7
7. 1
7. 0
7. 1
7. 1
7. 7
7. 7
7. 0
6.9
6.9
6.9
6. 8
6.8
7. 1
7. 1
                               -86-

-------
APPENDIX K (continued)

CHARACTERISTICS OF WASTEWATER FROM COMMERCIAL
SPINACH BLANCHER (1972)

Date Sample type

SC-3. 5H
SC-4. 5H
SC-5. 5H
SC-6. 5H
COD,
mg/1
3550
4450
4120
4330
SS,
mg/1
140
140
120
160
PH

1. 1
1, 1
1, 1
7. 1
a  WO-OH = water overflow at zero hr.
b  SC-1H = steam condensate at one hr.

APPENDIX L

SHORT DURATION HOT-GAS BLANCHING OF GREEN PEAS

Run
no.

TLFP-1
TLFP-2
TLFP-3
TLFP-4
TLFP-5
TLFP-6
TLFP-7
TLFP-8
TLFP-9
TLFP-10
TLFP-11
TLFP-12
TLFP-13a
Feed
wt, kg

15. 1
9.6
9. 1
9. 1
9. 1
9. 1
22.7
9. 1
13.6
9. 1
22. 7
9. 1
produ
Product
wt.kg

15. 1
8. 8
8. 0
7.9
7. 8
8. 0
20.4
8. 0
12.6
8.6
22. 2
8. 7
ct canned
Temp,
°C

127-138
121-132
136-143
136-154
108-116
119-143
118-127
127-143
138-152
143-149
138-146
143-149
110-132
Residence
time, sec

90
90
90
110
150
102
110
105
105
107
106
107
106
Steam
flow
kg/min
1. 0
1. 0
1. 0
2. 0
2. 0
2. 0
2. 0
1. 0
1. 0
1. 0
1. 0
1.4
0.6
Peroxidase
reduction, %

17
25
92
99
99
99
99
99
100
99
99
99
18
                                -87-

-------
APPENDIX L
SHORT DURATION HOT-GAS BLANCHING OF GREEN PEAS

Run Feed
no. wt, kg
TLFP-14b
TLFP-15 9.8
TLFP-16
Product Temp, Residence Steam Peroxidase
wt, kg °C time, sec flow reduction, ^
kg/min
121-
8.3 129-
138-
166
138
143
2. 0
144 1.0
190 1.0
99
99
— —
a  10 min operation.
b  15 min operation.

APPENDIX M

GRAB SAMPLE CHARACTERISTICS FOR MAKE-UP WATER FROM
COMMERCIAL BLANCHER FOR GREEN PEAS (Volume =  570 1/hr)

Sampling
date
(operating
time)
5-8-73
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
5-9-73
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
Weight
blanched,
kkg


4. 8
5.4
5. 0
5. 2

5. 1
5.6
5.4
5. 1
Sample
typea



2 hr
4 hr
6 hr
8 hr

2 hr
4 hr
6 hr
8 hr
BOD,
mg/1



5980
3440
4300
5010

6130
5640
5250
4200
COD,
mg/1



12200
5820
5790
7630

8550
9410
9800
8160
SS,
mg/1



320
200
240
230

450
260
220
390
PH




7. 5
8. 5
8. 8
8. 5

8.3
8. 0
8. 0
8. 0
                                 -88-

-------
APPENDIX M (continued)

GRAB SAMPLE CHARACTERISTICS FOR MAKE-UP WATER FROM
COMMERCIAL BLANCHER FOR GREEN PEAS (Volume = 570 1/hr)

Sampling
date
(operating
time)
5-10-73
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
5-11-73
(0-2 hr)
(2-4hr)
(4-6 hr)
(6-8 hr)
5-12-73
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
5-14-73
(0-2 hr)
(2-4 hr)
(4-6 hr)
(6-8 hr)
Weight
blanched,
kkg


