Our mobile processing plants are intended to simultaneously solve a number of serious logistics problems in the food industry from farm-to-final sale. For example - to greatly shorten the time cycle and shrink storage buffer space involved in the chain, severely curtail losses from transporting/processing bruise damage and spoilage, and moving away from those costs via use of unique specialized handling and sterile processing methods in a modular and compact (mobile) form.
  As part of this overall scheme, some unique innovations are planned. Including, but not limited to, process segments that it appears could be developed separately or in whole to meet your needs for fruits & vegetables to be processed & frozen, frozen then processed, or delivered fresh with high-quality characteristics...
- Very specific and highly-controlled accurate cleaning, dessication, and/or pre-bake.
- Zero-G final stages. Weightless Zero-Contact, no conveyor no-touch perfection until final container/wrap/palletize/etc. air-capture occurs.
- Ultra-high pass-thru temperatures (thousands of degrees) in a highly-controlled duration measured in milliseconds. Cuts final surface levels of bacteria/yeast/pathogens. Adds additional exterior surface dryness (reducing suceptibility to further ambient exposure).
- This combination appears to firm the outer-surface of high-water content fruits and vegetables in a "molecules thick" layer, producing no evident change in color/texture/taste as this layer is very thin indeed, yet such firming seems to improve further transport durability and, importantly, an improved result when any further slice/dice/pit/core type operations are done. A "molecular-scale barrier seal" that traps flavor and aromatics.
- Immediately after the above (more milliseconds), product enters an oxygen-starved environment for the final process or packup steps. Once it is in its final place, product is in the best condition, better than ever seen before, and is further protected by a choice or combination of films, wraps, controlled atmospheres, controlled temperatures, and shock-buffered automated crating.
- These unique segments of process do not apply to particular robust husk items such as pumpkin, melon, or oranges. Nor to leafy produce such as lettuce or cabbage. However for those, there are the more standard methods that can be utilized in a mobile processing plant format simply for the logistics advantages.

• In a completely symmetrical universe we would enjoy a mobile semi-trailer... used at the source... outdoors in any  weather... or at a central processor center... hub... warehouse... or at a regional distributor.


• Product is automatically taken from the 'raw-pick' form then all desired and regulated-compliance functions are completed in-situ in this mobile unit.


• Product is completely processed from the raw input state to the final form ready for retail endpoints, distributor warehouse, or processors small to large, computerized on-spec.  Inside space for operator/manager, incidental labor for non-automatables such as stemming/disjointing.


• Product is protected via unique high-technology buffering techniques and stabilization methods in both individual-surround and shock-designed pallet carriers (the perfect application of DDM, Direct Digital Manufacture).


• There is no bruising or time-oxidation between the field-input and the retail carton or food processor destination, even frozen slurries. Zero defects.


• All pallets and automated carrier platforms are recycled back to the P³ during the route deliveries, there is no waste or dumping, and certainly no carbon-footprint. Even the delivery carton surround package can be made this way so that no cardboard is required hence zero-landfill impact.


• Cold-Paks are automatically installed in pallet carriers when this is programmed for the product type. "Refer" trucking is only needed to maintain over very long-hauls.


• Very Important: Our special "zero-gravity" stacks, when specified and used, are critical to the goal of 'Surface/texture/taste/color/sterility/content-preservation' that is not just P³ critical, but is key to reduced costs being the result of improved delivered quality/efficiency.  These permit sterilizing on produce that is desired to be pre-treated bacterially or even pre-cooked or 'singed' for hardening or taste/texture/color robustness, or for frozen-processed direct aggregate content for use in top-quality products such as ice-cream or yogurt and many other input-preps for packaged frozen presentations that are not the fruit or vegetable isolated and presented by itself alone. This novel process is very unique, and occurs in zero-gravity, and each unit/dollop/berry-group is bagged with cling-wrap individually during the air-deceleration process in a cryo-halt oxygen-free region. All weightless. And all in less than a second. The secondary intention for this process is that no product touches anything, as it is in free-fall, until it lands in the air-deceleration catch location which is the wrap film (perforated or non), then proceeding through the cryo section to auto-inspection, any final process work, and pack-out-fill.


• ALL process variables, status, packout and completion, sizes distribution charts, weight, are computer-controlled, and ALL are operator-adjustable (or remotely anywhere on the planet) provided they have the password and/or key, and everything starts from our software templates already provided for every type of fruit and vegetable processing possible.


• Rates are also fully-adjustable, up to 3600 units per-hour... sometimes more... well above any normal provisioner ability. Our system automatically adapts parameters in each section based on the requested output rate.  Large plant processing sites enjoy low cost redundancy from parallel trailer modules.


• Fine-processing options include adsorption additives, colorants, nutrients, stabilizers, or waxy buff-coatings. Flash pre-cook options that completely stabilize product destined for "perfect" processing that will soon follow at a plant location or retail destination, or finished on site directly in the P³.


