Abstract: Systems and methods including modular electromagnetic heating systems enable heating of articles using electromagnetic energy. The systems include a primary processing vessel equipped with electromagnetic energy launchers and fluid delivery systems to enable capable of preheating, heating, and cooling of the articles within the primary processing vessel. The primary processing vessel is further configured to be coupled to one or more upstream or downstream vessels such that portions of the preheating and/or heating functionality may instead be performed by the additional vessels. This flexibility enables scaling of the electromagnetic heating system between a relatively small (e.g., lab) scale system and a relatively large (e.g., production) scale system while minimizing capital expenditures and space requirements.

Abstract: Carriers suitable for transporting a plurality of articles through a microwave heating zone are provided. Carriers as described herein may include an outer frame and upper and lower support structures vertically spaced from one another to provide a cargo volume into which the articles are loaded. At least a portion of the upper and/or lower support structures may be formed of an electrically conductive material. Additionally, the carrier may include removable article spacing members, such as vertical spacing members and dividers, that can be selectively inserted to adjust the size and/or shaper of the cargo volume. Carriers as described herein may be configured to receive a variety of different articles, including trays and pouches, and the articles may be loaded into the carrier in a nested or overlapping manner.

Abstract: A method for processing articles using a microwave heating system includes obtaining an operating profile for heating a type of article using the microwave heating system. The operating profile includes a temperature-time profile for a target F0 value and a group of set point values for achieving the temperature-time profile, the group of set point values including a target for a control parameter of the microwave heating system. Using a control system operatively coupled to the microwave heating system, the microwave heating system is operated in accordance with the group of set point values such that each of the articles achieves an F0 value that is greater than or equal to the target F0 value.

Abstract: Systems and processes for use in heating articles include passing a carrier loaded with an article through a vessel inlet and into a first vessel portion and moving the loaded carrier in a first direction through the first vessel portion away from the inlet. During at least a portion of the movement through the first vessel portion, the article is contacted with a first fluid medium. The loaded carrier is moved carrier in a second direction opposite the first direction through a second vessel portion toward a vessel outlet. During at least a portion of the movement through the second vessel portion, the articles is contacted with a second fluid medium. In certain implementations, each of the first direction and the second direction are vertical.

Abstract: Processes and systems for pasteurizing and sterilizing a plurality of articles in a microwave heating system are provided. In certain aspects, groups of articles may be passed by a microwave launcher in a first convey direction and a second, opposite convey direction, so that each group of articles passes the microwave launcher more than once. Processes and systems described herein are also configured to uniformly heat spaced apart groups of articles without disrupting the operation of the microwave generator or distribution system.

Abstract: Processes and systems that enhance the heating of packaged foodstuffs and other items in various microwave heating systems are described herein. The foodstuffs may be contained in a package including one or more energy control elements that interact with microwave energy in order to alter the effect that microwave energy has on the foodstuff. These energy control elements can enhance or inhibit microwave energy and a single package may include one or more energy control elements. In some cases, the energy control element may respond differently to different types of microwave energy. As a result, some packages described herein may exhibit different absorption or reflectance characteristics when exposed to microwave energy while being pasteurized or sterilized in a larger-scale microwave heating system than when the package is reheated in an at-home microwave oven prior to consumption or use.

Abstract: A process for heating articles includes sequentially passing loaded carriers in a continuous manner through a first processing section and sequentially passing said plurality of loaded carriers in an incremental manner through a second processing section using an incremental convey segment. The incremental convey segment includes sequential carrier-receiving slots, each carrier-receiving slot configured to receive one of the loaded carriers. The incremental convey segment is further configured to be move incrementally at multiples of discrete intervals corresponding to the carrier-receiving slots. The process further includes sequentially passing the loaded carriers in a continuous manner through a third processing section and heating articles supported by the carriers with microwave energy in at least one of the processing sections, the heating of the articles occurring while the articles are at least partially submerged in a liquid bath and at an pressure greater than atmospheric pressure.

Abstract: A process for heating articles in a heating system includes passing an article in a carrier through a heating chamber that is at least partially filled with a liquid medium to form a liquid bath. The process further includes heating the article in the carrier by at least partially submerging the article into the liquid bath during heating, the heating being performed, at least in part, using microwave energy. The process further includes one or more of adding fluid into and removing fluid from at least one location in the heating chamber to maintain a temperature profile across the heating chamber. In one implementation, the temperature of the liquid bath at an inlet area of the heating chamber is at least 10° C. cooler than a temperature of the liquid bath at an outlet area of the heating chamber.

Abstract: Processes and systems that enhance the heating of packaged foodstuffs and other items in various microwave heating systems are described herein. The foodstuffs may be contained in a package including one or more energy control elements that interact with microwave energy in order to alter the effect that microwave energy has on the foodstuff. These energy control elements can enhance or inhibit microwave energy and a single package may include one or more energy control elements. In some cases, the energy control element may respond differently to different types of microwave energy. As a result, some packages described herein may exhibit different absorption or reflectance characteristics when exposed to microwave energy while being pasteurized or sterilized in a larger-scale microwave heating system than when the package is reheated in an at-home microwave oven prior to consumption or use.

Abstract: Carriers suitable for transporting a plurality of articles through a microwave heating zone are provided. Carriers as described herein may include an outer frame and upper and lower support structures vertically spaced from one another to provide a cargo volume into which the articles are loaded. At least a portion of the upper and/or lower support structures may be formed of an electrically conductive material. Additionally, the carrier may include removable article spacing members, such as vertical spacing members and dividers, that can be selectively inserted to adjust the size and/or shape of the cargo volume. Carriers as described herein may be configured to receive a variety of different articles, including trays and pouches, and the articles may be loaded into the carrier in a nested or overlapping manner.