4. 8
4. 9
5. 2
5.2

5. 1
5. 2
5. 0
5.2

5. 3
5. 1
5. 2
5. 0

5. 1
5. 3
5. 2
5. 1
Sample
type



2 hr
4 hr
6 hr
8 hr

2 hr
4 hr
6 hr
8 hr

2 hr
4 hr
6 hr
8 hr

2 hr
4 hr
6 hr
8 hr
BOD,
mg/1



3990
3970
8330
4930

3590
4970
7030
5860

7750
7330
3950
6920

8010
9280
7210
8230
COD,
mg/1



7180
8170
13800
6390

5320
7100
12100
9770

11800
9540
5850
10600

11500
12400
8620
13000
SS,
mg/1



360
220
290
280

210
180
190
210

490
370
200
380

270
200
230
190
PH




8. 0
7.5
7. 1
8. 0

8.6
8. 1
7.5
7.6

7.8
8. 0
8.6
8. 2

7.9
7.8
8. 0
80 0
a  Grab sample taken from blancher return surge tank after each 2 hr
  of operation.
                                 -89-

-------











































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-93-

-------
APPENDIX O

MINERAL CONTENT OF RAW, HOT-GAS BLANCHED, AND
COMMERCIALLY BLANCHED VEGETABLES (mg/100 g wet wt)

Commodity Mineral

Green beans


Corn
Beets

Spinach






Peas





Ca
Mg
P
P
Pa

Caa
Mga
Ca
Mg
P
Fe

Ca
Mg
P
Fe

Raw Hot-gas blanched

36, 31, 28 (4. 2)b
19, 15, 22 (3. 6)
18,21,20 (1. 6)
87,95,93 (4.2)
—

—

39,48, 53 (7. 2)
62,62,40 (12. 7)
36, 34, 29 (3. 6)
2. 3,2. 2, 3.2
(0.6)
24,27,23 (2. 1)
34, 36, 33 (1. 0)
93,92,81 (6. 7)
1. 8,2. 1 (1. 0)


30, 31, 31 (0. 2)b
18, 18, 14 (2. 3)
18, 18, 18 (0)
90,88,93 (2.6)
129, 112, 90
(19.5)
74, 70 (2. 0)
99,99 (0)
65, 73, 60 (6. 5)
65,75,59 (8. 1)
35, 31, 34 (3. 0)
2. 5,3. 0, 3. 7
(0.6)
23,23, 22 (0. 3)
36,36,35 (0. 5)
95,95, 90 (2. 7)
3. 3,2. 7 (0. 5)

Commercially
blanched
30, 39,46 (8. l)b
22, 26,20 (3. 1)
22,22, 19 (30 0)
87, 84, 86 (1. 6)
89, 104,98
(7.5)
88, 86 (1. 0)
95,92 (1.6)
69, 63, 65 (3. 1)
56,43, 36 (10. 1)
41,41, 39 (2.4)
2. 5, 1. 9, 3. 0
(0.6)
20,21, 19 (0. 8)
29, 30,28 (1. 3)
82, 73, 81 (5.4)
2.2, 1. 8, 1.6
(1.3)
a  Canned sample
b  Standard deviations shown in parentheses.
                                 -94-

-------
APPENDIX P

VACUUM, HEADSPACE, NET WEIGHT, COUNT, AND MATURITY
OF CANNED GREEN PEAS

Vacuum,
in. of Hg
Headspace
in. /32
, Net wt, No. of 50 sinking in NaCl brines
oz
Count
Commercial line
8
11
8
10
10
11
10
11
10
11
6
10
13
13
13
14
15
13
16
13
10
14
13
13
16.9
16.9
16.9
16.7
16.6
16.8
16.4
16.7
17. 1
16.8
16.6

16.8
700
680
701
657
641
660
716
648
681
676
622
Ave.
671
Special hot-gas
7
9
16. 9
641
11%
samples
19
20
15
15
24
20
14
22
19
17
16

