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Thermal Processing 2610

This document discusses food spoilage and methods for food preservation, specifically thermal processing techniques like pasteurization. It begins by explaining how food spoilage occurs due to microorganism growth, enzyme activity, and chemical/physical changes. It then provides details on common storage times for different foods. The document focuses on pasteurization, describing the process, appropriate temperatures for different foods, examples of pasteurization equipment, and its effects on nutritional and sensory properties. Thermal death times of microorganisms during heat processing are also addressed.

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235 views70 pages

Thermal Processing 2610

This document discusses food spoilage and methods for food preservation, specifically thermal processing techniques like pasteurization. It begins by explaining how food spoilage occurs due to microorganism growth, enzyme activity, and chemical/physical changes. It then provides details on common storage times for different foods. The document focuses on pasteurization, describing the process, appropriate temperatures for different foods, examples of pasteurization equipment, and its effects on nutritional and sensory properties. Thermal death times of microorganisms during heat processing are also addressed.

Uploaded by

teorikdeli
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Introduction

Food production occurs at specific areas


and at certain periods of the year due
to variation in weather conditions.
Food therefore has to be collected and
stored for use during periods of low or
no food production.
However, storage is complicated by the
fact that food begin to deteriorate
shortly after harvest, gather or
slaughter.

Food spoilage

Food spoilage is defined as damage or


injury to food rendering in unsuitable
for human consumption.
Food must be considered spoiled if it
is contaminated with pathogenic
microorganisms or various poisonous
agents, such as pesticides, heavy
metals etc.

Table 1: Storage life of some foods


Food product

Storage life (days) at


21oC

Raw beef and mutton


Raw fish
Raw poultry
Dried
salted
or
smoked
meat and fish
Fresh fruits
Dried fruits
Leafy vegetables
Root crops
Dried seeds

1-2
1-2
1-2
360 or more

1-7
360 or more
1-2
1-20
360 or more

Causes of food spoilage


(a). Growth and activity of
microorganisms Bacteria, yeasts and molds
are microorganisms that cause food spoilage.
They produce various enzymes that
decompose the various constituents of food.
(b). Enzyme activity: Action of enzymes found
inherently in plant or animal tissues start the
decomposition of various food components
after death of plant or animal.
(c). Chemical reactions: These are reactions
that are not catalysed by enzymes.,e.g.
oxidation of fat

(d). Vermin. Vermin includes weevils,


ants, rats, cocroaches, mice, birds, larval
stages of some insects. Vermin are
important due to:
(i). Aesthetic aspect of their presence,
(ii) Possible transmision of pathogenic
agents, (iii). Consumption of food.
(e). Physical changes. These include
those changes caused by freezing,
burning, drying, pressure, etc.

Thermal processing
Pasteurization
Sterilization

Pasteurisation
Pasteurization is a relatively mild heat
treatment, in which food is heated to below
100C. In low acid foods (pH>4.5, for
example milk) it is used to minimize
possible health hazards from pathogenic
micro-organisms and to extend the shelf life
of foods for several days.
In acidic foods (pH <4.5, for example
bottled fruit) it is used to extend the shelf
life for several months by destruction of
spoilage micro-organisms (yeasts or
moulds) and/or enzyme inactivation

4.1 Theory
The sensible heat required to raise the temperature
of a liquid during pasteurization is found using:

Purpose of pasteurization for different foods

Equipment
Pasteurization of packaged foods
Some liquid foods (for example beers
and fruit juices) are pasteurized after
filling into containers. Hot water is
normally used if the food is packaged in
glass, to reduce the risk of thermal
shock to the container (fracture caused
by rapid changes in temperature).
Maximum temperature differences
between the container and water are
20C for heating and 10C for cooling.

Metal or plastic containers are processed using


steamair mixtures or hot water as there is little risk
of thermal shock. In all cases the food is cooled to
approximately 40C to evaporate surface water and
therefore to minimize external corrosion to the
container or cap, and to accelerate setting of label
adhesives.
Hot-water pasteurisers may be batch or continuous
in operation. The simplest batch equipment consists
of a water bath in which crates of packaged food
are heated to a pre-set temperature and held for
the required length of time. Cold water is then
pumped in to cool the product. A continuous
version consists of a long narrow trough fitted with
a conveyor belt to carry containers through heating
and cooling stages.

Timetemperature relationships for pasteurization.


The hatched area shows the range of times and
temperatures used in commercial milk pasteurization.

