Patent Description:
Aspects of the present disclosure are directed to heating systems in which articles are heated, at least in part, by exposure to microwave energy. In particular, the present disclosure is directed to approaches for controlling such microwave heating systems to ensure that the articles being heated achieve desired levels of pasteurization and sterilization.

Microwave energy has been used as a source of energy to rapidly and effectively heat articles in many different applications. Because of its ability to quickly and thoroughly heat an article, microwave energy in particular may be employed in specific applications where the rapid achievement of a prescribed minimum temperature is desirable, such as, for example, pasteurization or sterilization processes. Additionally, because microwave energy is generally volumetric, it may be useful for heating many dielectrically and thermally sensitive articles, such as food and pharmaceuticals. However, to date, the complexities and nuances of safely and effectively applying microwave energy, particularly on a commercial scale, have severely limited its application in rapid thermal processing. Accordingly, a need exists for efficient and cost-effective industrial scale microwave energy heating systems suitable for use in a wide variety of end-use applications and corresponding methods of controlling and operating such systems. One example of a microwave energy heating system known in the art is disclosed in <CIT>.

In one aspect of the present invention, a method for processing articles is provided as defined in claim <NUM>.

In another aspect of the present invention, a microwave heating system is provided as defined in claim <NUM>.

The foregoing and other objects, features, and advantages of the present disclosure set forth herein will be apparent from the following description of particular implementations of those inventive concepts as illustrated in the accompanying drawings. It should be noted that the drawings are not necessarily to scale; however, emphasis instead is being placed on illustrating the principles of the inventive concepts. It is intended that the implementations and figures disclosed herein are to be considered illustrative rather than limiting.

The present disclosure relates to methods and systems for pasteurizing or sterilizing articles in a liquid-filled microwave heating system. Methods for controlling this type of microwave heating system are also described herein and may be used to ensure that the articles being heated achieve desired levels of pasteurization and sterilization.

Systems and methods in accordance with the present disclosure utilize operating profiles for controlling the operation of microwave heating systems so that the articles being heated by the system achieve desired levels pasteurization or sterilization. The operating profiles are based on empirical data and provide specific target values for one or more microwave system parameters. Microwave heating systems operated according to these operating profiles can help ensure that sufficient pasteurization or sterilization of treated articles is achieved, while also ensuring that any processing criteria specified to impact the final properties of the article (e.g., taste, texture, appearance) are also met. The operating profiles described herein may be used to operate the system under typical operating conditions, or may be used to manage process deviations. These profiles may also be used to evaluate operating data from completed runs in order to determine whether or not articles treated during the completed run meet certain processing criteria, including, but not limited to, target lethality rates.

In general, pasteurization involves the rapid heating of an item to a minimum temperature between about <NUM>° C and about <NUM>° C, while sterilization involves heating the item to a minimum temperature between about <NUM> and about <NUM>. In some cases, the processes and systems described herein may be configured for pasteurization, sterilization, or both pasteurization and sterilization. Examples of suitable types of items to be pasteurized and/or sterilized include, but are not limited to, packaged foodstuffs, beverages, medical instruments and fluids, dental instruments and fluids, veterinary fluids, and/or pharmaceutical fluids.

Implementations of the present disclosure may be carried out in a variety of different microwave heating systems including, for example, those similar to the microwave heating systems described in <CIT> as well as those described in <CIT>.

Turning now to <FIG>, a schematic representation of the major steps in a microwave heating system of the present disclosure is depicted in <FIG>, while <FIG> depicts one implementation of a microwave system <NUM> operable to heat a plurality of articles according to the process outlined in <FIG>. As used herein, the term "microwave energy" generally refers to electromagnetic energy having a frequency between <NUM> and <NUM>.

As shown in <FIG>, one or more articles can initially be introduced into a thermalization section <NUM>, wherein the articles can be thermalized to a substantially uniform temperature. Once thermalized, the articles can then be optionally passed through a pressure adjustment section 114a before being introduced into a microwave heating section <NUM>. In microwave heating section <NUM>, the articles can be rapidly heated using microwave energy discharged into at least a portion of the heating section by one or more microwave launchers, generally illustrated as launchers <NUM> in <FIG>. The heated articles can then optionally be passed through an optional holding section <NUM>, wherein the articles can be maintained at a constant temperature for a specified amount of time. Subsequently, the articles can then be passed to a quench section <NUM>, wherein the temperature of the articles can be quickly reduced to a suitable handling temperature. Thereafter, the cooled articles can optionally be passed through a second pressure adjustment section 114b before being removed from system <NUM> and further utilized.

According to one implementation of the present disclosure, each of the above-described thermalization, microwave heating, holding, and/or quench sections <NUM>, <NUM>, <NUM>, and <NUM> can be defined within a single vessel, as generally depicted in <FIG>, while, in another implementation, at least one of the above-described stages can be defined within one or more separate vessels. According to one implementation, at least one of the above-described steps can be carried out in a vessel that is at least partially filled with a liquid medium in which the articles being processed can be at least partially submerged. As used herein, the term "filled" denotes a configuration where at least <NUM> percent of the specified volume is filled with the liquid medium. In certain implementations of the present disclosure, "filled" volumes can be at least about <NUM> percent, at least about <NUM> percent, at least about <NUM> percent, or <NUM> percent full of the liquid medium.

When used, the liquid medium used may include any suitable type of liquid. The liquid medium may have a dielectric constant greater than the dielectric constant of air and, in one implementation, can have a dielectric constant similar to the dielectric constant of the articles being processed. Water (or liquid media comprising water) may be particularly suitable for systems used to heat edible and/or medical devices or articles. In one implementation, additives, such as, for example, oils, alcohols, glycols, and salts may optionally be added to the liquid medium to alter or enhance its physical properties (e.g., boiling point) during processing, if needed.

Microwave system <NUM> can include at least one conveyance system (not shown in <FIG>) for transporting the articles through one or more of the processing sections described above. Examples of suitable conveyance systems can include, but are not limited to, plastic or rubber belt conveyors, chain conveyors, roller conveyors, flexible or multi-flexing conveyors, wire mesh conveyors, bucket conveyors, pneumatic conveyors, screw conveyors, trough or vibrating conveyors, and combinations thereof. The conveyance system can include any number of individual convey lines and can be arranged in any suitable manner within the process vessels. The conveyance system utilized by microwave system <NUM> can be configured in a generally fixed position within the vessel or at least a portion of the system can be adjustable in a lateral or vertical direction.

In some cases, the articles may be transported along the convey line loaded into one or more carriers configured to secure the articles as they pass through one or more of the processing sections of the microwave heating system. A description of carriers that might be used with systems and methods of the present disclosure is provided in <CIT>.

The articles processed by the microwave heating system <NUM> may include packages of any suitable size and/or shape and may contain any food or beverage, any medical, dental, pharmaceutical, or veterinary fluid, or any instrument capable of being processed in a microwave heating system. Examples of suitable articles can include, but are not limited to, packaged foodstuffs such as, for example, fruits, vegetables, meats, pastas, pre-made meals, soups, stews, jams, and even beverages. The specific type of packaging is not limiting, but at least a portion of it must be at least partially microwave transparent in order to facilitate heating of the contents using microwave energy.

The articles can include individual packages each having, for example, a generally rectangular or prism-like shape. In some cases, the articles can have a top and a bottom and the top and bottom of each article can have different widths. For example, in some cases, the top can be wider than the bottom and top edge of each article may be longer and wider than the bottom edge. In other cases, the top may be narrower than the bottom when, for example, the article includes a flexible pouch. Specific types of articles can include, but are not limited to, flexible and semi-flexible pouches with or without spouts, cups, bottles, and other rigid or semirigid containers having circular, elliptical, or other cross-sectional shapes with or without lidding, including flexible lidding. The articles may be constructed of any material, including plastics, cellulosics, and other microwave-transparent materials.