17
blanched
11
13%
7
6
4
4
5
4
4
6
5
5
6
5
1
15%
0
1
0
0
0
0
0
2
0
0
1
0
0
Hot -gas blanched
5
5
6
5
6
5
5
5
13
16
12
12
14
8
13
12
16.8
16. 7
16.8
16. 9
16. 8
17. 7
16.7
17.7
687
710
667
684
667
688
706
689
23
13
20
16
22
17
19
21
7
8
5
8
8
4
5
10
0
0
2
2
3
1
1
0
                               -95-

-------
APPENDIX P (continued)

VACUUM, HEADSPACE, NET WEIGHT, COUNT,  AND MATURITY
OF CANNED GREEN PEAS

Vacuum,
in. of Hg
Headspace,
in. /32
Net wt,
oz
Count
No. of 50
11%
sinking in NaCl
13%
brines
15%
Hot-gas blanched
6
6
5
8

6
11
10
13
11

12
17. 1
17. 1
16.9
17. 0

17. 0
718
702
687
678
Ave.
690
17
17
29
26

20
12
2
10
8

7
0
0
3
1

1
APPENDIX Q

CALCULATIONS  FOR COMMERCIAL SPINACH BLANCHER
WASTEWATER
3-28-7Z

Steam  condensate -
Water  overflow =
Dump water -
Total wastewater/8 hr =
Weight of spinach
blanched =

(Volume/8 hr)/(kkg/8 hr) =
 6800 1/hr x
13600 1/hr x
 (174   )
 (  22.5)

 180, 380
    62
x 8 =
                  54,400 1
                 109,000 1
                  16,980 1
                 180,380 1
62 kkg
                                                          2900 I/kkg
                                 -96-

-------
APPENDIX Q (continued)


CALCULATIONS FOR COMMERCIAL SPINACH BLANCHER

WASTEWATER

3-29-72
Total wastewater/8 hr =
Weight of spinach
blanched =
(Volume/8 hr)/(kkg/8 hr) =
180, 380
(164 )
( 22.5)
180, 380

X O — Do ICiCg
•3. i nn i /i,i,~
4-12-73


Steam  condensate =   (110+76 + 110+110)    .
                      	'  x 60 x 8 =    48,7201



Water  overflow =     (604 + 572 + 572 + 545)
                      	  x 60  x 8 =  275, 160 1


Dump water =                                           16,9801

Total wastewater/8 hr =                                340,860 1

Weight of spinach     (8. 6 + 7. 8 + 8. 0 + 8. 4)    n           / r  / , ,
ui    T-  j              	;	  x8=         65.6kkg
blanched =           (         4                                  "


(Volume/8 hr)/(kkg/8 hr) =     340,860
                               	x   x '



4-13-73


Steam  condensate =             110 x 60 x 8 =            52,800 1

Water  overflow =               588 x 60 x 8 =           282, 200 1

Dump water =                     16,9801  =            16,9801

Total wastewater/8 hr =                                352, 000 1

Weight of spinach

blanched =                     8. 0 x 8  =                    64 kkg


(Volume/8 hr)/(kkg/8 hr) =     352,000
                               	—	 =                 5,5001/kkg
                                -97-

-------
APPENDIX Q (continued).

CALCULATIONS FOR COMMERCIAL SPINACH BLANCHER
WASTEWATER
4-19-73

Steam condensate =   (102 + 110 + 114)
                     (       3       )

Water overflow =     (481 + 572 + 604)
                            3       )
                               16,980 1 =
                                      x 60 x 8


                                      x 60 x 8
Dump water =
Total wastewater/8 hr =
Weight of spinach     (8. 4 + 8. 2 + 8. 8)
blanched =           (       3       )

(Volume/8 hr)/(kkg/8 hr) =      334, OOP
                                 67. 8

4-12-73
                                     x 8 =
BOD

Steam condensate =


Water overflow =


Dump water =


Total BOD =

COD

Steam condensate =


Water overflow =
                     (2840)   (48,720)
                     (  10b) X (  65.6 )
                     (7_0 )   (275, 160)
                     (106)X( 65.6   )
                     (3860)   (16,980)
                     (  106 ) X (  65.6 )
                     (4030)   (48, 720)
                     (lo^)X(  65.6 )

                     (140)   (275,160)
                     (TO&)X(   65.6 )
                                                        52, 160 1
                                                       265, 120 1

                                                        16,980 1
                                                       334, 000 1
                                                           67. 8 kkg
                                                        4, 900 I/ kkg
                                                           2.  1 kg


                                                           0. 29 kg

                                                           1.0 kg
                                                        3.4 kg/kkg



                                                            3.0 kg


                                                            0.59 kg
                                -98-

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APPENDIX O (continued).