• To prep the trailer for a run of a day to a week takes one person one-hour. All processes are self-cleaning and the cycle can be initiated anytime. After the job, do self-clean auto cycle then packdown/lockup takes one person one-hour.  All food route channels inside our processes are normally sealed and residuals are purged automatically, but flip-out covers also allow a person with a pressure-sprayer ready access to inspect and hard-clean periodically as well as maintenance inspection periodical reviews as required by code or desired elsewise.


• Each spec-trailer is unique in its mission, yet extremely flexible in the range of produce it can process, how much process to do, how far you take it, and how much buffer storage is required and how cold (depends on when or even if you have a truck comming to offload, and you may be working through the night anyway inside to fill the buffer storage section or maybe the weather is bad outside and no one is comming for awhile).


• Our modular system approach is also applied for use directly in a plant location, where there is no mobile trailer needed. It is indeed quite astounding to commission a process line like this that has extreme modular 3D form and rapid-servicing thinking, on a plant floor with just an 8x40 or 8x53 footprint.


• These principles represent a major shift toward "Seed-To-Gullet" thinking. Just like we engineers do now in electronic product development where we think "Cradle-To-Grave" cycles related to ROHS enviro-mandates and the increased carbon stewardship of our planet.


• Although this short discourse is mainly about fresh-final perfection, specifications could include variations such as pit, peel, slice, dice, chop, puree, blendmix, and a multitude of on-spec output packaging including cryo.  Other research and development is available related to the zero-gee process formats, not excluding hi-field magnetic resonance, laser analysis/mark/and profile cutting/shaping, microwave, UV, and xenon strobe profiles.


• Flexible logistics methods such as tandem trailer route-splitting, driver-operator, lockers and bunking areas.


• Our mobile methods also apply to numerous other rapid-ready industries, from daily in-city penetration pre-preps for restauranteurs, or exotic emerging industries like shale-oil fracking power support, mobile crew workcenters, and process plants on the wellhead sites.

Use Rugged modern control and expansive networking capabilities.

-  All process parameters are controlled by redundant networked computers, onboard, cloud, and mobile.
-  Process profile templates are specific to product type, destination, and input/output intention.
-  Library-Modular by design meaning physical segments of the process as well as software interoperability can be changed/swapped-out/deleted/or added at any time.
-  Any process segment can be monitored, changed, updated, stored. Specific to any single farm or process site in extreme particular detail.  Overview all or drill down all the way even to a specific sensor on a specific module's settings as well as history and maintenance instruction and the subsequent probability of projected failure in its future forecast (i.e.- "Dave... The AE35 antenna unit indicates a 90% historical probability of failure in the next 72 hours").
-  Real-time complete reports to operator and central office. History run-record too (here is what we did).
-  P³ trucks can also be controlled/monitored/configured from anywhere in the world, provided you have clearance.
-  Standard spec's include IP-67 & MIL-STD-810G for extreme water, humidity, sand/dust, vibration, altitude, shock, and temperature. Bluetooth, WiFi, 3G GSM cellular datalink, GPS to 2.5 meter, and HD camera for onsite situation detail from P³ to your central (as well as records for field reports and work completed/billable evidence).
-  Over the air schedule/logistic changes, updates/reprogramming.
-  On-board operator step-by step instructions for everything, process flowcharts, maint., sched, supplies, etc..
-  Gee its all pretty clever... but what did we miss? ...Hmmm... Nothing yet!

Perfect Produce Providers "Processing Plant in a Box". Each order is unique in specification and can vary widely in process details.
This is an example template to handle a wide varietal use, well equiped. Includes onsite training and global regulatory certification assistance...

Delivery...
  As of March 2013. Average current production capacity including unit-by-unit customization and normal compliance certifications is approx. 1-unit per month. Present lead-time is 19 months. Research and/or certification(s) for exotic processes under examination in your country may add to leadtime.

Costs and Economic Incentive... Timelines...
  Studies suggest that this big-picture 'stewardship of the planet'' attitude actually results in a gain instead of a cost. Being that the estimated cost of goods-movement from field to consumer is laden with a large amount of waste from decay, damaging thermal profiles, handling, and human-error that occurs along all paths. Another key wasted-cost element is the logistics problem where all the players are not on the same page (this means YOU... forecaster, grower, processor, distributor, delivery vehicular router, and grocer). The P³ attitude packs-out product at the earliest-possible source locations, automatically routes to every individual destination, and waste elimination alone from the otherwise useless transport and retry attempts would more than pay for the intention to control these pathways.  Interviews indicate that a large portion of processors/distributors/and larger farmers or micro-co-ops growers would all be able to utilize such trailers in the network to great advantage where everyone works from the same-page and there is no-waste or spoilage transport.  Not to mention scheduled harvest points and time flexibility based on weather and route logistics (who has it and when are they ready for PerfectProduceProvision pickup).  The old adage still applies today - "Get It While The Gettin's Good". Except now we use help from computers, internet, and of course P³ truck methods laced in tight.