As shown in <FIG>, the articles introduced into microwave system <NUM> are initially introduced into thermalization section <NUM>, wherein the articles are thermalized to achieve a substantially uniform temperature. For example and without limitation, in at least certain implementations of the present disclosure at least about <NUM> percent, at least about <NUM> percent, at least about <NUM> percent, at least about <NUM> percent, or at least about <NUM> percent of all the articles withdrawn from the thermalization section <NUM> have a temperature within about <NUM>, within about <NUM>, or within <NUM> of one another. As used herein, the terms "thermalize" and "preheat" generally refer to a step of temperature equilibration or equalization. Depending on the initial and desired temperature of the articles being thermalized, the temperature control system of thermalization section <NUM>, illustrated in <FIG> as heat exchanger <NUM>, can be a heating and/or cooling system.

When the thermalization section <NUM> is at least partially filled with a liquid medium, the articles can be at least partially submerged in the liquid during the passing. The liquid medium in the thermalization zone <NUM> can be warmer or cooler than the temperature of the articles passing therethrough. In some implementations and without limitation the liquid medium may have an average bulk temperature of at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>.

The thermalization step can be carried out under ambient pressure or it may be carried out in a pressurized vessel. For example and without limitation, when pressurized, thermalization may be performed at a pressure of at least about <NUM> psig, at least about <NUM> psig, at least about <NUM> psig, or at least about <NUM> psig and/or not more than about <NUM> psig, not more than about <NUM> psig, not more than about <NUM> psig, or not more than about <NUM> psig. When the thermalization zone <NUM> is liquid-filled and pressurized, the pressure may be in addition to any head pressure exerted by the liquid. Articles undergoing thermalization can have an average residence time in the thermalization zone <NUM> of various durations. For example and without limitation, in certain implementations, the residence time may be at least about <NUM> minute, at least about <NUM> minutes, at least about <NUM> minutes and/or not more than about <NUM> minutes, not more than about <NUM> minutes, or not more than about <NUM> minutes. The articles withdrawn from the thermalization zone <NUM> can have differing average temperatures. For example and without limitation, in certain implementations the articles may have an average temperature of at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>.

In one implementation wherein thermalization zone <NUM> and microwave heating zone <NUM> are operated at substantially different pressures, the articles removed from thermalization zone <NUM> can first be passed through a pressure adjustment zone 114a before entering microwave heating zone <NUM>, as generally depicted in <FIG>. Pressure adjustment zone 114a can be any zone or system configured to transition the articles being heated between an area of lower pressure and an area of higher pressure. In one implementation, pressure adjustment zone 114a can be configured to transition the articles between two zones having a pressure difference of at least about <NUM> psi, at least about <NUM> psi, at least about <NUM> psi, at least about <NUM> psi and/or not more than about <NUM> psi, not more than about <NUM> psi, not more than about <NUM> psi, or not more than about <NUM> psi. When the cooling/quench zone <NUM> shown in <FIG> is operated at a different pressure than the microwave heating zone <NUM>, another pressure adjustment section may be present to transition the articles between the microwave heating zone or hold zone <NUM> and cooling/quench zone <NUM>. In some cases, the first pressure adjustment zone 114a can transition the articles from a lower-pressure thermalization zone <NUM> to a higher-pressure microwave heating zone <NUM>, while the second pressure adjustment section 114b may transition the articles from a higher-pressure holding zone <NUM> to a lower-pressure cooling zone <NUM> or from the lower-pressure cooling zone <NUM> to ambient conditions. Other configurations of pressurization sections are also possible.

Referring again to <FIG>, the articles exiting thermalization section <NUM>, and optionally passed through pressure adjustment section 114a, as described above, can then be introduced into microwave heating section <NUM>. In microwave heating section <NUM>, the articles can be rapidly heated with a heating source that uses microwave energy. In one implementation, various configurations of the microwave heating section <NUM> can utilize microwave energy having a frequency of about <NUM> or a frequency of about <NUM>, both of which have been generally designated as industrial microwave frequencies. In addition to microwave energy, the microwave heating section <NUM> may optionally utilize one or more other heat sources such as, for example, conductive or convective heating or other conventional heating methods or devices. However, in at least some implementations of the present disclosure at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM> percent of the energy used to heat the articles in the microwave heating section be microwave energy.

As illustrated in <FIG>, operation of the various section so the microwave heating system <NUM> is controlled and facilitated by a control system <NUM>. The control system <NUM> generally includes one or more computing devices adapted to communicate with components of one or more of the sections of the microwave heating system <NUM>. Such communication may include receiving signals and data from sensors, switches, or other components of the microwave heating system <NUM> and/or transmitting signals, such as control signals, and data to components of the microwave heating system <NUM> such as, without limitation, actuators, heating elements, drives, lights, alarms, screens, and the like. The control system <NUM> may be configured to receive input from a user and to control operation of the microwave heating system <NUM>, at least in part, in response to such input. Similarly, the control system <NUM> may be configured to at least partially control operation of the microwave automatically.

Turning now to <FIG>, one implementation of a microwave heating section <NUM> is illustrated as generally comprising a microwave heating chamber <NUM>, at least one microwave generator <NUM> for generating microwave energy and a microwave distribution system <NUM> for directing at least a portion of the microwave energy from generator <NUM> to microwave chamber <NUM>. Microwave distribution system <NUM> comprises a plurality of waveguide segments <NUM> and one or more microwave launchers, shown as launchers 222a-f in <FIG>, for discharging microwave energy into the interior of microwave chamber <NUM>. As shown in <FIG>, microwave heating section <NUM> can further comprise a conveyance system <NUM> for transporting carriers <NUM> loaded with articles to be heated through microwave chamber <NUM>. Each of the components of microwave heating section <NUM>, according to various implementations of the present disclosure, is now discussed in detail.

As they move along the conveyance system <NUM> in the microwave heating section <NUM>, the articles may be heated so that the coldest portion of each article achieves a minimum target temperature. When the microwave heating section <NUM> is a sterilization or pasteurization system, the target temperature can be a sterilization or pasteurization target temperature. For example and without limitation, the target temperature may be at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>.

When the microwave heating chamber <NUM> is liquid-filled, the average bulk temperature of the liquid in the microwave heating chamber <NUM> may vary and, in some cases, can depend on the amount of microwave energy discharged into the microwave heating chamber <NUM>. The average bulk temperature of the liquid in the microwave heating chamber <NUM> can be at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM> and/or not more than about <NUM>°, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>.

As the articles pass through the microwave heating chamber <NUM>, they may be heated to the target temperature in a relatively short period of time, which can help minimize any damage or degradation of the articles caused by prolonged exposure to high temperatures. For example, the average residence time of each article passing through the microwave heating section <NUM> can be, in certain implementations and without limitation, at least about <NUM> seconds, at least about <NUM> seconds, at least about <NUM> seconds and/or not more than about <NUM> minutes, not more than about <NUM> minutes, not more than about <NUM> minutes, not more than about <NUM> minutes, not more than about <NUM> minutes, or not more than about <NUM> minute. The increase in minimum temperature of the articles heated in the microwave heating section <NUM> may also vary. For example, in certain implementations, the minimum temperature of the articles can increase by at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>.

The microwave heating chamber <NUM> can be operated at approximately ambient pressure. Alternatively, it may be a pressurized microwave chamber that operates at various pressures including, without limitation, at least about <NUM> psig, at least about <NUM> psig, at least about <NUM> psig, or at least about <NUM> psig and/or not more than about <NUM> psig, not more than about <NUM> psig, not more than about <NUM> psig, or not more than about <NUM> psig above ambient pressure. As used herein, the term "ambient" pressure refers to the pressure exerted by the fluid in the microwave heating chamber <NUM> without the influence of external pressurization devices.

In some cases, the articles passing through the microwave heating section <NUM> may be exposed to microwave energy intermittently, with alternating periods of exposure to microwave energy followed by "dwell" period during which no microwave energy is discharged toward the articles, but during which the articles may thermalize. In some cases, the articles may be moving between adjacent microwave launchers or sets of launchers during at least a portion of the dwell period, while, in other cases, the articles may remain stationary during the dwell period. As the articles move through the microwave heating chamber <NUM>, the articles may move in single direction between the entrance and exit of the microwave heating chamber <NUM>. Alternatively, the carrier or groups of articles may be moved in a "back-and-forth" pattern along the convey line, as described in detail in <CIT> and <CIT>.

