Comparison of a computer evaluation with a standard evaluation of retort pouch thermal processing

Flexible retort pouches (188x127x25.4 mm) filled with 10% bentonite suspension, tomato ketchup and potato puree were processed under computer control using steam-air or hot water, and the heating/cooling curves and thermal diffusivities were determined. A computer method, developed for the evaluation of the thermal process using the one-dimensional heat conduction equation, was used to calculate F ₀ values which were then compared with those obtained using the General- and the Stumbo's Formula methods. Temperatures at the pouch centre estimated by the Formula- and the Computer method were in good agreement with those obtained experimentally. The F ₀ values estimated by the computer method were closer to the F ₀ values estimated by the General method than those obtained by the Formula method.     

Continuous Flow Microwave‐Assisted Processing and Aseptic Packaging of Purple‐Fleshed Sweetpotato Purees

ABSTRACT: Pumpable purees from purple‐flesh sweetpotatoes (PFSP) were subjected to microwave heating using a 60 kW, 915 MHz continuous flow system, followed by aseptic packaging in flexible containers to obtain a shelf‐stable product. Initial test runs were conducted using a 5 kW 915 MHz microwave system to measure dielectric in‐line properties and examine the puree temperature profiles. The results demonstrated uniformity in heating of the puree at sterilization temperatures (>121 °C), and the dielectric constants and loss factors were within the range of published values for orange‐fleshed sweetpotato purees. The pilot‐scale test runs in a 60 kW microwave unit produced shelf‐stable puree packages stable at room temperature. Polyphenolic content of the PFSP purees were evaluated and the results showed that while total phenolics increased (5.9%) and total monomeric anthocyanins slightly decreased (14.5%) with microwave application, antioxidant activity determined by 2,2‐diphenyl‐1‐picrylhydrazyl (DPPH) radical scavenging activity and oxygen radical absorbance capacity (ORAC) assays did not significantly change as a result of microwave processing. Color values showed that microwave‐processed samples differed from fresh puree in saturation and hue angle, but not in overall color change. PFSP purees increased in gel strength when microwave processed, packaged, and stored, but the gel could be easily disrupted into flowable purees. Overall, high‐quality retention can be obtained by microwave processing and aseptic packaging of PFSP purees so that they can be used as functional food ingredients.     

Improved Aseptically Filled Sweet Potato Purees

A high quality sweet potato puree with better color stability than frozen purees was produced by flash sterilization followed by aseptic packaging. Starch conversion time was shortened by slicing the sweet potatoes and accurately controlling the temperature during conversion. Processing of inoculated purees for 13 sec at 138°C followed by aseptic filling was adequate for commercial stability. The effect of several processing variables on puree and sweet potato souffle quality was examined. Improved quality and storage stability of sweet potato purees were accomplished by flash sterilization at very high temperatures followed by aseptic packaging.     

Determination of a process time for a new product: canned low acid artichoke hearts

In order to obtain a process time for canned low acid artichoke hearts, the heat resistance of Clostridium sporogenes PA 3679 in phosphate buffer (pH 7) and in artichoke puree (pH 5.2) was determined in the range of 100–118°C. D _T values in artichoke puree were determined by the most probable number and plate count methods. D _121°C values were deduced by extrapolation of the curves. An F 8.3/121 (see nomenclature section) target value of 1.8 min, equivalent to an F ₀= 2.5 min, was established considering a D _121°C value of 0.36 min for artichoke puree. The cold point for canned artichoke hearts in 1/2 kg (71.5x117 mm) cans was determined, a set of heat penetration and cooling curves were obtained and the values of the parameters ' j ' and ' f ' were found. A process time was deduced, 21.5 and 23 min of heating at 121°C, following the methods of Patashnik (1954) and Hayakawa (1970, 1974) respectively, in order to reach the F ₀ target of 2.5 min for this new canned food. This process was adequate, as the inoculated experimental pack test showed no altered cans out of 50 inoculated after 21.5 min of heating at 121°C.     