Financing...
  Our standard model is a pay-as-you-go process that makes for the best cash-flow model and conservation-of-capital between supplier and buyer. We require evenly disbursed  monthly payments that equal your total order divided by our que months of lead time on your order. When spec's and the PO-contract are complete and you finally place an order with first payment, your delivery schedule will be inserted in the que. You can not 'buy your way' in to an earlier point in our que to accelerate delivery as that would compromise our perfectionist-attitude, other previous orders come first since we prefer 'perfection' and do not buckle to monetary incentive in that old-fashioned way of thinking. If fast-tracking is required due to government mandate, emergency, or exceptional harvest loss forecasting, then we will create a parallel pathway potential to deal with such urgency in an appropriate manner. 

Alternatives/Leasing Services...
  Create your own local "Hub-Zone" co-op groups. Send our P³ trucks around like the old circuit-court hopping-method.  Timed and scheduled by you according to harvest optimum conditions for each type of produce in your territory. The Hub is either at your group centralized warehousing location, or have the trucks set themselves up at a local large farm, and all the micro-growers too sign-up on your net and bring in scheduled small supply which adds up as you know so-long as their pricing is "on your dock".  Anyone with your simple certification then can grow and sell produce and be very competitive on price that way.  The old problem was routes too long, loads too small, large spoilage/reject at arrival, and it limited the food-industry and their consumers to living with the heavy cost-load associated with it.  Now the freshest in-season organics can even be grown by single households, infrastructure-newspaper-boys pick up daily excess picked today since they're there already (with his wagon?... today mine do the route with a parent in the family minivan), and batch-delivery to a Hub-Zone can be nothing more than a regular pickup truck or a van!  Delivery to your Hub is zero charge to you the processor and distributor, makes for some interesting market pricing play with instant same-day pick speed and some unique market-planning, and business development grants near large cities as a beneficial preferred provider, and consumer-grower reciprocity benefits (the same people selling are also buying).

Backgrounds...
  These principals, concepts, and processes are proprietary information of David A. Masters/ President TDDI (Techni-Digital Design, Inc., an Ohio USA corporation). Your viewing of this information constitutes "prior-art public release".  All existing patent and trademark rights of customers, as well as reveals appertaining thereto, remain privately-held and secret information of our customers. All ensuing patent rights for this information and that derived from work-in-progress that are not given by ordering parties are reserved-right by David A. Masters. USA Contacts: Ph:419-465-2484 Fx:419-465-2484 Em:tddi@tech2000astronomy.com
  TDDI is a product and process development manufacturer operating since 1979, grounded as a development partnership in 1987 and then incorporated as a full C-Corp manufacturer in 1989 Ohio USA.
  Dave in the capacity of President/TDDI, is assigned the 'Perfect-Produce-Provider' picker to lead new projects with an impressive 36 year track record.  Previous work includes some very large companies as well as small ones, i.e. Senior Development Engineer 10 years Corvette, including GM Truck&Bus advanced development group, plus 10 years industrial food equipment executive engineering and certifications (globally) which includes groundbreaking technologies in "Tactile-Lockout" that has saved lives and prevented grievous injuries in the meat-processing industrial plants worldwide.  Add JohnDeer/Lubrizol/Lockheed/RCA/Duracell/National Semiconductor for a few more noticeable names.  And many many others less recognized.  Not to mention Dave spent his youth as a lead-farm-hand, being recognized early for his astute abilities in the cherry orchards and large berry farm picker environment in Central Ohio.  And not to mention you will find (if your security clearance allows) that Dave Masters is also on the ExoStar supplier list under his personal/individual name! ... certified to execute rated defense contracts for the likes of Lockheed-Martin, Boeing defense, Grumman, and Raytheon.
  All inquiries are welcome.

Little Big Problems Solved...
  Did you know?  Processors in New York City make jars of cherries, Maraschino etc. etc.  Frozen for ice cream etc. etc.  But cherry growers in New York State ship their produce to Michigan for 'pitting & brining'! Then ship it back! Does that sound insane?  And you were all worried about local gas and vehicle mileage getting regular produce a few miles to your processing place. It turns out there is too much overhead in the EPA regulations, along with the other business model problems like 'a place and equipment and people', to build small plants around a state that does not have enough growers.  Roving P³ trucks change all that in a big cost-saving way.

  See the NYC report on a farm-to-factory pilot program, USDA et.al. funded, that identifies the criticality of these missing component views we have been discussing above. The program studied logistics issues regarding problems getting produce into all New York City locations and a goodly portion of it goes beyond the provider networks and wasted spoilage. The focus on P³ needs are quite evident in the latter portions, yet they were unaware that we are already formulating the solutions...

fsmipnyfarm-to-factory-final-report.pdf

  An Airbus P³ cargo plane takes off with its incidental cargo of dessicated/highly-weight-reduced produce enroute to global destinations.
  Only "Perfect Produce" is present, only zero waste and zero damage goods are moved.
  Its quite minor and incidental to the total aircraft load, but critical to the receivers who want it, need it now, and pay for it.
  All P³ trailers designed by TDDI are also readily-shipped to any location on the planet with CE-mark directives completed.