As shown in <FIG>, upon exiting the microwave heating section <NUM>, the articles may be passed to a holding section <NUM>, wherein the temperature of the articles can be maintained at or above a certain minimum target temperature for a predetermined period of time. For example and without limitation, in the holding section <NUM>, the temperature of the coldest part of the article can be held at a temperature at or above a predetermined minimum temperature of at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM>, at least about <NUM>, at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>, for a period of time (or "holding period") of at least about <NUM> minute, at least about <NUM> minutes, or at least about <NUM> minutes and/or not more than about <NUM> minutes, not more than about <NUM> minutes, or not more than about <NUM> minutes.

Once the heated articles exit the holding section <NUM>, the articles may then be introduced into a cooling or quench section <NUM>, wherein the articles are rapidly cooled via submersion in a cooled fluid. The quench section <NUM> may reduce the external surface temperature of the articles by various amounts. For example, in certain implementations the extemal surface temperature may be reduced by at least about <NUM>, at least about <NUM>, at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, or not more than about <NUM> in a time period of at least about <NUM> minute, at least about <NUM> minutes, at least about <NUM> minutes and/or not more than about <NUM> minutes, not more than about <NUM> minutes, or not more than about <NUM> minutes. Any suitable fluid may be used in the quench section <NUM> and the fluid may include a liquid similar to, or different than, the liquid used in the microwave heating section <NUM> and/or the holding section <NUM>. When removed from the quench section <NUM>, the temperature of the cooled articles may vary. For example and without limitation, in certain implementations the cooled articles can have a temperature of at least about <NUM>, at least about <NUM>, at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>. Once removed from the quench section <NUM>, the cooled, treated articles can then be removed from the microwave heating system <NUM> for subsequent storage and/or use.

The present disclosure provides microwave heating systems and methods for operating microwave heating systems using an operating profile. In some cases, a microwave heating system may be selectively operated according to a single operating profile, while, in other cases, it may be operated according to two or more different operating profiles. When a system is operated by two or more different operating profiles, each profile can be specifically designed for heating a different type of article or to heat the same type of article differently. Each operating profile may be designed to process a certain type of article and, so, may include certain specifications for the type of article to be heated according to that profile.

In some cases, an operating profile may be selected to heat a certain type of article. Thus, each profile may be created based on certain specifications for one or more article parameters. Examples of the article parameters specified by an operating profile can include, but are not limited to, food type and properties (e.g., pH, weight, sugar content, thickness, density, dielectric constant, moisture content, and others), package type and properties (e.g., shape, thickness, size, microwave transparency, thermal conductivity, barrier properties, and others), as well as the arrangement of the food or beverage within the package (e.g., percent filled, head space, and others). In some cases, an operating profile may specify target values for one or more of the above article parameters in order to delineate the types of articles that can be processed according to that profile. Alternatively, an operating profile may not specify any article parameters, or may simply provide values or ranges of values for the target parameter as a guideline.

<FIG> is an illustration of an operating profile schema <NUM> in accordance with the present disclosure. As described below in further detail, the operating profile schema <NUM> includes a collection of operating profiles 302a-n, each of which generally store information related to the operation and control of microwave heating systems, such as the microwave heating system <NUM> of <FIG>. The following description refers to and discusses the operating profile 302a and its components in further detail; however, it should be appreciated that, unless otherwise the following description similarly applies to the other operating profiles 302b-n.

In general, each operating profile 302a-n includes one or more groups of operational set points that are used to control various aspects of the microwave heating system during processing of articles. Each group of set points is further associated with a temperature-time profile that generally describes the thermal behavior of an article over time when that particular group of set points is applied. Each temperature-time profile may in turn be associated with a particular level of pasteurization or sterilization. Accordingly, an operational profile may include one or more sterilization or pasteurization levels, each of which results from one or more temperature-time profile. Each of the temperature-time profiles may in tum be achieved using one or more groups of associated operational set points.

As shown in <FIG>, the operating profile 302a can include at least one target F<NUM> value <NUM> specifying a desired level of pasteurization or sterilization for the articles being heated. In general, an F<NUM> value (which is also commonly referred to as a "sterilization value") is a cumulative representation of all thermal treatments encountered by an article during processing and can represent the minimum level of microbial lethality achieved by an article during heating. Higher values for F<NUM> indicate higher microbial lethality levels, which correspond to higher levels of pasteurization or sterilization. The reference microbe used to measure lethality levels generally depends on whether the article is being pasteurized or sterilized, with Clostridium botulinum typically being used to characterize the microbial lethality of a sterilization process. The reference microbe used for pasteurization varies with the specific type of article being pasteurized, but can include, for example, Salmonella or Escherichia coli.

In some cases, such as that illustrated in <FIG>, an operating profile may include a single target F<NUM> value <NUM>. Alternatively, an operating profile may include at least two, at least three, at least four, or five or more different target F<NUM> values. Each target F<NUM> value may be a single point value, or it may be a range of values. In some cases, the operating profile may not include any express values or ranges for a target F<NUM> value, but the temperature-time profiles and groups of set point values within the profile (each of which are discussed below in further detail) may be pre-selected in order to achieve an absolute minimum F<NUM> value, even though the profile may not list a specific target F<NUM> value. Typically, a target F<NUM> value of around <NUM> or <NUM> is considered to be an absolute minimum, with values around <NUM> or <NUM> being a more practical minimum. In some cases, the operating profile can include at least one target F<NUM> with a value of at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM> and/or not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, not more than about <NUM>, or not more than about <NUM>. Again, the reference microbe may be one or more of the above, or it may be a different microbe, depending on the type of article being heated and whether the article is being pasteurized or sterilized.

The operating profile 302a may also include at least one temperature-time profile 306a-<NUM>, shown generally in <FIG> as "T-t PROFILE <NUM>" to "T-t PROFILE M". The temperature-time profile (which can also be called the heating rate curve) is generally describes the temperature of an article throughout the heating process. In one implementation, the temperature-time profile may correspond to temperature measurements obtained from the coldest portion of the article or where the heating rate is slowest in order to ensure that the entire article achieves the desired degree of pasteurization or sterilization. Alternatively, or in addition, the temperature-time profile may be correspond to temperature measurements at another portion of the article, such as, for example, the hottest or quickest heating point or the point that achieves an average temperature or exhibits an average heating rate. In still other cases, the temperature-time profile may be based on temperature measurements at the geometric center of the article. In certain implementations, a first temperature-time profile may corresponds to measurements at the coldest (or slowest heating) portion of the article such that the treated article is ensured to meet a minimum level of pasteurization or sterilization, while a second temperature-time profile may corresponds to measurements at the hottest (or quickest heating) portion of the article may help ensure product quality by, for example, minimizing overcooking of the article.

Each temperature-time profile in an operating profile achieves an F<NUM> value. Accordingly, even if the operating profile does not include a specific target F<NUM> value (such as the F<NUM> value <NUM> of <FIG>), the temperature-time profile will achieve an F<NUM> value and may, for example, be selected to achieve some desirable minimum, such as, for example, an F<NUM> of at least <NUM> or <NUM>. An operating profile may include a single temperature-time profile or it may include at least about <NUM>, at least about <NUM>, or at least about <NUM> different temperature-time profiles, each selected to achieve a target F<NUM> value. When the operating profile includes two or more different temperature-time profiles, each profile may achieve the same, or a different, target F<NUM> value than one or more of the other temperature-time profiles in the same operating profile. For example, in <FIG>, each of the T-t profiles 304a-<NUM> is illustrated as corresponding to the F<NUM> value <NUM>. In other words, heating an article according to any of the temperature-time profiles 306a-<NUM> will generally result in achieving the F<NUM> value <NUM>. However, in other implementations, the temperature-time profile 306a may result in the F<NUM> value <NUM> while the temperature-time profile 306b may result in a second F<NUM> value different than the F<NUM> value <NUM>.