Immobilized bacterial spores for use as bioindicators in the validation of thermal sterilization processes

Spores of Bacillus subtilis ATCC 6051 and Bacillus stearothermophilus NCTC 10003 were immobilized in monodisperse alginate beads (diameter, 550 microm +/- 5%), and the capacity of the immobilized bioindicators to provide accurate and reliable F-values for sterilization processes was studied. The resistance of the beads to abrasion and heat was strong enough to ensure total retention of the bioindicators in the beads in a sterilization cycle. D- and z-values for free spores were identical to those for immobilized spores, which shows that immobilization does not modify the thermal resistance of the bioindicators. A D(100 degrees C) value of 1.5 min was found for free and immobilized B. subtilis spores heated in demineralized water, skimmed milk, and milk containing 4% fat, suggesting that a lipid concentration as low as 4% does not alter the thermal resistance of B. subtilis spores. Providing that the pH range is kept between 3.4 to 10 and that sufficiently low concentrations of Ca2+ competitors or complexants are present in the medium, immobilized bioindicators may serve as an efficient, accurate, and reliable tool with which to validate the efficiency of any sterilization process. The environmental factors (pH, media composition) affecting the thermoresistance of native contaminants are intrinsically reflected in the F-value, allowing for a sharper adjustment of the sterilization process. Immobilized spores of B. stearothermophilus were successfully used to validate a resonance and interference microwave system that is believed to offer a convenient alternative for the sterilization of temperature-sensitive products and medical wastes.     

Artificial neural network modeling for temperature and moisture content prediction in tomato slices undergoing microwave-vacuum drying

ABSTRACT:  Inputs for ANN (multihidden-layer feed-forward artificial neural network) models were drying time ( t _{i + 1}), initial temperature ( T ₀), moisture content ( MC ₀), microwave power, and vacuum pressure. The outputs were temperature ( T _{i + 1}) and moisture content ( MC _{i + 1}) at a given t _{i + 1}. After training the ANN models with experimental data using the Levenberg-Marquardt algorithm, a two-hidden-layer model (25-25) was determined to be the most appropriate model. The mean relative error (MRE) and mean absolute error (MAE) of this model for T _{i + 1} were 1.53% and 0.77 °C, respectively. In the case of MC _{i + 1}, the MRE and MAE were 11.48% and 0.04 kg_water/kg_dry, respectively. Using temperature ( T _i ) and moisture content ( MC _i ) values at t _i in the input layer significantly reduced the computation errors such that MRE and MAE for T _{i + 1} were 0.35% and 0.18 °C, respectively. In contrast, these error values for MC _{i + 1} were 1.78% (MRE) and 0.01 kg_water/kg_dry (MAE). These results indicate that ANN models were able to recognize relationships between process parameters and product conditions. The model may provide information regarding microwave power and vacuum pressure to prevent thermal damage and improve drying efficiencies.     

Sterilization of Scrambled Eggs in Military Polymeric Trays by Radio Frequency Energy

ABSTRACT: There is a current need for fresh-cooked-like yet shelf-stable egg products for U.S. military combat rations. Novel thermal processes based on radio frequency (RF) energy can shorten the heating time and reduce overheating. This technology was explored to produce shelf-stable egg products for combat ration development. Clostridium sporogenes (PA 3679) spores were used as a surrogate to validate the RF sterilization process to control Clostridium botulinum . Decimal reduction time (D value) of PA3679 in scrambled eggs was determined using aluminum thermal-death-time (TDT) tubes. The thermal inactivation kinetic information was then used in inoculated pack studies to validate a novel thermal process based on 27.12 MHz radio frequency (RF) pilot scale unit. Trays of scrambled eggs inoculated with PA 3679 were subjected to 3 processing levels: target process (F₀ about 5.3 min), under-target process (F₀ about 3.0 min), and over-target process (F₀ about 9.1 min). The results of the microbial challenge study showed that microbial destruction from the RF process agreed with sterilization values calculated from time-temperature data measured at the cold spot in the treated trays. A comparison of RF- and retort-treated scrambled eggs showed significant differences in the degree of lightness ( L *) and redness ( a *). RF-processed egg was less brown compared with conventional retorted eggs. Retort treatment of fully cooked scrambled eggs had higher hardness, springiness, and smaller cohesiveness than RF -treated samples. This study suggests that RF thermal processes can produce safe, shelf-stable sterilized scrambled eggs for both military and civilian uses.     

Effect of Thermal Process Time on Quality of "Shrimp Kuruma" in Retortable Pouches and Aluminum Cans

ABSTRACT:  The effect of processing time on biochemical, sensory characteristics, and instrumental texture profiles of "Shrimp Kuruma" in retortable pouches and aluminum cans with equal pack weight and lethality was studied. Processing in pouches resulted in a 35% reduction in processing time compared to cans for equal lethality ( F ₀ 8.0). Thermal processing resulted in a 14% loss of water in canned samples compared to 9% in pouched products. Thermal processing resulted in an increase in the volatile compounds and a decrease in the oxidation products in both canned and pouched samples. Products processed in pouches were rated as lighter in color, more succulent, and more desirable in firmness compared to products in cans. Chewiness and hardness showed a significant difference ( P < 0.05) between the 2 treatments.     

