ADVANCED FOOD PROCESSING LABORATORY

• SMALL SCALE PRODUCTION EQUIPMENT
  • ALL-FILL PISTON FILLER AND FOOD YIELD QUANTIFIER Measures out semi-solid food matrices to specific volumetric/gravimetric quantities for pilot scale food productions.

  • DOUGH SHEETER Automatically or manually rolls out various types of bread, pizza dough and pastries to a predetermined thickness utilizing a stepped rolling mechanism to gently reduce the thickness of the dough with or without imparting excessive shearing forces.

  • HIGH TEMPERATURE/SHORT TIME EXTRUDER Uses screw conveyors in which a dough/grain mass is conveyed along a barrel toward a perforated die plate. As it is conveyed, the dough is “cooked” and textured by a combination of shear, friction, and pressure. Food extruders are used to produce breakfast cereals, pasta, pet food and a variety of puffed snacks.

  • IMPINGEMENT OVEN (PIZZA OVEN) Cooks 2 to 4 times faster than conventional ovens by surrounding the food with small jets of hot air while moving the product through the oven chamber via a chain conveyor.

  • MEAT PROCESSING CHAMBER Is a temperature regulated chamber that provides an environment for various types of meat production to include cutting, grinding, pureeing, flaking, and vacuum infusion.

  • RHEON ENCRUSTER Coextrudes dough and filling into various shapes (e.g. spherical, bar and cylindrical) to create fully enrobed sweet or savory items (sandwiches, pies and cookies). Product weight, filling, dough ratio and length are flexible. Optional devices such as the solid feeder and double filling feeder are also available.

  • STARCH RESEARCH AND BAKING AREA Offers numerous ovens, proofers/retarders and dough forming equipment to provide virtually everything required for standard R&D and small scale productions for a variety of baked items.

  • RETORTSSteam and steam/water retorts coupled with validator systems provide dependable thermal processing and validation of all in-house productions utilized for product development efforts and field testing.

• BENCH TOP ELECTROPORATOR Is used for electrochemical studies related to pulsed electric field processing in addition to genetic transfer experiments.

• FREEZE DRYER Removes moisture through sublimation which directly converts water from a frozen state to a vapor. Removal of this unbound moisture is one of the most effective methods for producing a shelf stable product while retaining the product’s inherent natural flavor and color.

• HIGH PRESSURE PROCESSING
  • HIGH PRESSURE PROCESSING UNIT Studies the effects of pressures up to 80,000 psi and temperatures up to 70° C on food quality and microbial and enzymatic activity. The unit is lab scale with a 2-liter capacity.

  • HIGH PRESSURE KINETICS UNIT (AVURE PT-1) Studies microbial spore inactivation kinetics at pressures up to 100,000 psi and temperatures over 100° C.

• MICROWAVE DIGESTIVE SYSTEM Is a pressurized microwave system with electronic control of temperature and time for treatment of food materials and biological tissues.

• OHMIC HEATING UNIT Treats model food samples with electric current that induces heating patterns that mimic electrical circuits.

• FERMENTER Isolates and produces target strains of “good” microorganisms and subsequently harvests various bacteriocins for use in food preservation research. Includes Vertical Autoclave unit to ensure sterility of the fermentation vesicle.

ANALYTICAL MICROBIOLOGY LABORATORY

• ANAEROBIC GLOVE BOXES These sealed boxes are used in a variety of applications where durable and economical enclosures are required: microbiology, incubation chamber, inert gas atmosphere, oxygen (O2) controlled environment, tissue and culture work. Inside the chamber, a strict 0-5 parts per million (ppm) O2 atmosphere is maintained through a hydrogen gas (5% mix) reacting with palladium catalyst to remove O2.

  

• BIOLOG MICROSTATION SYSTEM Is capable of identifying more than 2000 species of bacteria, yeast, and filamentous fungi. Its proprietary carbon-source utilization technology and 95 tests per microplate provide more information than any other phenotypic microplate or strip test on the market.

• BIOLOGICAL SAFETY CABINETS A Class ll biological safety cabinet that protects and reduces exposure to the laboratory worker and the environment by containment when handling Level 1 & Level 2 biological agents. It also maintains a sterile work area to prevent contamination of samples.