CALCULATIONS FOR COMMERCIAL SPINACH BLANCHER
WASTEWATER
Dump water =

Total COD =

SS
(4630)  (16,980) _
       x
(  10°)  (  65.6 )
Steam condensate =   (170)  (48, 720) _
                     (lO6) X (  65. 6 ) ~
Water overflow =     (75  )  (275, 160)
                     (106)X(  65.6   )

Dump water =        (160)  (16, 980)
                     (To"5) X(  65.6 ) ~
Total SS =

4-13-73

BOD

Steam condensate =   (3070)   (52, 800)
                     (  10b) X (  64  )
                            (282,200)
                        ^
                     (106)X(  64    )
                     (3540)   (16,980)
(  10°)
                           x
                                64  )
Water overflow =


Dump water =

Total BOD =

COD
Steam condensate =   (3740)   (52, 800)
                     (  106) X (   64  )

Water overflow =     (140)   (282, 200)
                     (TO5") X (    64  )
                                                             1.2 kg
                                   4. 8 kg/kkg



                                      0. 12 kg

                                       .32 kg

                                      0. 04 kg
                                   0.48 kg/kkg
                                      2.5 kg


                                      0. 35 kg

                                      0.94 kg
                                                        3.8 kg/kkg
                                                           3.1
                                                           0. 62 kg
                                -99-

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APPENDIX Q (continued).

CALCULATIONS FOR COMMERCIAL SPINACH BLANCHER
WASTE WATER

Dump water =
Total COD =
SS_
Steam condensate =
Water overflow =
Dump water -
Total SS =
4-19-73
BOD
Steam condensate =
Water overflow =
Dump water =
Total BOD =
COD
Steam condensate =
Water overflow =
(5050)
( io6)
(230)
(T^)X
(12 )
(16,980)
~( 64 )-
(52, 800)
( 64 )
(282, 200)
(10D)"( 64 )
(190) (16,980)
(IO6)"
(2740)
(70 )
(106)X
(3390)
( io6)
(3160)
(IF")
(120)x
( 64 )
(52, 160)
A ( 67.8 ) ~
(265, 120)
( 67.8 )
(16,980)
x ( 67. 8 ) ~
(52, 160)
(67.8 )
(265, 120)
( 67.8 f
-100-
1.3 kg
5. 0 kg/kkg
0. 19 kg
0. 05 kg
0. 05 kg
0. 29 kg/kk^
2. 1 kg
0. 27 kg
0. 85 kg
3. 2 kg/kkg
2 . 4 kg
0. 47 kg

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APPENDIX O (continued).

CALCULATIONS FOR COMMERCIAL SPINACH BLANCHER
WASTEWATER
Dump water -

Total COD =

SS_

Steam condensate =

Water overflow =


Dump water =

Total SS =
                     (4050)   (16,980)
                           x
                     (10°)    ( 67.8  )
    1.0 kg
                     (13Q)   (52.160)
                     (76*) X (  67. 8 ) "
                     (20  )   (265, 120)
                     (T5^)X( 67.8  )
                     (150)   (16.980)
                     (76*) *(  67.8 ) =
 3. 9 kg/kkg



    0.10 kg

    0.08 kg

    0. 04 kg

 0. 22 kg/kkg
Use of above values in partial calculation of the cost of commercial
blanching of spinach [5 kkg (5. 5 tons)/hr].
                                             x 5   =
Water cost = 2900 + 3100 + 5200 + 5500 + 4900
                            5
                     4320 1  x $0. 10/3785 1

