Capabilities and Pricing

Pricing

External Clients (individuals and companies not employed by Cornell):

As of November 1st, 2023:

Full use of Pilot Plant and associated equipment:
$188/hour
$750/ half day (4 hours)
$1,500 daily rate

Cooler/Freezer/Warehouse Storage:
$250/month for partial use
$500/month for special and specific conditions, exclusive use

Evaporator/Ultra Filtration Membrane Unit:
$3,000/day 1st day
$1,500/day subsequent days

Freeze/Nyle/Carbonation (Passive time):
$15/hour

External Clients, Please Contact: Roger Morse: rtm1 [at] cornell.edu
Internal Clients, Please Contact: George Howick: gh342 [at] cornell.edu or Bob Martin: rm822 [at] cornell.edu

Notes

All ingredients, product containers, analytical testing, shipping containers and shipping charges supplied by Pilot Plant are additional.
Any facilities used (Pilot Plant, analytical laboratory, refrigerated/frozen storage space, etc.) shall be cleaned and returned to the same condition as they were initially found before any work was conducted in that area. This includes any equipment and all materials used during the course of a single trial.
Cornell reserves the right to change these prices based on the specifics of any particular project.
Any work performed in the Pilot Plant or analytical laboratory must be completed within normal working hours (8:30 a.m. – 5:00 p.m.).
Any work performed outside normal working hours will incur charges at twice the hourly rate(s) listed above.

Capabilities and equipment available

Dehydration technologies

Vacuum-microwave dryer

Process overview:

Vacuum- microwave dehydration involves creating a very low pressure environment, which decreases water’s boiling point to around room temperature and then using microwaves to increase the rate of evaporation and ensure even drying. The result is a product uniform moisture content, produced quickly (typically under an hour), with protein structures still intact due to the low temperatures.

We use the Enwave 10KW Machine.

Specifications:

Processing rate: 9.1 kg water removal per hour
Batch capacity: 8 trays measuring (26in x 8.5in x 1.5in)
Power consumption: 10 kW
Vacuum: 12-300 Torr

Example applications

Milk can be non-thermally dried to produce powdered milk.
- Cheese or yogurt can be dried to desired consistency.
Fruits and vegetables can be preserved to extend shelf life.
- Apples or bananas can be dried into ‘chip’ like snacks.

Freeze dryer

Process overview

During freeze drying the product is chilled to around -40F. Once the product is frozen, the freeze dryer reduces the pressure of the chamber (to around 100 mT) and warms the product to around 1°C inducing sublimation (the process of water evaporating from a frozen state). The water is then collected and frozen on the condensing coil.

This process often takes 24-48 hours. It is not uncommon for clients to leave their product freeze drying at the pilot plant and have it shipped to them later.

We use the Milrock Magnum XL Pilot Freeze Dryer.

Specifications:

Condensing rate: 20 L in 24 hours
Batch capacity: 30L (10 3L shelves)
Temperature range: +70° to –60°F in less than 40 minutes
Pressure range: 100 mT in less than 20 minutes.

Example applications:

Coffee can be freeze dried to make instant coffee.
Produce can be preserved to extend shelf life.
Food grade enzymes can be dried, vacuum packaged and re-hydrated later.

Air dehydrator

Process overview

Using heated, low humidity, airflow, the air dehydrator is capable of producing 20 trays of dehydrate product. As the temperature in the chamber rises, water in the food product begins to evaporate and is carried away by the airflow. This process accelerates drying time. The dehydrator can also detect the humidity of the airflow, giving the user a high degree of control over the moisture content over the final product.

We use the Nyle systems FD 10.

Specifications:

Water removal rate: 10 lb/hr (nominal)
Batch capacity: 20 trays (18.5in by 11in)
Temperature range: 80F to 160F.
Humidity range: 0-100%

Example applications

Produce can be preserved (with some texture, flavor and color change).
Seeds can be primed for pressing.

Pasteurization technologies

UHT pasteurizer

General overview

The UHT (Ultra High Temperature) pasteurizer makes use of very high temperatures (up to 300°F) to kill microorganisms in liquid products.

The continuous feeding allows for a wide range of batch sizes to be processed, as they are pumped in to the system, first through a pre-heater, then a final heater to reach temperature, then enter a “hold tube” which can hold the product at pasteurization temp anywhere from 3 to 150 seconds. After the kill step is complete the product is direct through two coolers and to a “ultra-clean” where the product can be filled with minimal risk for contamination.

We use the Microthermics UHT Pasteurizer.