• PATHOGEN DETECTION SYSTEMS
  • BIOVERIS M1R BIOSENSOR ANALYZER Is used for rapid detection of pathogenic bacteria and toxins. This rapid detection technology is useful for identifying bacteria that can cause illness or fatalities in food that is consumed by the Warfighter. Samples are measured and analyzed automatically. The analyzer processes a single sample in about one minute and an entire 96-well plate in approximately 90 minutes and it targets food pathogens.

  • PROTOCOL COLONY COUNTER Is equipped with a unique colony detection system which combines special LED illumination and digital color camera control with powerful software. It has a built in computer to minimize the footprint on the lab bench. The system compensates for writing on plates, variations in agar thickness, touching colonies, meniscus effects, spreaders, bubbles, debris, different sized colonies and different colored media. Measuring applications include enumeration of pour, spread & spiral plates, multi well plate analysis and inhibition zone measurement.

  • WATER ACTIVITY METERS Consists of a chilled mirror dewpoint and temperature controlled meter that measures the water activity of a food product in less than 5 minutes, determining the quality, safety, and shelf life of that food product.

• FLUORESCENT AND CHEMILUMINESCENT DETECTION SYSTEMS
  • FLUORESCENT MICROSCOPE Is a multifunction fluorescence detection system that allows for the visualization of fluorescently labeled antibodies bound to cellular components. The technology is extremely useful for the evaluation of antibody binding assays including biofilm detection and planktonic cell capture on immunomagnetic beads.

  • IMAGING SYSTEM Consists of a sensitive charge-coupled device (CCD) camera with a darkroom that allows for the detection of fluorescent and chemiluminescent labeled protein, DNA, and RNA in electrophoresis gels or on nitrocellulose membranes. It can also be used to detect bacterial cells that are labeled with HRP antibodies reacting with chemiluminescent substrates.

  • LUMITEC LUMINOMETER Is a sensitive photomultiplier based detection system that is used to test antibodies with chemiluminescent labels for biosensor development.

  • ANALYTE 2000 IMMUNOASSAY SYSTEM Is a laser based fiber optic fluorometer that is used for assays to test antibodies in biosensor development studies.

• VETERINARY SERVICES ACTIVITY (VSA) FOOD DIAGNOSTIC FIELD TEST KIT The field test kit was assembled by the United States Army Medical Material Agency (USAMMA) as a portable laboratory, providing veterinary food inspectors with the tools and capabilities to make decisions regarding the safety and quality of food being purchased and consumed by US forces overseas. Equipment includes the Charm II analyzer and the Charm novaLUM, instruments that can detect aflatoxins, antibiotics, and insecticides in a variety of food matrices, as well as measure sanitation of surfaces, two centrifuges, one high speed and another to spin down blood, a bacterial plate counter, microscope, incubator, refrigerator, balance, pH meter, and chlorine analyzer/colorimeter.

• FOOD SAMPLE PROCESSING AND ANALYSIS
  • PULSIFIER® Is a revolutionary new technology for processing of food samples for microbiological examination. Unlike paddle-type instruments the Pulsifier® beats the outside of the plastic bag containing the food sample at a high frequency producing shock waves and intense stirring which drives the microbes out of the food matrix and into suspension. The Pulsifier® offers processed samples that are more compatible with the demands of rapid microbiology methods featuring less food matrix destruction and a cleaner aqueous phase making filtration and pipetting easier and minimizing interference with EIA and PCR methods. Microbial recovery is at least equivalent to paddle type instruments and minimal temperature increases of the sample during processing protects damaged organisms.

  • REFRIGERATED AND NON-REFRIGERATED CENTRIFUGES
    • AVANTI J 20 XP ULTRACENTRIFUGE Is a high-performance centrifuge designed for high throughput and versatility. Teamed with the J-Lite® JLA-8.1000 6-liter rotor, polycarbonate and polypropylene bottles, the Avanti J 20 XP centrifuge can process 6 liters in 10 minutes. It is routinely used to concentrate and wash cell suspensions.

    • FORMA 5590 HP CENTRIFUGE Is one of the most powerful MicroCentrifuges on the market. This unit offers G-forces as high as 21,000 xg and features selectable acceleration and deceleration rates for precise control over every run. Designed with space conservation (12" × 13") and performance in mind these powerful MicroCentrifuges are ideal for use in research, clinical and production laboratories.