4.2.2 Pasteurization of unpackaged


liquids
Swept surface heat exchangers (Barclay et al.,
1984) or open boiling pans are used for small-scale
batch pasteurization of some liquid foods.
However, the large scale pasteurization of low
viscosity liquids (for example milk, milk products,
fruit juices, liquid egg, beers and wines) usually
employs plate heat exchangers. Some products
(for example fruit juices, wines) also require deaeration to prevent oxidative changes during
storage. They are sprayed into a vacuum chamber
and dissolved air is removed by a vacuum pump,
prior to pasteurization.

The plate heat exchanger consists of a series of


thin vertical stainless steel plates, held tightly
together in a metal frame. The plates form parallel
channels, and liquid food and heating medium (hot
water or steam) are pumped through alternate
channels, usually in a counter-current flow pattern.
Each plate is fitted with a synthetic rubber gasket
to produce a watertight seal and to prevent mixing
of the product and the heating and cooling media.
The plates are corrugated to induce turbulence in
the liquids and this, together with the high velocity
induced by pumping, reduces the thickness of
boundary films to give high heat transfer
coefficients (3000 11 500Wm2K1).

Plate heat exchanger

Counter-current flow through plate heat exchanger:


(a) one pass with four channels per medium; (b) two
passes with two channels per pass and per medium

Pasteurizing using a plate heat


exchanger.

Effect on foods
Pasteurization is a relatively mild heat treatment
and even when combined with other unit
operations (for example irradiation and chilling
there are only minor changes to the nutritional and
sensory characteristics of most foods. However,
the shelf life of pasteurized foods is usually only
extended by a few days or weeks compared with
many months with the more severe heat
sterilization. Minimizing post processing
contamination is essential to ensure an adequate
shelf life.

Color, flavor and aroma


In fruit juices the main cause of color deterioration
is enzymatic browning by polyphenoloxidase. This
is promoted by the presence of oxygen, and fruit
juices are therefore routinely deaerated prior to
pasteurization. The difference between the
whiteness of raw milk and that of pasteurized milk
is due to homogenization, and pasteurization alone
has no measurable effect.
A small loss of volatile aroma compounds during
pasteurization of juices causes a reduction in
quality and may also unmask other cooked
flavors.

Vitamin loss
In fruit juices, losses of vitamin C and carotene are
minimised by deaeration. Changes to milk are
confined to a 5% loss of serum proteins and small
changes to the vitamin content
Vitamin losses
during
pasteurization of
milk

HEAT PENETRATION TEST


Process of putting a temperature
sensitive element in food container
and gathering temperature data over a
time course during a thermal process.
Reports on penetration tests need to
state the type of thermocouple used
and where the thermocouple was
placed.

For penetration test the


thermocouple should be placed in
the coldest place of the container
for conduction heating product it is
located at a geometric center of
container
for convection heating products it is
located
1/10 to 1/5 of the container height
from the
bottom of the container

Public health hazard

Clostridium botulinum is the main


public hazard b/c spores are heat
resistant. Spores may survive when heat
processing is insufficient. The health
hazard is due to ability of Cl. botulinum
to grow under anaerobic conditions and
to produce toxin.

Classification of thermal processes


based on processing temperature

Sterilization >100 oC
Pasteurization < 100 oC

Classification of thermal processing based


on method of product packaging

Terminal processes
Aseptic processes
Hot pack/hot fill processes

Food classification

Low acid food pH > 4.6

Acid food pH 4.6

Acid Foods
pH 4.6
Generally all fruits
Tomatoes, with added acid
Sauerkraut and fermented pickles
Foods to which large amounts of
acid are added

Low Acid Foods


pH > 4.6
Generally all vegetables
Meats
Poultry
Seafood
Soups
Mixed canned foods

Retorting consist of :

heating phase:
removal of air, come-up
time (CUT) , holding time at
processing temperature
cooling phase

Types of retorts:
Still retorts (nonagitating retorts):
vertical, horizontal, malo, hydrostatic.
Agitating retorts: sterilmatic, orbitort,
rotomat,
Flame sterilizers
Aseptic systems

Still retort - vertical retort

Still retort -hydrostatic retort

Agitating retort - Sterilmatic

Agitating Retort - ORBITORT

Effect of heat on microorganisms


Yeast are the least resistant, followed by
mold and then bacteria. All vegetative cells
are destroyed instantly at 100 0C . Spores of
C. botulinum, C. sporogenes, C.
bifermentans, C. butiricum, C.
pasteurianum, C. perfringens, C.
thermosaccharolyticum, D. nigrificans, and
B. stearothermophilus are very heat
resistance.