Specifications:

Processing rate: Product Dependent (Typically 1.5-2.5L per minute for dairy/soft drinks).
Max pasteurization temperature: 300°F
Hold time range: 3 to 150 seconds
Filling temperatures: 70° – 185 °F

Example applications

Dairy beverages, soft drinks, fruit and vegetable juices, protein shakes (depending on consistency).

Batch pasteurizer

General overview

The batch pasteurizer takes small batches of bottled or canned product and pasteurizes the contents using recirculated heated water. The batch pasteurize is usually used in combination with a data logger to confirm PU’s (pasteurization units) delivered to the product.

We use the Pro Engineering Batch Pasteurizer.

Specifications:

Batch capacity: 60 bottles (750ml) 168 cans (355ml).
Max pasteurization temperature: 200°F.
Typical pasteurization time: 20 mins.

Example Applications

Wine, cider, beer.
Canned or bottled beverages.

Fruit & vegetable processing

Fruit and vegetable processor

Process overview:

The fruit and vegetable processor involves pushing produce through a screen rotating at speeds of up to 1900 RPM, which separates the soft flesh from skins, cores, stems and other undesirable solids. The pulp and waste are collected in separate containers.

We use the Bertocchi CX Extractor.

Specifications:

Max processing capacity: 1000 kg/h to 24 t/h.
Processes: whole (de-stoned) fruits.
Screen hole sizes: 0.023 to 0.314 inches.

Applications:

Fruit and vegetable puree and pulpy juices.

Accordion press

General overview:

The Accordion Press first processes the product into a pulpy puree and collects it in an intermittent hopper. From here the product can flow into the accordion press, where it sits between solid boards designed to press and direct juice. The accordion presses the pulp with a pressure up to 1200 PSI, forcing juice through the cloth, and into a collection container.

We use the Good Nature X-6.

Specifications:

Max output rate: 40 – 100 US Gallons per hour (product dependent).
Max pressure: up to 1200 PSI.

Applications:

Apples and other fruits and vegetables that can be pressed for juice.
Almonds and some other nuts.

Small scale juice press

General overview:

The small juice press is a grinds and presses small batches (less the 5lb) batches of fruits and vegetables to produce juice. The hopper features a hand press to apply pressure to producing heading towards the grinder. The press utilizes an adaptive pressure system, where the the press adjusts the pressure applied during pressure according to live feedback to optimize juice production.

We use the Good Nature X-1 Mini.

Specifications:

Max output rate: 3-6 gallons per hour (product dependent).
Batch size: 5 lbs
Adaptive pressure system.

Applications:

Fruit and vegetable juices.

Please see our Mixing Technologies for more information about fruit and vegetable processing equipment.

Homogenization technologies

In-line homogenizer

General overview

Homogenization is the process of making a product uniform. This process can be added seamlessly to the UHT pasteurization process, before or after pasteurization. Using jumpers the product flows continuously from the UHT system to the homogenizer where is it pressurized with up to 6000 PSI before jumping back to the UHT system.

Specifications:

Processing rate: Typically 1.5-2.5L per min (must be synchronized with Microthermics).
Max. homogenization pressure: 6000 PSI.
Max. operation temperature: 245°F (Can be placed before or after pasteurization stage).

Example applications:

Protein shakes, flavored dairy products, formulated fruit and vegetable beverages.

High pressure homogenizer

General overview

The high pressure homogenizer is capable of homogenizing products at a cellular level, disrupting cells and creating a uniformed product.

We use the Mini DeBee Homogenizer.

Specifications:

Processing rate: Max. 380ml/min (product dependent)
Batch capacity: 1 Liter reservoir or Tri-Clover attachment for continuous flow.
Max. homogenization pressure: 45,000 PSI.

Example applications:

Create highly stable emulsions with product specific encapsulations of ingredients such as color, nutrients or structural components.
High pressures may reduce concentrations of microorganisms and active enzymes.

Mixing technologies

Vertical cutter

General overview

The Vertical Cutter uses a powerful motor and interchangeable cutting blades to produce a smooth textured product from a variety of solid and liquid ingredients.

We use the Robot Coupe R30 T.

Specifications:

Max batch capacity: 28L (31 Qt) or 34 lbs.
Blade speed settings: 1800 & 3600 rpm.
Blade type: Straight or serrated.

Example applications

Puree blends, smooth sauces, hummus and mousses.
Reduce particle size of solids.
Create temporary emulsions or suspensions using high-shear.

High shear mixer

General overview

The high shear mixer has a versatile mixing head that can create effective mixing patterns in liquid solutions while reducing particle size over time.

We use the Ross High Shear Mixer.

Specifications: