A-Ferm A New Fermentation Technology Global Gherkin Days

®
A-Ferm
A New Fermentation
Technology
Global Gherkin Days
July 7, 2015
Fermenting Solutions International, LLC
Bill Scott
Lisa Moeller
Objectives
1. Fermenting Solutions International, LLC
a. Lisa and Bill’s professional experience
b. Creation of a new company
2. Calcium Fermentations
a. History
b. Comparisons to traditional salting
3. A-Ferm® / Patent Pending
a. What it is!
b. Revolutionary process
c. Simple application for processing
d. Worldwide utilization
e. Low initial capital investment
4. Opportunities & Applications
Bill Scott
• Thirty two years of experience in vegetable
•
•
•
•
fermentation/acidified foods.
Seventeen years as Plant Manager.
Worked for Dean Foods, Treehouse Foods, Mount Olive
Pickle Company and Vlasic Foods.
Managed factories in Massachusetts, Mississippi,
Colorado and North Carolina.
Bachelor of Science Degree, Business Management,
Plymouth State University.
Lisa Moeller
• Twenty nine years of experience in vegetable
•
•
•
•
fermentation/acidified foods.
Masters of Science Degree, Food Chemistry, North
Carolina State University.
Bachelors of Science Degree, Agronomy, University of
California at Davis.
President of the Cape Fear River Assembly.
Pickle Packers International, Manufacturing &
Technology Committee Member for ten years.
Why Pickle Fermenting Practices
Are Changing
•
•
•
•
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Increased processing costs.
Interest in reducing salt discharges.
Concerns with open top, outdoor tanks.
Intermingling of “used brines” = no traceability.
Inconsistent product quality.
FSI was created to promote accelerated “no salt”
fermentation practices on an industrial scale.
FSI recognizes calcium fermentations can improve:
• The production of high quality fermented products.
• Desire to reduce salt discharges worldwide.
• The need for traceability in the supply chain.
• Concerns for uncovered tanks.
• Changes in the purchasing and types of bulk salt.
• Possible reduction of sodium in finished products.
• The desire to reduce bloated cucumbers for slices.
Current Steps for Tanking
Stock to be Fermented
Cushion Brine
Added
Empty Tank
Cucumbers
Added
Green Brine
Added
Purging
TRADITIONAL Fermented Pickles
 Require a lot of salt.
 Create a lot of salt waste.
Brine Formula Comparison
Salt Brine Formula
Calcium Brine Formula
•
Salt
•
Calcium chloride
•
Calcium chloride
•
Potassium sorbate
•
Potassium sorbate
History Tank yard Calcium
Fermenting (TCF)
During the 1970’s, Dr. McFeeters with the USDA in North
Carolina was studying the importance of calcium.
From 2008 until 2010, with his encouragement, we began
experimenting with different fermentation brines in 55
gallon barrels.
History TCF Continued
• In November of 2010, we successfully fermented two 3300
gallon tanks of 2B’s in a “no salt brine” and packed the
product into salable chips.
• In May, June, July, August and November of 2011, we
fermented 2’s, 3’s and relish stock with the “no salt brine”.
• In 2012, we put in 21 experimental tanks to conduct
extensive sensory testing with trained panels at NCSU.
• During 2013, a total of 80 (8000 and 10,000 gallon tanks)
were fermented with the “no salt brines.”
Fermented Pickles in Both
Brines After Day 5
NaCl
CaCl2
A-Ferm® - 48 hour Fermentation
Grade
Cucumbers
Soak
Soak
Tank
Tank
Flume/
pump
Rinse/
Wash
Flume/
pump
Hydrosieve
Slice
Hydrosieve
Vacuum
Press
Shaker
Screen
Fermentation
Vessel
Packing
1. Temperature
Controlled
2. Brine
Circulation
3. Fermenting
Ingredients
a. Calcium
chloride
b. Potassium
sorbate
c. Culture
SPEED
IS
POWER
®
A-FERM
IS
VERY
FAST
48 Hours
DESALT
(REDUCING CALCIUM)
IS INCLUDED
IN THE 48 HOURS
TRADITONAL
FERMENTATION
IS VERY SLOW
Three to Five Weeks Depending
on Outside Temperature
LETS TALK BUSHELS
1 Bushel of Cucumbers
= 50 pounds
1 Bushel of Cucumbers
= 22.7 kg
IMAGINE
Six Vessels (Tanks)
Each Holding
800 bushels
One 8 Hour
Production Shift
Requires
1600 Bushels
All Six Are Full On Friday
800
Bushel
800
Bushel
Monday Production
Refill for Thursday
800
Bushel
800
Bushel
Tuesday Production
Refill for Friday
800
Bushel
800
Bushel
Wednesday Production
Refill for Monday
There is NO lower
cost than this
scenario during the
local crop season!
Cost per Case of Pickles
10% Overhead
20% Labor
70% Material
COST OF 1 BUSHEL OF FRESH
CUCUMBERS
(Graded & Delivered)
3A/3B (44.5/51mm)
€ 8.00 /bushel
Cost to Ferment (Traditional)
€ 2.27/bushel
3A/3B - € 8.00/bu. + € 2.27=
€ 10.27 (fermented bu.)
Cost to Ferment (A-FERM®)
€ 0.82/bushel
3A/3B - € 8.00/bu. + € 0.82/bu=
€ 8.82 (fermented bu.)
Cost of A-Ferm®
vs.
Traditional Tank yard
(Ingredients, Labor, & Overhead)
Cost per bushel for A-Ferm®
€ 0.82
Cost per bushel for Traditional
€ 2.27
SAVINGS:
€ 1.45 /bushel
A-Ferm Cucumber Yield Savings
 No Bloaters
 Tanking
 Tank Unloading
 Transporting
 Cutting Loss
 Shrink

SAVINGS
9% (conservative number)
A-FERM® SAVINGS
€ 1.45 /bu. Fermentation
€ 0.72 /bu. Defects Yield
€ 2.17 /bu. Total Savings
Cost Saving Analysis
 Calcium Chloride vs Sodium Chloride
 Tank Yard Operational Costs
 Waste Disposal
 Yield Savings
 Cucumber Holding Cost Comparison
 Cucumber Blended Cost Comparison
Cucumber Growing
Areas by Month
(Eastern United States)
July
August
June, July,
Sept., Oct.
Nov., Dec., Jan.,
Feb., March
Apr., May,
Nov., Dec.
Cucumber Growing
Areas by Month - Europe
JulySept
.
May/
Nov.
June/
Oct.
Transformation of Food Service /
Restaurant Chain Pickle Business
 A-Ferm® = 48 hour fermented finished
products
 Minimal capital investment (no tank yard)
 Transportation costs
 Maximize regional cucumber crops as it
relates to finished goods distribution
 Increased seasonal production capabilities
(no desalt production limitations)
 Supply chain considerations
Hamburger Dill Chips in 48 Hours