The F<NUM> value of the article during the heating process may then be calculated by integrating the area under the temperature-time curve above a minimum temperature. For example, if an article is being pasteurized, the minimum temperature may be at least about <NUM>, and the F<NUM> value can be calculated by integrating the area under the temperature-time curve where the article had a temperature of <NUM> (or other minimum) or above. For sterilization, this minimum temperature may be around <NUM> or so. Thus, each temperature-time profile provided in an operating profile is selected to achieve a certain target F<NUM> value, whether or not the target F<NUM> value is expressly specified in the operating profile.

In certain implementations, one or more of the temperature-time profiles may obtained by monitoring temperature of an article during a heating process. For example, one or more articles of a certain type may be equipped with one or more temperature sensors (e.g., thermocouples) and subjected to a heating process according to a first group of operational set points. The temperature-time profile may then be generated based on the temperature data obtained from the thermocouples and associated time data corresponding to when the temperature data was obtained. The resulting curve may then be used to calculate a corresponding F<NUM> value as described above. The foregoing process may be repeated for multiple articles of the same type using different groups of operational set points to generate multiple temperature-time profiles, each of which resulting in a particular F<NUM> value. The groups of set point values may then be organized based on the relative similarity of the temperature-time profiles and F<NUM> values into a tree or similar linked structure, such as illustrated in <FIG>.

It should be appreciated that the temperature and time data of the temperature-time profiles 306a-<NUM> illustrated in <FIG> may be specific or may correspond to a range of values. For example, a given temperature-time profile may include a minimum temperature for a period of time of the heating process, a maximum temperatures for a period of time of the heating process, a specific target temperature at a specific time in the heating process, or any variation thereof. Accordingly, while groups of operational set points may result in different thermal behavior for an article, the thermal behavior for groups of set points may nevertheless be sufficiently similar or otherwise meet common thresholds such that the resulting time-temperature profiles for the groups of set points are considered the same for purposes of generating an operating profile.

The operating profiles as described herein also include at least one group of set points. For example, the operating profile 302a of <FIG> includes set point groups A-D 308a-d, with set point groups A and B achieving T-t profile <NUM>306a and set point groups C and D achieving T-t profile <NUM>306b. Each group of set points includes one or more target values for at least one microwave system parameter. These target values may be used to control the operation of the microwave heating system so that the temperature of the articles passed through the heating system approximates the temperature-time profile to achieve the target F<NUM> value.

Each operating profile includes at least <NUM>, and may include at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM> different groups of set point values. Although not necessarily limited on the upper end, an operating profile may include less than <NUM>, less than <NUM>, less than <NUM>, less than <NUM>, or less than <NUM> groups of set point values. In cases where an operating profile includes two or more temperature-time profiles, at least one group of set point values can be selected to achieve the same temperature-time profile. In some cases, two or more different groups of set point values may be selected to achieve the same temperature-time profile. Alternatively, or in addition, two different groups of set point values may be selected to achieve different temperature-time profiles.

For example, an operating profile can include a single temperature-time profile and two or more groups of set point values selected to achieve that temperature-time profile. In another example, an operating profile could include two temperature-time profiles and at least one group of set point values selected to achieve each temperature-time profile. When an operating profile includes at least two-temperature time profiles, each profile may have at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM> and/or not more than <NUM>, not more than <NUM>, not more than <NUM>, not more than <NUM>, not more than <NUM>, or not more than <NUM> different groups of set point values for achieving that profile. Each temperature-time profile may have the same, or a different, number of groups of set point values than one or more other temperature-time profiles in the same, or a different, operating profile.

Each group of set point values may include at least one target value for each of one or more different microwave system parameters. As illustrated in <FIG>, for example, set point group A 308a includes, among other things, set points/target values for microwave (MW) net power, water temperature, and convey speed. When the operating profile includes two or more groups of set point values, each group may have a target value for a microwave system parameter that is different than, or the same as, the target value for the same parameter in one or more of the other groups. In some cases, each group of set point values may include target values for the same microwave system parameters, or one or more groups may include target values for different microwave system parameters.

Examples of suitable microwave system parameters can include, but are not limited to, total net microwave power discharged, liquid temperature in the microwave heating chamber, liquid flow rate in the microwave heating chamber, convey line speed through the microwave heating chamber, net microwave power discharged (per launcher or pair of launchers), dwell time, liquid temperature in the preheating section, liquid flow rate in the preheating section, convey line speed in the preheating section, liquid temperature in the holding section, liquid flow rate in the holding section, convey line speed in the holding section, liquid temperature in the cooling section, liquid flow rate in the cooling section, convey line speed in the cooling section, overall convey line speed, and overall production rate. Example values (provided as broad, intermediate, and narrow ranges) for each of these parameters are summarized in Tables <NUM> (pasteurization) and <NUM> (sterilization), below. Values within one or more of the other ranges described herein may also be suitable.

The specific form of each target value provided in a group of set point values can vary. For example, in some cases, the target value may be a single targeted value with or without an allowable deviation. This deviation can be, for example, a permissible variation from the target value expressed as a percentage of the target value and/or as an absolute difference. For example, a group of set point values may include a target value of <NUM> for the temperature of the liquid in the microwave heating chamber and may specify a permissible deviation of ± <NUM> or ± <NUM>% of the set point value. When the permissible deviation is specified as a percentage of the set point value, it may be t at least about <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or <NUM>% of the set point value. Specific deviations expressed as an absolute difference depend on the specific parameter itself. For example and without limitation, deviations for temperature-related values (e.g., liquid temperatures in any of the sections) may have a permissible deviation of t at least about <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Deviations for speed-related values (e.g., convey speed) may have a permissible deviation of t at least about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> in/s. Deviations for power-related values (e.g., total net power discharged or net power discharged per launcher) may have a permissible deviation of t at least about <NUM>, <NUM>, <NUM>, or <NUM> kW.

In other cases, the target value specified in a group of operating set points may be a range of values for a given parameter. Such ranges may or may not include an allowable deviation as described previously. In some cases, a range of values provided as the target value may encompass a desirable set point value and its permissible deviations. For example, a target value of <NUM> ± <NUM> (or ± <NUM>%) for the liquid temperature in the microwave heating chamber may be expressed in a group of operating set points as a target value for liquid temperature in the microwave heating chamber of <NUM> to <NUM>.

Alternatively, or in addition, one or more groups of set point values in an operating profile may include a predetermined maximum value and/or a predetermined minimum value as a target value for one or more microwave system parameters. These maximum and minimum values may represent the highest and lowest values, respectively, for a given parameter that are permissible in order to maintain the final quality of the foodstuff and/or its requisite level of pasteurization or sterilization.

Minimum and maximum values related to the target level of pasteurization or sterilization may include, for example, minimum total net microwave power discharged, minimum liquid temperature in the microwave heating chamber, maximum convey line speed through the microwave heating chamber, minimum net microwave power discharged (per launcher or pair of launchers), minimum liquid temperature in the preheating section, maximum convey line speed in the preheating section, minimum liquid temperature in the holding section, maximum convey line speed in the holding section, and maximum overall convey line speed. In some cases, exceeding these maximums or operating below these minimums may result in articles that fail to achieve the desired level of pasteurization or sterilization. Minimum and maximum values related to the overall quality of the final product may include, for example, maximum total net microwave power discharged, minimum convey line speed through the microwave heating chamber, maximum net microwave power discharged (per launcher or pair of launchers), maximum convey line speed in the holding section, and minimum overall convey line speed. Exemplary minimum and maximum target values for several of these parameters are summarized in Tables <NUM> and <NUM>.