BOD disposal cost = 3. 4 + 3. 8 + 3. 9

                     18. 5 kg x $0. 023/kg
SS disposal cost = 0. 48  + 0. 29 + 0. 22
                 	x5

                     1.65/kg x $0. 023/kg
Total waste  disposal cost  = $0. 47/5kkg spinach blanched.
4320 l/5kkg
    $0. 11

18.5 kg/5kkg
    $0.43

1.65 kg/5kkg

    $0. 038
                                 -101-

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APPENDIX R

COST ESTIMATE FOR COMMERCIAL PIPE BLANCHER AND HOT-
GAS BLANCHER FOR GREEN PEAS
Cost Estimate for Commercial Pipe Blancher
[2.73 kkg (3 tons)/hr capacity]

First cost (FC) =  $8685.00

Annual fixed cost
Amortization = FC x erf (7%,  5 yr - 0. 24389)        = $  2118. 18
Space rent                                         =   2000. 00
Taxes [$5. 00/$100 assessed value (25% of FC)]      =    108.50
Insurance (0. 2% of assessed value)                  =      4. 34
Maintenance (1% of FC/yr)                          -     86. 85
                                     Total         = $  4317. 87/yr
Hourly fixed cost (1800 hr/yr)                      =$     2. 40/hr
Hourly operating  costs

Electrical power                                    = $     0. 220
Steam                                             =      1.200
Water                                             =      0. 016
Waste disposal                                     =      0. 092
Labor                                             =      2. 600
                                                     $     4.13/hr
Hourly fixed cost                                   = $     2.40
Hourly operating  cost                              =      4.13
Total hourly cost                                   =      6. 53
Cost per kkg blanched                              =      2. 39/kkg

Cost Estimate for Commercial Hot-Gas  Blancher
[5 kkg (5. 5 tons)/hr]

First cost (FC) =  $100,000.00
                                  -102-

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APPENDIX R (continued).

COST ESTIMATE FOR COMMERCIAL PIPE BLANCHER AND HOT
GAS BLANCHER FOR GREEN PEAS
Cost Estimate for Commercial Hot-Gas Blancher
[5 kkg (5. 5 tons)/hr]

Annual fixed cost
Amortization = FC x erf (7%, 5  yr = 0.24389)
Space  rent
Taxes [$5. 00/$100 assessed value (25% of FC)]
Insurance (0. 2% of assessed value)
Maintenance (1. 5% of FC/yr)
                                        Total

Hourly fixed cost (1800 hr/yr)
Hourly operating costs
Electrical power
Steam
Water
Gas
Waste disposal
Labor (half-time worked at $5. 20/hr)
= $ 24389. 00
    12000.00
     1250.00
       50. 00
     1500.00
= $ 39189. 00/yr

       21.77/hr
                                        Total
Hourly fixed cost
Hourly operating cost
Total hourly cost
Cost per kkg blanched
$





$
$


$
4.45
1. 87
0. 00
0. 22
0. 01
2. 60
9. 15/hr
21. 77
9. 15
30. 92
6. 18/kkg
                                 -103-

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APPENDIX S

CALCULATION OF COST OF HOT -GAS BLANCHING OF PEAS



Electrical power:
         140 +110 + 4   =   254   -   8.46kw/hr
              30           30
Scale -up factor = 15
8.46 x 15 = 127 kw/5 kkg
127 x $0. 035/kw = 1.27 x  102 x 3. 5  x 10'2 = 4. 45 x 10° = $4.45/5 kkg/hr

Steam:

         1.7kkg/30hr   =   0. 0567 kkg/hr
Scale-up factor = 15
15 x 0. 0567 = 0. 85 kkg/hr
$2.20 x . 85 = $1. 87/hr

Gas:

         I6.4m3/30hr   =   0.546m3/hr

Scale -up factor = 15
15 x 0. 546 = 8. 2 m3/hr

!firr! x $0.76 =  $0.22/hr
Waste disposal: (80 percent removal)

        0. 124 kg/kkg   BOD + SS   =   . 620 kg/ 5 kkg
        0. 620 x $0. 023/kg   =   $0.0143/5 kkg
                                 -104-