Equivalent processing times

330
150
36
10
5.27
2.78
1.45
0.78

min at
min at
min at
min at
min at
min at
min at
min at

100 oC
104 oC
110 oC
116 oC
118 oC
121 oC
124 oC
127 oC

The destruction of
microorganisms is affected
by:

their inherent resistance


by environmental influences during
the growth and formation
the heating time & temperature
pH
humidity
protective effect of food
components: fat, proteins, salt

Order of destruction of
microorganisms
The death of bacteria exposed to
wet heat is of logarithmic order.
The logarithmic order means that
theoreti- cally the survivors can be
reduced to less than one. Thus the
number of survivors may become
very small such as one survivor in
million units etc.

The survivor curve

The number of viable bacteria plotted on


the logarithmic scale against the
corresponding heating time (processing
time) on the linear scale provides the
graph known as
the
survivor curve.

DECIMAL REDUCTION TIME, DT


The time in minutes required to
reduce the viable cells in
suspension of bacteria to one
tenth of their original value. The
slope of semilogarithmic survivor
curve determi -nes the decimal
reduction time.

The logarithmic model for


microbial destruction is
described by the equation
U =DT *(log N - log N )
0

U - the equivalent heating time at


processing temperature
N0 - the initial numbers of
microorganisms
Nu -the number of microrganisms after
heating

Survivor Curves at Different


Temperatures.

Comparison of D for Microbial


Population

THERMAL DEATH TIME

The longest time when the unit


test are positive for growth and
the shortest time when the
units are negative

The thermal death (TDT) curve


The value of F plotted on the
logarithmic scale against the
corresponding temperature on
the linear scale provides graph
known as TDT curve.

Thermal Death Time Curve

The thermal resistance curve


Values of DT plotted on the
logarithmic scale against the
corresponding temperature on
the linear scale provide a
graph called phantom thermal
death time curve or thermal
resistance curve.

Parameter Z

The parameter Z
represents the number of
degrees of Fahrenheit,
centigrade, or Kelvin
necessary to cause the Fvalue or D value to change by
a factor ten.

TDT curve is described by


equation:

Log FT = ( Tref - T)/Z +


Log Fref
Q10
Q10

Z = 10/log Q10
- 2.2- 4.6 dry heat
- 8 - 20
wet heat

Lethal rate

It is described as minutes at T
ref per minute at T. Can be
calculated using the following
equation:
L = Fref/FT = 10

(T -Tret)/ Z

Z = 10 C or 18 F, Tref = 121.1
C or 250 F

Sterilization value of heat process,


F

F = Dref * (log N0 - log NF )


F = t * Li

F = L *dt

Sterilization
( 250 F T )

t Fo 10
Thermal death time:

The z value is the temperature increase that will


result in a tenfold increase in death rate
The typical z value is 10C (18F) (C. botulinum)

Fo = time in minutes at 250F that will produce the


same degree of sterilization as the given process at
temperature T
Standard process temp = 250F (121.1C)

Thermal death time: given as a multiple of D

Pasteurization: 4 6D
Milk: 30 min at 62.8C (holder method; old batch
method)
15 sec at 71.7C (HTST high temp./short time)
Sterilization: 12D
Overkill: 18D (baby food)

Sterilization
z

Thermal Death Time


Curve (C. botulinum)
(Esty & Meyer, 1922)
( 250 F T )

t Fo 10

t = thermal death time, min


z = T for 10x change in t,
F
Fo = t @ 250F (std. temp.)

2.7

Sterilization
Thermal Death Rate Plot
(Stumbo, 1949, 1953; ...)
D

D = decimal reduction time


N
t

D
No

ln

Dr = 0.2

N No ek

121.1

Sterilization equations

D To T
log

Do
z

( 250 T )

DT D250 10

Fo FT
No
log


Do DT
N

Fo D250

No
log
N

(T 121.1 C )

(T 250 F )

Fo t 10

Fo t 10

Sterilization
Popular problems would be:
Find a new D given change in
temperature
Given one time-temperature
sterilization process, find the new
time given another temperature,
or the new temperature given
another time

Example 3
If D = 0.25 min at 121C, find D at
140C.
z = 10C.

Example 3
equation
substitute
solve

D To T
log

Do
z

D121 = 0.25 min


z = 10C

D140
121.1C 140C
log

10C
... 0.25 min

answer:

D140 0.003 min

Example 4
The Fo for a process is 2.7 minutes. What would be the
processing time if the processing temperature was
changed to 100C?

NOTE: when only Fo is given, assume


standard processing conditions:
T = 250F (121.1C); z = 18F (10C)

Example 4
Thermal Death Time
Curve (C. botulinum)
(Esty & Meyer, 1922)
(121.1 C T )

t Fo 10

t = thermal death time, min


z = T for 10x change in t,
C
Fo = t @ 121.1C (std.
temp.)

2.7

Example 4
t Fo 10

(121.1 C T )
z

t100 (2.7 min) 10

t100 348 min

(121.1 C 100 C )
10 C

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