QUALITY OF ORANGE JUICE DRINK SUBJECTED TO A PREDICTIVE MODEL-BASED PASTEURIZATION PROCESS

The utility of a previously developed predictive model for the decimal reduction time ( D _72C) of Salmonella Typhimurium (ATCC 13311) in citrus systems was validated by establishing a pasteurization process ( P _72C) for Philippine native orange juice drink (POD). Quality characteristics of the pasteurized POD were evaluated and used as bases for assessing the utility of the developed model. The ^p P _72C for POD was calculated by multiplying the model-generated D _72C of the reference strain with the recommended order of lethality ( m ) of 5.00 log₁₀ cycles. A ^a P _72C was likewise calculated based on D _72C that resulted from actual thermal inactivation study of the reference strain on POD. Pasteurization resulted to PODs with significantly ( P <  0.05) altered color, microbial quality and sensory profile. Except for the overall quality, differences in the consumer acceptance of various unpasteurized and pasteurized PODs quality characteristics were found to be not significant.

PRACTICAL APPLICATIONS

A mathematical model was developed to estimate the thermal death times of the pathogen Salmonella Typhimurium (ATCC 13311) from the pH, titratable acidity (% citric acid) and soluble solid (°Brix) values of suspending citrus systems. In this study, the utility of this model in establishing a pasteurization process for a test orange juice drink was determined. As the establishment of specific thermal process schedule for individual food products can be difficult, utilization of the validated model shall be a convenient alternative to the traditional but rigorous process.     

HIGH HYDROSTATIC PRESSURE PROCESSING OF PEACH PUREE WITH AND WITHOUT ANTIBROWNING AGENTS

High hydrostatic pressure (HHP) (103 to 517 MPa) was applied for selected times (5 to 25 min) on peach puree with and without the addition of antibrowning agents (1000 ppm ascorbic acid or 300 ppm cysteine). Polyphenoloxidase (PPO) activity was assessed before and after HHP processing. Peach purees were stored at 3C for 13 days and then at 22C for 15 additional days. A z_p value of 224 MPa, in a range from 207 to 517 MPa of pressure, was obtained for peach puree without the addition of antibrowning agents. PPO activation at 103, 207 and 310 MPa or inhibition at 414 and 517 MPa was observed in peach purees containing added ascorbic acid. More than 50% inactivation of PPO was observed after adding cysteine to the peach puree and 99% inhibition was observed after 517 MPa of pressure at the experimental times. The higher the pressure treatment and the longer the treatment time for inactivating PPO, the less the discoloration of the peach puree with and without antibrowning agents during storage at low temperatures.     

Dielectric Properties of Sweet Potato Purees at 915 MHz as Affected by Temperature and Chemical Composition∗

A process for rapid sterilization and aseptic packaging of sweet potato puree using a continuous flow microwave system operating at 915 MHz has been successfully developed. In microwave processing, dielectric properties have a major role in determining the interaction between purees and the electromagnetic energy. The objective of this research was to determine how dielectric properties are affected by temperature and chemical composition of purees derived from thirteen sweet potato cultivars with varying flesh colors. Results indicated that temperature, moisture, sugar and starch content had a pronounced effect (p < 0.001) on dielectric properties measured from 15°C to 145°C at 915 MHz. Dielectric constant decreased with increasing temperature, while dielectric loss factor increased quadratically. Power penetration depth of all cultivars decreased with increasing temperature. Predictive equations were developed for dielectric constant (R²?=?0.82) and dielectric loss factor (R²?=?0.90) as a function of temperature, moisture, sugar, and starch. The predictive equations would be useful in determining the dielectric properties of sweet potato purees for the microwave processing technology.     

APPLICATION OF CHLORINE TO REDUCE POPULATIONS OF ESCHERICHIA COLI ON BEEF

The effects of chlorine against 2 strains of E. coli attached to the surface of beef carcass tissue (BCT) were examined using a model carcass washer. Lean and adipose BCT with approximately 5 log ₁₀ CFU/cm ² E. coli bacteria were spray-treated with water and sodium hypochlorite (NaOCl) to give chlorine concentrations of 50, 100, 250, 500, or 800ppm, incubated for 24 h, 4C, and E. coli populations enumerated. Spray treatments with water did significantly (P < 0.05) reduce the bacterial populations of either organism attached to lean or adipose BCT, as compared to populations of controls; however, reductions were less than 0.60 log ₁₀ CFU/cm ². Treatments with 500 and 800 ppm chlorine against E. coli ATCC 25922 attached to BCT resulted in the greatest reductions of 1.22 and 1.28 log ₁₀ CFU/cm ², respectively. At 800 ppm chlorine , E. coli O157:H7 ATCC 43895 attached to BCT was reduced by 1.04 log ₁₀ CFU/cm ², whereas spray treatments with 50, 100, 250, and 500 ppm chlorine resulted in reductions of < 1 log ₁₀ CFU/cm ². Spray treatments with chlorine from sodium hypochlorite solutions reduced populations of E. coli, however, these reductions were not sufficient to completely inactivate the bacteria attached to red meat .     