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APPENDIX T

CHECKLIST FOR MEASUREMENTS NECESSARY FOR HOT-GAS
BLANCHING OPERATION
(Data to be  recorded in bound notebook as taken)
Commodity
Location	
Date
Starting time
Product feed
Rate     	 (every 2 hr)
Conveyor drive

S e ttin g	
Setting	
Temperature, °F (hourly)
(or when significant change)
Electrical meter
Start
Finish
Electrical meter #2
Start	
Finish
Electrical meter #3
Start	
Finish
Gas meter
Start	
Finish
Steam flow meter
Start	
Finish
                                Blanched product weight
                                (every 2 hr)
                               2 hr grab sample volume + COD
                               sample
                               Commercial
          (refrigerate)
                                8 hr wastewater volume + COD
                                sample
                                                    hot-gas
                                Commercial	
                                (ice-cooled)
                                Peroxidase sample,  hourly	
                                (hot-gas only)
                                Vitamin,  mineral samples (1 run)
                               Raw
Commercial blanched
                               hot-gas
                               Finishing time
                                  -105-

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                                   TECHNICAL REPORT DATA
                           (I'li'asc read Instructions on the reverse before completing}
1, FUPOR1 NO.
  EPA-660/2-74-091
4. TITLE AND SUBTITLE
                             2.
  CONTINUOUS IN-PLANT HOT-GAS BLANCHING
  OF VEGETABLES
                                                           3. RECIPIENT'S ACCESSIOI»NO.
             5. REPORT DATE
                December 1974
             6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
  Jack W. Rails,  and Walter A. Mercer
             8. PERFORMING ORGANIZATION REPORT NO.

                   D-2647
9. PERFORMING ORG "VNIZATION NAME AND ADDRESS
  National Canners Association
  Research Foundation
  1950 Sixth Street
  Berkeley, California  94710
             10. PROGRAM ELEMENT NO.
                   1BB037
             11. CONTRACT/GRANT NO.
                   S-800250
12. SPONSORING AGENCY NAME AND ADDRESS

  Pacific NW Environmental Research Laboratory
  National Environmental Research Center
  Corvallis, OR   97330
             13. TYPE OF REPORT AND PERIOD COVERED
               Final:  6-12-72  to  9-31-73
             14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT

  An experimental  hot-gas blancher was operated in two food processing  plants using
  green beans,  corn-on-cob, beets, spinach,  and green peas.  A side  stream of
  commercially  prepared vegetables was hot-gas  blanched and returned to the production
  line.   Electrical,  gas, and steam flow meters were used with the hot-gas blancher
  to obtain data for  operational cost estimates.

  Wastewater samples  were collected from the commercial blancher and the hot-gas
  blancher for  each commodity studied; these were measured for volume and analyzed
  for BOD, COD, SS and pH.  Comparisons were made of reductions in wastewater
  volume, BOD,  COD and SS when steam or hot-water blanching were replaced by hot-
  gas blanching.   For beans, spinach and peas these reductions were  91  to 99 percent.
  Operational costs were higher for hot-gas  blanching than for steam or hot-water
  blanching for all vegetables studied except for green beans which  were slightly
  lower.  The flavor, texture, appearance, nutritional content and safety of hot-gas
  blanched vegetables are generally equivalent  to hot-water or steam blanched vege-
  tables.
17.
                               KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
  Blanching, vegetables, food processing,
  wastewater,  reduced waste generation,
  hot-gas blanching
b.lDENTIFIERS/OPEN ENDED TERMS  C. COSATI Field/Group
 Freezing,  canning,  food
 preservation
13 DISTRIBUTION STATEMENT
  Release Unlimited.   Available through
  Government Printing Office, Wash., D.C.
19. SECURITY CLASS (This Report)
21. NO. OF PAGES
     105
20. SECURITY CLASS (This page)
22. PRICE
EPA Form 2220-1 (9-73)
                        U S GOVERNMENT PRINTING OFFICE 1974-697-757/70 REGION 10

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