Each group of set point values in an operating profile may include a single target value for each microwave system parameter, or it may include two or more target values. When the group of set points includes two or more target values, one or more of the values may be listed as being more important than one or more of the others. Typically, a single group of set point values may not include more than three different target values for a single parameter. For example, a group of set point values may include a single targeted value (e.g., a total net power discharged of <NUM> kW) with or without an allowable deviation (e.g., ± <NUM> kW), along with a predetermined maximum (e.g., <NUM> kW) and a predetermined minimum (e.g., <NUM> kW). These are intended to be illustrative values and are not necessarily limiting.

In some cases, the target values provided in the operating profile may be "point," or static values, while, in other case, one or more of the target values may change with time. When the target value or values change with time, the change may be step-wise, such that the value of the target value changes at a given time or times during the process and then remains generally constant until the next change, or it may be continuous, so that the target value follows a line or smooth curve as a function of process time.

The microwave system parameters listed previously are those which tend to be directly controlled during the operation of the microwave heating system. In some cases, the operating profile may also include target values, or ranges of target values, for one or more other microwave system parameters that may not be as easily controllable or measurable, but that may still be part of achieving the desired level of pasteurization or sterilization. Examples of such "indirect" parameters can include, but are not limited to, minimum article temperature, maximum temperature difference between hot and cold spots in a single article, maximum temperature difference between hot and cold spots amongst articles in a single carrier, article residence time in the heating zone, and combinations thereof. Tables <NUM> (pasteurization) and <NUM> (sterilization), below, provides broad, intermediate, and narrow ranges of possible values for each of the additional parameters listed above.

Although the parameters in Tables <NUM> and <NUM>, above may not necessarily be directly used as inputs to the control system of the microwave heating system, one or more groups of set point values in an operating profile may include desirable ranges for one or more of these indirect parameters as well.

Overall, the groups of set point values are selected to achieve a desired temperature-time profile that, when followed, will achieve a target F<NUM> for the articles being heated. In some cases when all or a portion of the operating profile has been approved by a governmental regulatory agency, articles produced according to the operating profile may be in compliance with applicable food safety standards, although the specific procedure and approvals may vary by country or region.

Turning now to <FIG>, below, the main steps of a method <NUM> for pasteurizing or sterilizing articles using a microwave heating system according to implementations of the present disclosure is provided.

As shown in <FIG>, the process begins with the step of obtaining an operating profile (operation <NUM>). The operating profile can be in any suitable form, including an electronic form such as, for example, a spreadsheet or database. It may be saved locally on a computer or memory device, or saved in a central location accessible by one or more remote users. In other cases, the operating profile may be in printed form, such as in a table or other similar format. A single operating profile may be in both electronic and printed forms.

In some cases, the operating profile may be obtained by gathering empirical data from one or more process runs where the same (or similar) articles are pasteurized or sterilized using the same, or a different, microwave heating system. During these runs, values for various microwave system parameters may be measured or calculated, and the resulting data may be correlated to create the operating profile. Each profile may be composed of data from at least one, at least two, at least three, at least four, or five or more process runs operated under the same or different conditions. In some cases, these preliminary runs may be conducted by the same person or party using the operating profile, while, in other cases, another person or party may perform these preliminary runs in order to create an operating profile for use by another person or party. When two or more parties are involved, the parties may be part of the same organization (e.g., R&D department and operations department) or the parties may be part of different organizations.

As shown in <FIG>, once obtained, all or part of the information in the operating profile may be provided to a computing device (operation <NUM>). Typically, the computing device is a control system or is associated with a control system of the microwave heating system. In some cases, the computing device may be directly connected to the control system, such as, for example, a process logic controller (PLC), while, in other cases, the computing device may be an auxiliary computer into which data is entered and which outputs at least a portion of the data for use by the PLC or other controller. In some cases when an auxiliary computer is used, the output data may be directly transmitted to the control system, or it may be provided in printed or electronic format for input into the PLC by an operator.

When the operating profile includes two or more groups of set point values (and, optionally, two or more temperature-time profiles), providing the operating profile may also include selecting an initial group of set point values on which to operate the system. This initial group of set point values may have already been entered into the computer and are accessible by the user. This selection may be done manually during or after the entry of the operating profile into the computer or it may be done automatically by the computer or PLC. In some cases, the step of providing the operating profile to the computing device may include providing multiple operating profiles into the computing device at one time and the selection of the initial group of set point values may be chosen from amongst groups of set point values in different operating profiles at a later time after the profiles have been entered.

As shown in <FIG>, above, once a group of set point values has been selected, the microwave heating system can then be operated based on these values (operation <NUM>). For example, the values of the operating profile which may be used by the control system as control set points for each of the applicable microwave system parameters. For example, if a selected group of set point values includes target values for net microwave power discharged, convey line speed through the microwave heating chamber, and liquid temperature in the preheating section, these values may be used by the control system as set point values for each of these parameters. Operation of the microwave heating system may be done directly by the computing device into which the operating profile was entered and the group of set point values selected, indirectly, such as, for example, by an operator, or any combination thereof.

Once entered, the operation of the microwave heating system is controlled using the control set points. Turning now to <FIG>, a method <NUM> of operating a microwave heating system using an operating profile is provided.

As shown in <FIG>, once the control set points have been entered, the actual value for the microwave system parameters for which a control set point has been set are measured while the system is operating (operation <NUM>). For example, if the selected group of set point values included a target value for liquid temperature in the microwave heating chamber and the target value for set as the control set point, operation <NUM> would include measuring the actual value of the temperature of the liquid in the microwave heating chamber while the system is operating (e.g., while articles are being processed). Measurement of the actual values may include direct measurement and/or a calculation performed on a direct measurement to provide the measured value.

The measured value for each parameter is then compared with the control set point for that parameter to determine a difference (D1) (operation <NUM>). This comparison may be done by the control system, but could be performed manually by an operator. Such a comparison can be a point comparison determined at a set interval, such as, for example, every <NUM> seconds, <NUM> seconds, <NUM> minute, <NUM> minutes, or <NUM> minutes. Or the comparison can done in "real-time" by continuously comparing the actual value and the control set point for a given parameter. A combination of these types of comparison could also be used.

The measured difference (D1) may then be compared with a predetermined allowable difference (PAD) to determine whether the measured difference is greater than or less than the PAD (operation <NUM>). In some cases, the PAD may be calculated by finding the difference between an absolute maximum value which may not be exceeded and the control set point. In other cases, the PAD may be calculated by finding the difference between the control set point and an absolute minimum value below which the actual value for the microwave system parameter may not fall. In other cases, the PAD may be calculated from a maximum allowable deviation from the set point, which may be expressed as an absolute deviation (e.g., ± <NUM>) or as a percentage of the set point (e.g., ± <NUM>% of the set point). The PAD can include an absolute value (e.g., ± <NUM> kW) or it may be positive or negative, indicating values higher or lower than the control set point (e.g., - <NUM> in/s or + <NUM>).

As long as the difference (D1) between the measured value and the control set point value (D1) for the microwave system parameter are less than the PAD, the system continues to operate according to the selected group of set point values (i.e., the system returns to operation <NUM>). In some cases, the difference between D1 and the PAD may result in various adjustments to the system itself (e.g., opening a valve, adding more cooling water, adjusting generator output, or starting, changing the speed of, or stopping a convey line). Such adjustments are in line with typical control system operation, but do not result in changing the control set points and no action is taken with respect to the articles except continuing to process the articles according to the originally-selected control set points.

If, however, during operation of the microwave heating system, the difference (D1) determined by comparing the measured value of a microwave system parameter with its control set point value (D1) exceeds the predetermined allowable difference (PAD), then corrective or other action may be taken with respect to the microwave heating system and/or the articles undergoing processing. In the past, these types of deviations typically meant that the articles that had been exposed to the undesirable operating conditions had to be disposed of, which not resulted in the articles being wasted, but also increased the cost of operating and lost time due to the shutting down and restarting of the system.

However, methods of the present disclosure in which an operating profile is used to control the microwave heating system may permit these process deviations to be "cleared," by adjusting the control set points of the system so that the "out-of-range" value falls within a new, acceptable range and the articles are able to achieve a desirable level of pasteurization or sterilization.

Referring again to <FIG>, when D1 exceeds the PAD, the deviation can be "cleared," by next comparing the measured value for the microwave system parameter with other target values for the same microwave system parameter provided in other groups of set point values within the operating profile (operation <NUM>). For example, if the difference between the actual measured value and the set point value for the liquid temperature in the microwave heating chamber in a first group of set point values exceeded the PAD, then the actual measured value for the liquid temperature in the microwave heating chamber could then be compared to other set point values for this parameter in one or more other groups of set point values within the operating profile. Each comparison between the measured value and other target values in other groups of set point values results in a second difference (D2).

Each second difference (D2) is then compared with the PAD to determine if any of the new differences (D2) are lower than the PAD (operation <NUM>). Where this comparison step includes comparing the measured value of the parameter with the target value for that parameter in two or more different groups of set point values, there will be two or more second differences (D2) determined. Each of the new differences then are compared with the PAD to determine if any of the new differences (D2) are lower than the PAD.

When at least one of the new differences (D2) is lower than the PAD, the new group of set point values may be selected for use as a new set of control points for operating the system (operation <NUM>). When two or more of the new differences (D2) are less than the PAD, one of the two groups of set point values including these target values may be chosen for use as the new control set points. In some cases, the group of set point values including the target value with the smallest difference from the measured value for the microwave system parameter (e.g., smallest D2) may be selected. In some cases, the group of set point values with a larger difference D2 may be chosen because, for example, it offers some additional advantage, such as increased production rate, shortened production time, or energy savings. In some cases, the control system may require the operator to choose which groups of set point values are used, while, in other cases, no choice may be given and the control system may automatically select one of the new groups of set point values.

The target value for the microwave system parameter in the new group of set point values will be closer to the measured value for the microwave system parameter, which was "out-of-range" with the previous target value. This effectively brings the deviation "into range," by changing the group of set point values used to operate the system. The measured value for the microwave system parameter is no longer out-of-range in the newly-selected group of set points. Once selected, the new group of set point values are optionally entered into or otherwise provided to the computer or control system (if not done already) and these set point values are then selected as the new control set points (operation <NUM>). The microwave heating system can adjust to its new operating parameters, and the system can now be controlled according to the new group of control set points. The steps of measuring and adjusting as described above continue with the new control set points as the system continues to operate.

As an example, if a microwave heating system was operating with an operating profile using a group of set point values that included a target value for the liquid in the microwave heating chamber of <NUM>, and the actual temperature of the liquid in the microwave heating chamber dropped to <NUM> during some point of the processing run, the difference between the set point value and the measured value at that point would be <NUM>. If the operating profile specified a PAD for liquid temperature in the microwave heating chamber of <NUM>, this measured difference (D1) would be "out-of-range" for the initial group of set point values on which the system was operating.

In order to address this deviation, the "out-of-range" value (e.g., <NUM>) for the temperature of the liquid in the microwave heating chamber could be compared with the target values for liquid temperature in the microwave heating chamber in one or more other groups of set point values within the same or a different operating profile. These other groups may be designed to achieve the same, or a different, temperature-time profile, which itself may be selected to achieve the same, or different, target F<NUM> value as the initial group of set point values and initial temperature-time profile. When the out-of-range measured value (e.g., <NUM>) is compared with the target values for the same parameter (e.g., liquid temperature in the microwave heating chamber) in each of the other groups of set point values, a difference (D2) is determined for each. Each of these differences (D2) is then compared with the PAD. If any of these individual differences are less than the PAD, then that group of set point values (including the target value that resulted in the smaller difference) can be selected as the new group of set point values on which to operate the system.

In the above example, the measured value for the temperature of the liquid in the microwave heating chamber of <NUM> can be compared to the target value for the temperature of the liquid in the microwave heating chamber in several other groups of set points. These groups may also have target values for other parameters (e.g., net power discharged, convey speed in the microwave heating chamber, etc.), which can be the same as or different than the target value for these parameters in the original group. For example, one group of set point values, referred to as Group B, may have a target value for the temperature of the liquid in the microwave heating chamber of <NUM>, and another group, Group C, may have a target value for the same parameter of, for example, <NUM>. Thus, the difference (D2) between the measured value of <NUM> and the target value in Group B is <NUM> and the difference (D2) between the measured value of <NUM> and the target value in Group C is <NUM>.

If, in this example, the predetermined allowable difference is <NUM>, Group C would be selected as the new group of set point values, since the difference between the target value for the temperature of the liquid in the microwave heating chamber and the measured value for this temperature of <NUM> (D2) is less than the predetermined allowable difference of <NUM>. Group B would not be selected as the new group of set point values, since the difference between the target value for the temperature of the liquid in the microwave heating chamber in this group of set point values and the measured value for this temperature of <NUM> (D2) is more than the predetermined allowable difference of <NUM>.

After selecting Group C as the new group of set point values, the set point values in this group would be used by the control system as the new control set points, and the operation of the microwave heating system can be adjusted as needed to meet the set point values. In some cases, this can include changing at least one other set point value for one or more other microwave system parameters, but may or may not require the other control set points to change. For example, when the new set point of <NUM> for the liquid temperature in the microwave heating chamber is entered as a new control set point in the control system, this may result in the control set points for one or more other microwave system parameters to change as well. Or, one or more control set points may stay the same. Then, the microwave heating system can continue its operation as outlined above. If another deviation occurs, the above process may be repeated as necessary.

Referring back to <FIG>, in some cases, none of the new differences (D2) will be lower than the predetermined allowable difference. This means that the deviation cannot be cleared, as the operating profiles does not include any sets of conditions that could bring the "out-of-range" value into an acceptable range so that the articles could still reach the target level of pasteurization or sterilization. As shown in <FIG>, this results in an action being taken with respect to the articles (operation <NUM>). Such actions might include stopping the run, removing and disposing of the articles, rerunning the articles, or combinations thereof.

Turning back to <FIG>, after operating the system according to the operating profile, the pasteurized or sterilized articles may be removed from the microwave heating system (operation <NUM>). Prior to doing so, the articles may optionally be passed through holding and/or cooling sections, as described previously. In some cases, at least a portion of the operating profile may include target values for various parameters associated with these sections, such as, for example, liquid temperatures, convey speeds, etc. The articles removed from the microwave heating system may have achieved the target F<NUM> value and can have an F<NUM> value that is, for example, greater than or equal to the target value. In some cases, the actual F<NUM> value of the pasteurized or sterilized articles may be at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or more percent higher than the target F<NUM> value. The actual F<NUM> value achieved by a group of articles processed in a microwave heating system can be measured by numerically integrating the area under the actual temperature-time curve that the articles were at or above a minimum threshold temperature. As discussed previously, this minimum threshold temperature depends on whether the articles are being pasteurized or sterilized.

Additionally, in some cases, the microwave heating system may also be configured to store measured values for one or more microwave system parameters obtained during the processing of articles in one or more runs. This data may be stored in accordance with applicable regulatory procedures, or it may be used to create a new temperature-time profile, a new operating profile, or a new group of set point values.

Alternatively, or in addition, the measured values of microwave system parameters generated during one or more prior process runs may be used to evaluate data from a more recent process run and determine whether or not the most recent process run met certain criteria such as, for example, a certain temperature-time profile or a specific target F<NUM>. In general, this can be done by comparing the values for one or more microwave system parameters measured during a given process run with an operating profile including one or more groups of set point values that have been selected to achieve a desired temperature-time profile and/or target F<NUM> value. In some cases, this method can be done after a processing run is complete and can include comparing one or more actual values for at least one microwave system parameter with the target values for that parameter in one or more groups of set point values in at least one operating profile. In some cases, multiple groups of set point values in two or more different operating profiles may be used for this comparison. This use of an operating profile for pasteurizing or sterilizing articles in a microwave heating system may be useful for R&D or pilot-plant scale up purposes, but may also have various uses in a commercial-scale facility.

<FIG> is a method <NUM> of using an operating profile after a process run has been completed. As illustrated, a set of measured values for one or more microwave system parameters may be obtained while a group of articles is being heated in a microwave heating system (operation <NUM>). After at least a portion, or all, of the process run has been completed, measured values for the microwave system parameter collected during the run can be compared to one or more target values for the same parameter in one or more groups of set point values in an operating profile (operation <NUM>). In some cases, a measured value may be compared to two or more target values for the same parameter present in two or more different groups of set point values in order to determine several differences. Each comparison of a measured value to each target value results in a difference (D3). The groups of set point values may be selected to achieve the same or a different temperature-time profile and may be present in the same or a different operating profile.

If the difference (D3) between a measured value and each corresponding target value for a given microwave system parameter is less than a predetermined allowable difference (PAD), then the measured value can be said to "pass" (operations <NUM>, <NUM>). Alternatively, if the difference (D3) between the measured value and a target value for a given microwave system parameter is greater than the predetermined allowable difference, then the measured value can be said to "fail" (operation <NUM>). Depending on the measured value for the parameter and the target values in each group of set points, a single measured value can "pass" when compared with one or more groups of set point values and "fail" with one or more other groups.

These pass/fail analyses can be performed for a single microwave system parameter across several groups of set point values to determine several differences, and the step may optionally be repeated with one or more other microwave system parameters for which actual values were measured during the run. In other words, the general process illustrated in operation <NUM>-<NUM> of <FIG> may be repeated for each of a set of microwave system parameters.

Once all comparisons have been made an analysis of the pass/fail results can be used to determine which, if any, of the existing groups of set point values satisfactorily encompasses the measured data from the process run. For example, <FIG> illustrates an example method <NUM> of analyzing pass/fail results for a given process run. As indicated in <FIG>, the method <NUM> begins with obtaining pass/fail data (operation <NUM>). As discussed above in the context of <FIG>, the pass/fail data generally includes a list of system parameters and a corresponding indication of whether measured values obtained during the process run were within a PAD of set points for the system parameters (a "pass") or fell outside the PAD (a "fail"). The pass/fail data may include such information for multiple groups of set points.

At operation <NUM>, an initial analysis is conducted to determine whether the measured values for the process run "passed" with respect to each set point requirements for a group of set points (operation <NUM>). In other words, the pass/fail data is evaluated to determine whether the process run was completed such that all system parameters during the process run were within known ranges for producing acceptable articles. If so, the articles are accepted (operation <NUM>).

If no existing groups of set point values satisfactorily encompass the measured data, the temperature-time curve of the process run may be analyzed to determine if the articles achieved a desired F<NUM> value (operation <NUM>). If so, the measured data can be correlated to form a new group of set point values (operation <NUM>), a new temperature-time profile, and/or a new operating profile. In other words, if the measured values obtained during the process run did not fall within range of set points for established groups of set points but nevertheless achieved satisfactory sterilization or pasteurization of the article, the measured values of the process run may be stored as a new group of operating set points for use in subsequent process runs. If, on the other hand, the temperature-time profile for the article is not met, further action may be taken regarding the articles including, without limitation, disposing of the articles or rerunning the articles (operation <NUM>).

Additionally, or in the alternative, the step of comparing the measured data set with a target value may include comparing the actual temperature-time profile generated during the processing run with at least one target temperature-time profile present in an operating profile. In some cases, the actual temperature-time profile may be compared with two or more temperature-time profiles in the same, or different, operating profiles. This comparison can include, for example, calculating maximum deviations of the actual temperature-time profile and the target profile and comparing these deviations with a maximum allowable deviation set forth in the operating profile. Alternatively, this comparison can include calculating the F<NUM> value based on the actual temperature-time profile and comparing it with the target F<NUM> value inherent one or more temperature-time profiles or target F<NUM> values expressly listed in the temperature-time profile. In certain implementations, for example, the actual temperature-time profile may deviate from the target temperature-time profile by not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, not more than about <NUM>%, or not more than about <NUM>% over all or a portion of the heating steps.

As noted above, based on the differences determined by comparing the actual data from a completed process run with the groups of set point values, temperature-time profiles, and/or target F<NUM> values in one or more operating profiles, one or more actions can be taken with regard to the microwave heating system. In some cases, the articles may be discarded or rerun, if it has been determined that the articles have not achieved the desired level of pasteurization or sterilization. However, if the articles have achieved the desired treatment level, the pasteurized or sterilized articles can be transported to further processing, storage, and/or sale. Alternatively, one or more adjustments can be made to the physical configuration of the microwave system, and/or to its overall operation. Further, the differences may result in changes to an existing operating profile, or may result in a new group of set point values, temperature-time profile, or operating profile being created.

Microwave heating systems of the present disclosure can be commercial-scale heating systems capable of processing a large volume of articles in a relatively short time. In contrast to conventional retorts and other small-scale systems that utilize microwave energy to heat a plurality of articles, microwave heating systems as described herein can be configured to achieve an overall production rate of at least about <NUM> packages per minute, at least about <NUM> packages per minute, at least about <NUM> packages per minute per convey line, at least about <NUM> packages per minute per convey line, at least about <NUM> packages per minute per convey line, or at least about <NUM> packages per minute per convey line, measured as described in <CIT>.

Referring to <FIG>, a schematic illustration of an example computing system <NUM> having one or more computing units that may implement various systems, processes, and methods discussed herein is provided. For example, the example computing system <NUM> may correspond to, among other things, the control system <NUM> or (a computing device in communication with or otherwise capable of interacting with the control system <NUM>) of the microwave heating system <NUM> of <FIG>. It will be appreciated that specific implementations of these devices may be of differing possible specific computing architectures not all of which are specifically discussed herein but will be understood by those of ordinary skill in the art.

The computer system <NUM> may be a computing system capable of executing a computer program product to execute a computer process. Data and program files may be input to computer system <NUM>, which reads the files and executes the programs therein. Some of the elements of the computer system <NUM> are shown in <FIG>, including one or more hardware processors <NUM>, one or more data storage devices <NUM>, one or more memory devices <NUM>, and/or one or more ports <NUM>-<NUM>. Additionally, other elements that will be recognized by those skilled in the art may be included in the computing system <NUM> but are not explicitly depicted in <FIG> or discussed further herein. Various elements of the computer system <NUM> may communicate with one another by way of one or more communication buses, point-to-point communication paths, or other communication means not explicitly depicted in <FIG>.

The processor <NUM> may include, for example, a central processing unit (CPU), a microprocessor, a microcontroller, a digital signal processor (DSP), and/or one or more internal levels of cache. There may be one or more processors <NUM>, such that the processor <NUM> comprises a single central-processing unit, or a plurality of processing units capable of executing instructions and performing operations in parallel with each other, commonly referred to as a parallel processing environment.

The computer system <NUM> may be a conventional computer, a distributed computer, or any other type of computer, such as one or more external computers made available via a cloud computing architecture. The presently described technology is optionally implemented in software stored on data storage device(s) <NUM>, stored on memory device(s) <NUM>, and/or communicated via one or more of the ports <NUM>-<NUM>, thereby transforming the computer system <NUM> in <FIG> to a special purpose machine for implementing the operations described herein. Examples of the computer system <NUM> include personal computers, terminals, workstations, mobile phones, tablets, laptops, personal computers, multimedia consoles, gaming consoles, set top boxes, and the like.

One or more data storage devices <NUM> may include any non-volatile data storage device capable of storing data generated or employed within the computing system <NUM>, such as computer executable instructions for performing a computer process, which may include instructions of both application programs and an operating system (OS) that manages the various components of the computing system <NUM>. Data storage devices <NUM> may include, without limitation, magnetic disk drives, optical disk drives, solid state drives (SSDs), flash drives, and the like. Data storage devices <NUM> may include removable data storage media, non-removable data storage media, and/or external storage devices made available via wired or wireless network architecture with such computer program products, including one or more database management products, web server products, application server products, and/or other additional software components. Examples of removable data storage media include Compact Disc Read-Only Memory (CD-ROM), Digital Versatile Disc Read-Only Memory (DVD-ROM), magneto-optical disks, flash drives, and the like. Examples of non-removable data storage media include internal magnetic hard disks, SSDs, and the like. One or more memory devices <NUM> may include volatile memory (e.g., dynamic random access memory (DRAM), static random access memory (SRAM), etc.) and/or non-volatile memory (e.g., read-only memory (ROM), flash memory, etc.).

Computer program products containing mechanisms to effectuate the systems and methods in accordance with the presently described technology may reside in the data storage devices <NUM> and/or the memory devices <NUM>, which may be referred to as machine-readable media. It will be appreciated that machine-readable media may include any tangible non-transitory medium that is capable of storing or encoding instructions to perform any one or more of the operations of the present disclosure for execution by a machine or that is capable of storing or encoding data structures and/or modules utilized by or associated with such instructions. Machine-readable media may include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more executable instructions or data structures.

In some implementations, the computer system <NUM> includes one or more ports, such as an input/output (I/O) port <NUM>, a communication port <NUM>, and a sub-systems port <NUM>, for communicating with other computing, network, or similar devices. It will be appreciated that the ports <NUM>-<NUM> may be combined or separate and that more or fewer ports may be included in the computer system <NUM>.

The I/O port <NUM> may be connected to an I/O device, or other device, by which information is input to or output from the computing system <NUM>. Such I/O devices may include, without limitation, one or more input devices, output devices, and/or environment transducer devices.

In one implementation, the input devices convert a human-generated signal, such as, human voice, physical movement, physical touch or pressure, and/or the like, into electrical signals as input data into the computing system <NUM> via the I/O port <NUM>. Similarly, the output devices may convert electrical signals received from the computing system <NUM> via the I/O port <NUM> into signals that may be sensed as output by a human, such as sound, light, and/or touch. The input device may be an alphanumeric input device, including alphanumeric and other keys for communicating information and/or command selections to the processor <NUM> via the I/O port <NUM>. The input device may be another type of user input device including, but not limited to: direction and selection control devices, such as a mouse, a trackball, cursor direction keys, a joystick, and/or a wheel; one or more sensors, such as a camera, a microphone, a positional sensor, an orientation sensor, a gravitational sensor, an inertial sensor, and/or an accelerometer; and/or a touch-sensitive display screen ("touchscreen"). The output devices may include, without limitation, a display, a touchscreen, a speaker, a tactile and/or haptic output device, and/or the like. In some implementations, the input device and the output device may be the same device, for example, in the case of a touchscreen.

The environment transducer devices convert one form of energy or signal into another for input into or output from the computing system <NUM> via the I/O port <NUM>. For example, an electrical signal generated within the computing system <NUM> may be converted to another type of signal, and/or vice-versa. In one implementation, the environment transducer devices sense characteristics or aspects of an environment local to or remote from the computing device <NUM>, such as, light, sound, temperature, pressure, magnetic field, electric field, chemical properties, physical movement, orientation, acceleration, gravity, and/or the like. Further, the environment transducer devices may generate signals to impose some effect on the environment either local to or remote from the example the computing device <NUM>, such as, physical movement of some object (e.g., a mechanical actuator), heating, or cooling of a substance, adding a chemical substance, and/or the like.

In one implementation, a communication port <NUM> is connected to a network by way of which the computer system <NUM> may receive network data useful in executing the methods and systems set out herein as well as transmitting information and network configuration changes determined thereby. Stated differently, the communication port <NUM> connects the computer system <NUM> to one or more communication interface devices configured to transmit and/or receive information between the computing system <NUM> and other devices by way of one or more wired or wireless communication networks or connections. Examples of such networks or connections include, without limitation, Universal Serial Bus (USB), Ethernet, WiFi, Bluetooth®, Near Field Communication (NFC), Long-Term Evolution (LTE), and so on. One or more such communication interface devices may be utilized via communication port <NUM> to communicate one or more other machines, either directly over a point-to-point communication path, over a wide area network (WAN) (e.g., the Internet), over a local area network (LAN), over a cellular (e.g., third generation (<NUM>) or fourth generation (<NUM>)) network, or over another communication means. Further, the communication port <NUM> may communicate with an antenna for electromagnetic signal transmission and/or reception.

The computer system <NUM> may include a sub-systems port <NUM> for communicating with one or more sub-systems, to control an operation of the one or more sub-systems, and to exchange information between the computer system <NUM> and the one or more sub-systems. Examples of such sub-systems include, without limitation, imaging systems, radar, LIDAR, motor controllers and systems, battery controllers, fuel cell or other energy storage systems or controls, light systems, navigation systems, environment controls, entertainment systems, and the like.

The system set forth in <FIG> is but one possible example of a computer system that may employ or be configured in accordance with aspects of the present disclosure. It will be appreciated that other non-transitory tangible computer-readable storage media storing computer-executable instructions for implementing the presently disclosed technology on a computing system may be utilized.

Numerous examples are provided herein to enhance understanding of the present disclosure. A specific set of statements are provided as follows. Such statements are intended merely as examples of potential implementations of the present disclosure and should not be viewed as limiting the scope of the disclosure.

As used herein, the terms "comprising," "comprises," and "comprise" are open-ended transition terms used to transition from a subject recited before the term to one or more elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up the subject.

As used herein, the terms "including," "includes," and "include" have the same open-ended meaning as "comprising," "comprises," and "comprise.

As used herein, the terms "having," "has," and "have" have the same open-ended meaning as "comprising," "comprises," and "comprise.

As used herein, the terms "containing," "contains," and "contain" have the same open-ended meaning as "comprising," "comprises," and "comprise.

As used herein, the terms "a," "an," "the," and "said" mean one or more.

As used herein, the term "and/or," when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed.

As generally used herein, the terms "about", "substantially", and "approximately" refer to an acceptable degree of error for the quantity measured, given the nature or precision of the measurement. Typical exemplary degrees of error may be within <NUM>%, within <NUM>%, or within <NUM>% of a given value or range of values.

All numerical quantities stated herein are to be understood as being modified in all instances by the term "about" unless otherwise indicated. The numerical quantities disclosed herein are approximate and each numerical value is intended to mean both the recited value and a functionally equivalent range surrounding that value. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical value should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding the approximations of numerical quantities stated herein, the numerical quantities described in specific examples of actual measured values are reported as precisely as possible.

All numerical ranges stated herein include all sub-ranges subsumed therein. For example, ranges of "<NUM> to <NUM>" and "between <NUM> and <NUM>" are intended to include all sub-ranges between and including the recited minimum value of <NUM> and the recited maximum value of <NUM>.

All percentages and ratios are calculated based on the total weight of the compound or composition unless otherwise indicated.

Claim 1:
A method for processing articles, the method (<NUM>) comprising:
accessing an operating profile (302a-n) for heating a type of article using a microwave heating system (<NUM>), the operating profile (302a-n) including a first group of set point values for operating the microwave heating system (<NUM>) to heat the type of article according to a first heating process and a second group of set point values for operating the microwave heating system (<NUM>) to heat the type of article according to a second heating process different than the first heating process; and
using a control system (<NUM>) operatively coupled to the microwave heating system (<NUM>), operating the microwave heating system (<NUM>) according to the first group of set point values, the first group of set point values including a target value for a control parameter of the microwave heating system (<NUM>), wherein operating the microwave heating system (<NUM>) includes:
passing a carrier loaded with a plurality of articles of the type of article corresponding to the operating profile (302a-n) through a liquid-filled microwave heating chamber (<NUM>) along a convey line such that the plurality of articles is submerged in a liquid medium within the microwave heating chamber (<NUM>); and
while passing the carrier through the microwave heating chamber (<NUM>), discharging microwave energy into the microwave heating chamber (<NUM>), the microwave energy used to heat the plurality of articles;
measuring the control parameter to provide a measured value;
calculating a difference between the measured value and the target value; and
responsive to determining the difference exceeds a predetermine allowable difference, operating the microwave heating system (<NUM>) according to the second group of set point values.