  • SPIRAL PLATE COUNTER AND PLATER (WASP2 SPIRAL PLATER) Eliminates the need for serial dilutions, offers a reduction in cost per test and standardizes counting methods. It is fully microprocessor controlled and allows depositions onto 10 cm and 15 cm plates in log volumes of 50 µl, 100 µl & 200 µl and a linear deposition of up to 400 µl. The plater is usually used when large microbiology studies are done, e.g., micro challenge and stability studies.

  • STACKABLE INCUBATOR SHAKER A large capacity, heavy duty biological incubator shaker with an adjustable and programmable temperature (4-80° C) and speed (25-400 rpm) ranges.

  • ULTRASONIC PROCESSOR Consists of a high wattage power supply and a sound proof enclosure to house and protect the user from the sonicator horns and high power sonification water bath. The intended use for this specialized equipment is the disruption of bacteria, yeast, and fungi cell walls for the extraction of protein, RNA, and DNA without the use of traditional chemicals that could interfere with sensitive analytical instrumentation, (i.e. HPLC, gene arrays, PCR, rtPCR, ELISA based detection).

FOOD MICROBIOLOGY CLEANROOM

• BATCH FERMENTERS Two BioFlo 110 Advanced Fermentation Kits provide the capability to isolate/produce target strains of “good” microorganisms and subsequently harvest various bacteriocins for use in food preservation research. A total of 12 liters of working capacity allow for bench top R&D as well as pilot scale production quantities.

• CONTRIFUGE Thermo Scientific Sorvall centrifuge allows for rapid separation of large volumes of biological suspensions from fermenters/bioreactors. The high speed, continuous contrifuge processes at a rate up to 54 liters per minute. The system is ideal for harvesting of plant/animal cultures, protein precipitates, yeast separation, bacterial harvesting, and cell enrichment.

• INCUBATOR/FREEZER Barnstead Imperial III incubator has a large internal capacity allowing for equipment insertion and/or gas pack jars allowing for aerobic as well as anaerobic incubation. Innova freezer has vacuum insulation panels allowing for temperatures down to -112° F for long-term specimen storage/preservation.

• VERTICAL AUTOCLAVE A Tomy ES-315 portable autoclave dedicated to sterilizing food fermentation equipment whose biological end-products are approved for food consumption.

FOOD SAFETY TESTING LABORATORY

FLEXIBLE FOOD PACKAGING LABORATORY

• COMPRESSION TESTER Is a fully automated test system used to determine the compression strength, load carrying capacity, or long term stacking strength of large packages. The tester uses a precision load frame, system controller and personal computer. A command signal from the control system to the load frame advances the upper platen toward the product and applies a compressive force until the test concludes. The system controller measures and records force, deflection, and time data in accordance with ASTM standards D-642 and D-4577.

• DROP TESTER Simulates the fall of a packaged shipping container. The container is lifted to a standard height and dropped on each face, corner, and edge in accordance with ASTM standard D-5276.

• INCLINE IMPACT TESTER Tests impact resistance of shipping containers in accordance with ASTM standard D-880.

• ENVIRONMENTAL CHAMBERS Tests the durability of packaging materials and ensures the quality of food in extreme environmental conditions. Since military rations are shipped and stored around the globe, environmental testing ensures that Warfighters receive high quality rations no matter where they are located.

• POUCH/TRAY BURST TESTERS Measures the ability of pouches and trays to withstand changes to internal pressure.

• VIBRATION TABLE Simulates the forces and motions of motor trucks, railroad cars and aircraft. This is standard practice for performance testing of shipping containers and palletized unit loads. It is used to verify protective capabilities of packaging in accordance with ASTM standard D-999.

• SPRAY CHAMBER Tests the water resistance of shipping containers in accordance with ASTM standard D-951.

• HERMETIC SEALERS

  

  • METAL TRAYCAN SEALER/POLYMERIC TRAY SEALER Hermetically seals both metal and polymeric trays prior to thermal processing.

  • THERMAL IMPULSE HEAT SEALERS Adjustable sealers apply uniform, consistent air-tight/water-tight seals in most thermoplastic films and laminates.

  • VACUUM/GAS FLUSH HEAT SEALER Evacuates headspace and applies a fusion (hermetic) seal to the pouches. The pouch is isolated from the atmosphere in an enclosed chamber. The chamber is then evacuated and two bars are used to heatseal the pouch.