Effect of Heat Processing on the Texture Profile of Canned and Retort Pouch Packed Oil Sardine (Sardinella longiceps) in Oil Medium

ABSTRACT: Sardine in oil was canned at 3 different Lethality values (F₀ 5,7, and 9) in retort pouches and aluminum cans in stationary retort. Process time calculations were done mathematically to find out the actual process time. Sardine in oil processed in retort pouches had a lower process time compared with aluminum cans for each F₀ value. Instrumental texture analysis was done using a food texture analyzer to study the effect of thermal processing on the texture of thermally processed sardine in oil in aluminum cans and retort pouches. As the F₀ value and cook value increased in both the retort pouches and aluminum cans, the textural properties showed a decreasing trend. Hardness of the product canned in both aluminum cans and retort pouches decreased with increase in F₀ values.     

Inactivation Kinetics of Geobacillus stearothermophilus Spores in Water Using High-pressure Processing at Elevated Temperatures

ABSTRACT: Establishment of a high-pressure sterilization process requires data on pressure and temperature-dependent inactivation kinetics of target pathogenic, spoilage, or surrogate spore-forming bacteria in the food being tested. The objective of this study was to examine the response of Geobacillus stearothermophilus ATCC10149 spores to various temperature, time, and pressure combination treatments (500 to 700 MPa; 92°C to 111°C, 0.01 to 360 s). The pressure inactivation of spores was characterized at elevated temperatures under isobaric and isothermal conditions during the holding time using a laboratory-scale high-pressure unit. The inactivation kinetics was well described by the log-linear regression model. As expected, the rate of spore inactivation increased with increasing pressure and temperature. Decimal reduction times at constant pressure ( D _T,P values) varied from 29.4 to 108.8 s at 92°C, 17.4 to 76 s at 100°C, and 6.1 to 51.3 s at 111°C within the pressure range of 500 to 700 MPa. The resistance of spores to temperature and pressure was characterized with z_T and z_P values and compared with their resistance to conventional steam heating. The conventional thermal resistance of G. stearothermophilus species did not correlate to the thermal resistance at high pressure. The study provides kinetic data on the effects of pressure and temperature on the inactivation of a heat-resistant bacterial spore species under conditions applicable to the commercial processing of low-acid foods.     

Irradiation as a Pretreatment to Thermal Processing

ABSTRACT: The Paired Equivalent Isothermal Exposures (PEIE) method was used to quantify the impact of irradiation pretreatments (0, 1.0 and 3.0 kGy) on thermal sensitivity of Bacillus stearothermophilus spores in canned pea puree. Mean rate constants, k_121.IC and activation energy values, E_a, for spore inactivation were 0.26, 0.28 and 0.38 min⁻¹ and 250, 200 and 200 kJ/mol for 0, 1.0 and 3.0 kGy, respectively. These parameters were used to simulate thermal processes that achieve equivalent sterilizing values. Computer retort simulations demonstrated the potential of irradiation pretreatment to reduce overall thermal exposures by about 10% and 25% for product pretreated with 1.0 and 3.0 kGy, respectively.     

Efficacy of Pressure-Assisted Thermal Processing, in Combination with Organic Acids, against Bacillus amyloliquefaciens Spores Suspended in Deionized Water and Carrot Puree

ABSTRACT:  Effect of organic acids (acetic, citric, and lactic; 100 mM, pH 5) on spore inactivation by pressure-assisted thermal processing (PATP; 700 MPa and 105 °C), high pressure processing (HPP; 700 MPa, 35 °C), and thermal processing (TP; 105 °C, 0.1 MPa) was investigated.  Bacillus amyloliquefaciens  spores were inoculated into sterile organic acid solutions to obtain a final concentration of approximately 1.3 × 10⁸ CFU/mL.  B. amyloliquefaciens  spores were inactivated to undetectable levels with or without organic acids after 3 min PATP holding time. At a shorter PATP treatment time (approximately 2 min), the inactivation was greater when spores were suspended in citric and acetic acids than in lactic acid or deionized water. Presence of organic acids during PATP resulted in 33% to 80% germination in the population of spores that survived the treatment. In contrast to PATP, neither HPP nor TP, for up to 5 min holding time with or without addition of organic acids, was sporicidal. In a separate set of experiments, carrot puree was tested, as a low-acid food matrix, to study spore recovery during extended storage following PATP. Results showed that organic acids were effective in inhibiting spore recovery in treated carrot puree during extended storage (up to 28 d) at 32 °C. In conclusion, addition of some organic acids provided significant lethality enhancement ( P  < 0.05) during PATP treatments and suppressed spore recovery in the treated carrot puree.     

Finding critical variables for food heating

It is important to identify intrinsic critical variables affecting the heating of products in processes aiming to achieve microbiological safety. The Taguchi method has enabled the identification of critical variables for heating of a complex canned product (spaghetti in a sauce) in an agitated process in a water immersion retort. Within the ranges tested one of eleven variables exerted a large effect upon product heating. The most important variable was the concentration of tomato puree in the sauce, which affected the process F ₀ by15–18 min between the two concentrations tested.     

The effect of trehalose, sucrose and maltodextrin addition on physicochemical and sensory aspects of freeze - dried strawberry puree

Use of trehalose as a novel drying aid to produce freeze-dried strawberry puree was studied and compared with conventional drying aids for fruit purees, namely sucrose and maltodextrin (MD). Glass transition temperature ( T _g), colour, sensory profile and consumer preference were determined. Purees dried with MD and/or trehalose presented higher T _g values as compared to sucrose. Sensory evaluation indicated that samples dried with trehalose retained fresh strawberry aroma and flavour, keeping a good sweetness/sourness balance, while puree dried with sucrose was mostly sweet. Addition of MD caused an increase in products visual viscosity and sourness, attributes which were negatively correlated to preference. Trehalose presented several advantages for increasing the quality of freeze dried fruit purees. It raised T _g, gave an adequate sweetness/sourness balance, and allowed a better perception of fresh strawberry flavour.     

Influence of vitamin E supplementation on spontaneous oxidized flavour of milk in dairy buffaloes

Twenty-four Murrah buffaloes (60 days pre-partum) were divided into four equal groups (T ₁ , T ₂ , T ₃ and T ₄ ) and were supplemented with 0, 1000, 1500 and 2000 IU α-tocopheryl acetate per day up to 30 days of lactation, and half of these doses from 30 to 60 days of lactation. Milk samples collected fortnightly were analysed for vitamin E, fat, and development of oxidized flavour, with and without copper addition by a panel of judges, and chemically by the thiobarbituric acid test. Scores for oxidized flavour ranged from 0 to 10 with 0–4 as definite, 5–7 as light and 8–10 having no defect. The α-tocopherol content in milk fat (µg/g) averaged 20.55, 25.56, 29.98 and 31.38 in T ₁ , T ₂ , T ₃ and T ₄ groups, respectively. The addition of Cu in the milk significantly increased milk fat oxidation. Better stability of milk in T ₃ and T ₄ groups was observed, which might be due to a higher level of milk α-tocopherol. Addition of 1500 IU α-tocopheryl acetate in the diet of buffaloes helped in improving the oxidative stability of milk.     

Acidified Sodium Chlorite as an Alternative to Chlorine for Elimination of Salmonella on Alfalfa Seeds

ABSTRACT:  The health and environmental hazard associated with the use of chlorine for food processing has been documented previously. This study was conducted to determine if acidified sodium chlorite (ASC) could be used to replace calcium hypochlorite (Ca[OCl]₂) for disinfection of alfalfa seeds. Contaminated seeds containing approximately 1.5 × 10⁷ CFU/g of Salmonella were treated with ASC or Ca(OCl)₂ at different concentrations and for different periods of time. Results showed that the efficacy of ASC and Ca(OCl)₂ for elimination of Salmonella on contaminated seeds could be improved greatly by extending the treatment time from the traditional 15 to 45 min. Treatment of seeds with 800 ppm of ASC for 45 min reduced the number of Salmonella by 3.9 log units, approximately 1.2 log units higher than that treated with 20000 ppm of Ca(OCl)₂. Treatment of seeds with a lower concentration (100 to 400 ppm) of ASC for 45 min reduced the number of Salmonella by 1.3 to 2.2 log units. Soaking alfalfa seeds in 800 ppm of ASC for 45 min did not affect seed germination. However, soaking seeds in 20000 ppm of Ca(OCl)₂ for 45 min reduced seed germination by 20%. Unlike Ca(OCl)₂, antimicrobial efficiency of ASC was not affected by pre-exposure to alfalfa seeds. Data presented also showed that Salmonella on newly inoculated seeds that had been stored at 4 °C for less than 7 d were more sensitive to sanitizer treatment than those on seeds that had been stored for 4 wk or longer.