• PACKAGING FABRICATION EQUIPMENT
  • ULTRASONIC WELDER Enables the precision, high-strength joining of thermoplastics using ultrasonics.

  • HORIZONTAL FORM-FILL SEAL MACHINE Fabricates the right-sized packaging on-line with rollstock materials. A base cavity is drawn, the product filled, and the lidding applied on-line. This simulates the commercial production of some military food products.

• PACKAGING QUALITY ANALYSIS
  • MEAD JAR TESTER Enables the non-destructive examination of leakage paths through finished cans and flexible/rigid packages.

  • HEADSPACE GAS ANALYZER Draws a headspace sample and analyzes it for oxygen and carbon dioxide content. The system is used for package integrity testing, quality control in food applications, bioprocess and fermentation testing. The unit is rugged, and portable when needed via battery operation. The analyzer measures oxygen from 0.1%-100%.

  • TAPTONE SEAL INTEGRITY TESTER Is a non-destructive device that measures the seal integrity of small trays and containers.

FOOD ANALYSIS LABORATORY

• CHROMATOGRAPHY: HPLC, Liquid, Gas
  • CHROMATOGRAPHY HPLC (INCLUDING ION CHROMATOGRAPHY) AGILENT 1200 Is an analytical instrument used for the separation and determination of organic and inorganic solutes in a sample. The compound to be analyzed is dissolved in a solvent, injected and permeated through a porous solid stationary phase and elutes the solutes into a flow-through detector. The compounds elute as individual peaks in a chromatogram which can be analyzed and quantified. The HPLC has a diode array, fluorescence, and refractive index detector. An additional interface allows for ion chromatography to be performed on the same instrument. Ion chromatography separates almost any type of charged molecule, often used for proteins and peptides.

  • LIQUID CHROMATOGRAPHY Measures antioxidants, sugars, organic acids, vitamins and other food components.

  • GAS ANALYZER FOR INFRARED ABSORBENT GASES SIEMENS ULTRAMAT 23 Uses the NDIR (non-dispersive infrared absorbance) method to continuously and highly selectively measure one or more IR active gases, with absorption bands in the infrared region from 2 to 9 micrometers, for example, CO, CO₂, NO, SO₂, NH₃, H₂O, CH₄ and other hydrocarbons. This can be used to measure headspace in ration components.

  • GAS CHROMATOGRAPH-AGILENT 6890 Separates compounds that have volatility and thermal stability. By separating the sample into individual components, it is easier to qualitate and quantitate various sample components. It is estimated that 10-20% of known compounds can be analyzed. The detector used with this system is a Flame Ionization Detector.

  • GAS CHROMATOGRAPH/MASS SPECTROMETRY-AGILENT 5975 Designed to separate gas phase ions according to their mass to charge ratio (m/z) value. It yields qualitative information about a pure component.

• SPECTROPHOTOMETERS
  • FLUOROSCENCE SPECTROPHOTOMETER The SPEX Fluorolog-2 spectrofluorometer measures the intensity fluorescence radiation over a region of wavelengths, resulting in an emission scan, with a stationary excitation wavelength, or scans an excitation spectrum with a fixed emission wavelength. Two different detection modes, front-face for solid samples or right-angle for fluid samples, variable entrance and exit slit widths, computer controlled settings and data acquisition can be used to tailor measurements for a wide variety of samples.

  • PERSONAL DIGITAL ASSISTANT SPECTROPHOTOMETERS (UV/VIS, FLUORESCENCE AND REFRACTIVE INDEX DETECTION) Are used in conjunction with High Performance Liquid Chromatography (HPLC) for analysis of a variety of biomolecules present in foods.

  • SPECTROPHOTOMETER Is the most precise and accurate method of measuring color in food products. It has scanning capability across the entire visible spectrum (400-700 nm) which allows for precise specification of any color.

• COLORIMETER Quantifies color by measuring the three primary color components (red, green, blue) of light seen by the human eye. The tristimulus measurement provides color information on the light reflected (solids) or transmitted (liquids) from foods. The system is capable of multiple illuminants, observers, indices, and color scales. The software allows for plotting color scans, changes in color trends, and color mapping.

• LASER DIFFRACTION PARTICLE SIZE ANALYZER Uses reverse Fourier lens optics incorporated in a binocular lens system enabling the optimization of light scattering across a wide range in a single scan. 126 optical detectors, 15-90 second analysis time, 0.375 micron - 948.2 micron particle size range, and 1% reproducibility allow for the most accurate measurement of particle size.

• LASER SCANNING CONFOCAL MICROSCOPE Performs single image and series scans, using dual Argon/Krypton lasers, fast shutters, automated slit/point aperture, filter wheel, Z-drive and cooled-CCD camera. It optically sections samples and using fluorescent dyes and analysis software can generate 3-D images that can discern spatial distributions of various components.

• OSMOMETER Is a high precision, low volume (10 microliter) vapor pressure osmolality instrument capable of measuring a wide range of biological materials. Measurement time is 1-2 minutes; the unit is capable of simple statistical functions and a 0-3300 mmol/kg measurement range. Osmolality measures a solution freezing point and ultimately, solution concentration.

• RHEOVISCOMETER Through rotational shear, the viscometer provides shear stress versus shear strain relationships (thickness) for liquid foods. It provides measurements accurate to within +/- 1.0% and a repeatability of +/- 0.2%. A temperature controlled small sample adapter with a rheologically correct cylindrical geometry provides a defined system for extremely accurate viscosity measurements.

• SOLUTION CALORIMETER AND HIGH SENSITIVITY SCANNING Monitors exothermic chemical reactions using a sensitive thermocouple interfaced for digital data acquisition. The system includes a high sensitivity scanning calorimeter that is used for monitoring chemical reactions by measuring heat and well as effects of heat on macromolecules. It is useful in structure-function studies of proteins, nucleic acids and lipid membrane assemblies.

  SOXHLET FAT EXTRACTOR (SOXTEC SYSTEM HT 1043) Extracts lipids from foods using a semi-continuous method. Oil and fat from solid material are extracted by repeated washing (percolation) with an organic solvent, usually hexane or petroleum ether. The solvent is able to be re-used for different extractions.

• SUPER CRITICAL FLUID CONVERTER Allows for the supercritical use of fluids, especially carbon dioxide and introduces the supercritical fluid into a model system. It changes the physical properties of a gas via pressure and temperature which gives it the diffusivity of a gas and the solvating power of a liquid. The altered liquid works extremely well as a processing media and is used for research of antimicrobial and anti-enzymatic properties.

• SUPERCRITICAL FLUID FAT EXTRACTOR Determines fat content by employing non-hazardous carbon dioxide gas in a supercritical state.

• PROTEIN ANALYZER Calculates the nitrogen content of materials determined by combustion and protein content. As an environmentally superior alternative to wet-chemistry Kjeldahl method, nitrogen by combustion provides no chemical waste. The system is equipped with an auto-loader capable of analyzing up to 40 samples without operator supervision and per sample analysis time is 1-3 minutes.

• TEXTURE ANALYZER Measures the force and distance in tension or compression. A wide range of programs include stress relaxation, adhesion, fatigue cycling, and compression cycling. Full statistical analysis capabilities are included. The system has a high range of speeds with high force and speed accuracy. It also provides stress versus strain relationships and fracturability on a wide range of solid foods.

• THERMAL ANALYSIS EQUIPMENT Has a set of techniques in which the physical property (glass transitions, melting point, heat capacity) of a material, or its reaction products, are measured as a function of temperature. The methods find a widespread use in quality control and research on polymers, pharmaceuticals, clays, metals, alloys, and foods.
  • DIFFERENTIAL SCANNING CALORIMETER (DSC) Is a technique in which the differences in heat flow are measured. DSC is a calorimetric method which measures differences in energy and has now become the most widely used of all thermal methods.

  • DYNAMIC MECHANICAL ANALYSIS (DMA) Is a technique in which an oscillating (or vibratory) force is applied to a material and the resulting displacement is measured. DMA is used to characterize the viscoelastic properties of materials. Temperature scanning during mechanical analysis is used to analyze state changes.

  • MASS BALANCE Uses a gravimetric method which also relies on measuring the weight of a sample prior to and after dehydration. The mass balance utilizes an all-in-one approach whereby a sample sits on a balance and a heating element continuously dries the sample. The mass balance is a fast, efficient and simple quality analysis method.

  • MOISTURE ANALYSIS Is a computer-assisted system for an accurate and rapid measurement of moisture in most food material. Unlike traditional vacuum oven methods that take 12-24 hours, this system can provide accurate readings in 5-10 minutes; hence it is a versatile unit for a rapid moisture analysis for prototype ration development.

  • THERMOGRAVIMETRIC ANALYSIS (TGA) Is a technique in which the mass of a sample in a controlled atmosphere is recorded continuously as a function temperature or time as the temperature is increased. The resulting thermal decomposition curve provides information on the thermal stability, shelf life, and bulk composition of material analyzed.

  • VACUUM OVEN Uses a gravimetric method which relies on measuring the weight of a sample prior to and after dehydration, and assigning the difference in weight to moisture content. The vacuum oven method uses scrubbed, dry air to create a vacuum and reduces the need for higher oven temperatures, thereby improving accuracy. Moisture analysis using a vacuum oven is a widely accepted AOAC method for many food products.

  • TIME DOMAIN NUCLEAR MAGNETIC RESONANCE (NMR) Uses a low field NMR to detect water mobility parameters of food samples (T1 and T2 relaxation times).

FOOD PACKAGING, POLYMER PROCESSING AND CHARACTERIZATION LABORATORY

• SINGLE AND MULTI-LAYER EXTRUSION AND COMPOUNDING
  • COMBINATION TWIN AND SINGLE SCREW EXTRUDER Has interchangeable barrels and a modular design which give this extruder the capability to easily be switched from a twin to a single screw extruder and is able to produce blown and cast film. The extruder also has the ability to quickly and easily produce plastic strand and pellets with a three strand die and pelletizing line.

  • MULTILAYER CAST FILM CO-EXTRUSION SYSTEM This system has five layer blown film capability and 9 layer cast film capability with a feed block layering system, and an adjustable slit die for film thickness control. This system uses five extruders and can blend five different polymers in many different configurations in order to maximize barrier and mechanical properties while minimizing material costs.

  • TWIN SCREW EXTRUDER The ThermoPrism extruder has programmable extruder screw elements for low to high shear processing which is excellent for the incorporation of nanocomposites into commercial polymers. There are blown and cast film production capabilities, and a strand die with pelletizing line for compounding and fabrication of custom made plastic pellets.

• POLYMER FILM CHARACTERIZATION
  • MOCON OXYGEN TRANSMISSION TESTING MACHINE Determines the oxygen barrier properties of polymeric films by measuring the transmission rate of oxygen gas through the material. Monolayer and multilayer film, sheet and packages can be tested using a variety of different supplies and equipment. In-house capabilities for oxygen permeation testing include three modulus which are able to test six different samples simultaneously. Conforms to ASTM standard D3985.

  • MOCON WATER VAPOR TRANSMISSION TESTING MACHINE Determines the water vapor barrier properties of polymeric films by measuring the transmission rate of humidified nitrogen gas through the material. Monolayer and multilayer film, sheet and packages can be tested. In-house capabilities for water vapor permeating testing include two modules which are able to test four different samples simultaneously. Conforms to ASTM standard F1307.

  • DART DROP IMPACT RESISTANCE TESTER Measures the impact resistance of plastic films, sheet and laminate. Conforms to ASTM standard D1709.

  • FLEX TESTER Determines whether plastic films and laminates can withstand repetitive strain. This machine demonstrates the visual results of pin-holing and delamination. Conforms to ASTM standard F392.

  • TEAR TESTER The Elmendorf tearing tester measures the force required to propagate a tear through a constant radius specimen. Tear resistance can help to determine an optimum thickness and also shows the ability of a packaging material to withstand rough handling. Conforms to ASTM standard D1922.

  • TENSILE TESTER The Instron tensile tester is used to test the tensile and seal strength properties of plastic films, sheet, and laminate. Using various ASTM methods, the impact resistance and tear resistance of plastic films can also be tested. Conforms to several ASTM standards including D638.

• PRE-PROCESSING CONDITIONING AND ANALYSIS
  • MELT FLOW INDEXER Measures the melt flow resistance of thermoplastic resins. The melt flow rate is an indirect measure of a polymers viscosity and molecular weight. Conforms to ASTM standard D1238.

SENSORY AND CONSUMER TESTING LABORATORY