Better Thermal Processing of Foods: In Container Processing. phariyadi.staff.ipb.ac.id

Better Thermal Processing of Foods:

In Container Processing

Purwiyatno Hariyadi phariyadi.staff.ipb.ac.id

• Departemen Ilmu dan Teknologi Pangan, Fateta, IPB • Southeast Asian Food & Agricultural Science & Technology (SEAFAST) Center, Bogor Agricultural University, BOGOR, Indonesia (www.seafast.ipb.ac.id) • Anggota Institute for Thermal Process Specialist (IFTPS)-USA (www.iftps.org)

Introduction

“potentially hazardous foods” (PHF)  “high risk foods (HRF)

Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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Introduction “Potentially Hazardous Foods” (PHF) (1962/US PHS) Any perishable food which (i) consists in whole or in part of milk or milk products, eggs, meat, poultry, fish, shellfish, or (ii) other ingredients capable of supporting the rapid and progressive growth of infectious or toxigenic microorganisms.

Introduction FDA 2001 – can’t easily define hazardous foods ~

PHF: Foods with more than a 1 log increase of a pathogen when the food is stored at 24 °C (75 °F) for a period of time that is 1.3 times the shelf life as determined by the manufacturer.


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Introduction Australian Food Standards Code 2002 Potentially hazardous foods are foods that meet both the criteria below: • they might contain the types of foodpoisoning bacteria that need to multiply to large numbers to cause food poisoning; and • the food will allow the food-poisoning bacteria to multiply.

Introduction Australian Food Standards Code 2002 The following foods are examples of potentially hazardous foods (1): • raw and cooked meat (including poultry and game) or foods containing raw or cooked meat such as casseroles, curries and lasagne; • smallgoods such as Strasbourg, ham and chicken loaf; • dairy products, for example, milk, custard and dairybased desserts such as • cheesecakes and custard tarts; • seafood (excluding live seafood) including seafood salad, patties, fish balls, stews containing seafood and fish stock; Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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Introduction Australian Food Standards Code 2002 The following foods are examples of potentially hazardous foods (2): • processed fruits and vegetables, for example salads and cut melons; • cooked rice and pasta; • foods containing eggs, beans, nuts or other protein-rich foods such as quiche, fresh pasta and soy bean products; and • foods that contain these foods, for example sandwiches, rolls and cooked and uncooked pizza

Factors Influence the Heat Resistance of Microbial • • • •

Species of microorganisms. Acidity (pH) Water activity (aw) Food Oxygen (some of the spores with high thermal resistance are anaerobic). • Food composition


4



Characteristics of potentially hazardous foods: 1

aw M

0.85

H

L

M

pH

0 4.5

10

14


5

Managing riks of potentially hazardous foods: food processing 1

aw M

0.85

Pengasaman (pH controlled)

H

Pengeringan, Penggaraman, dll (aw controlled) L

M

pH

0 4.5

10

14

Managing riks of potentially hazardous foods: food processing 1

aw M

0.85

H

Heating = L M Thermal Processing pH

0 4.5

10

14


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Thermal Processing: Tujuan • Menghasilkan produk yang aman: memenuhi persyaratan peraturan/standar (keamanan) pangan • Menghasilkan produk awet pada (i) suhu kamar (sterilisasi) atau (ii) suhu refrigerasi (pasteurisasi). • Meminimalkan kerusakan zat gizi dan atribut mutu • Meningkatkan produktivitas  memaksimalkan “yields” • Mengurangi biaya

Thermal Processing: Tujuan • Menghasilkan produk yang aman: memenuhi persyaratan peraturan/standar (keamanan) pangan • Menghasilkan produk awet pada (i) suhu kamar (sterilisasi) atau (ii) suhu refrigerasi (pasteurisasi). • Meminimalkan kerusakan zat gizi dan atribut mutu • Meningkatkan produktivitas  memaksimalkan “yields” • Mengurangi biaya Better Thermal Processing?? ~ Optimasi


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Thermal Processing: Tujuan

 Mengoptimalkan yield dan produktivitas, meminimalkan kerusakan mutu (dan gizi) tanpa mengkompromikan persyaratan keamanan pangan Better Thermal Processing?? ~ Optimasi

Thermal Processing:  Kasus A Highly PHFs pH > 4.5 dan aw>0.85 Proses Panas  Sterilisasi Komersial

 Terkemas/tertutup dengan kedap (hermetis)  Awet pada suhu ruang (shelf stable)  Tidak memerlukan refrigerasi  Contoh : Sardine, tuna dalam kaleng, susu steril, dll


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Thermal Processing:  Kasus B Highly PHFs pH > 4.5 dan aw>0.85 Proses Panas  Pasteurisasi

 Terkemas/tertutup dengan kedap (hermetis)  Hanya beberapa hari pada suhu refrigerasi  Harus refrigerasi  Contoh : Susu pasteurisasi, daging udang, kepiting, dan hasil laut lainnya

Thermal Processing:  Kasus C Highly PHFs pH > 4.5 dan aw<0.85 pH < 4.5 dan aw>0.85 Proses Pasteurisasi &/atau Hot-fill-hold

 Terkemas/tertutup dengan kedap (hermetis)  Awet (shelf stable), dengan/tanpa refrigerasi  Bisa tanpa refrigerasi  Contoh : Sari buah, sos tomat, jem/jelly, dll


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Thermal Processing • Hot-filling (Hot-fill-hold) • Pasteurisasi • Sterilisasi


Process Objectives (Process Criterias): • •

to kill microorganisms to keep away microorganisms


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Food Safety Objectives : • •

Protect public health hazard (reduce economic spoilage)




Food Safety Objectives : • •

Protect public health hazard (reduce economic spoilage)

? Bagaimana mengevaluasi/ menilai keamanan produk pangan yang diproses panas?


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Thermal Processing • Hot-filling (Hot-fill-hold) • Pasteurisasi • Sterilisasi Ingredients

Packaging Material

Cutting

Heating (sterilizing/ Addition of Liquid, Mixing Pasteurizing)

Forming

Sterilizing

Aseptic Filling

Aseptic/Continuous Processing

Aseptic Closing

Coding

Filled Pack

Thermal Processing • Hot-filling (Hot-fill-hold) • Pasteurisasi • Sterilisasi Ingredients

Preparation: Preparation cutting, etc of liquid

Filling Ready made (particulates) CAN

Filling (liquid)

In-Container Processing

Closing

Retorting

Labelling

Filled Can


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Thermal Processing In-container thermal processing

Produk

Kaleng, botol, gelas, dll Pengisian

Sterilisasi (pemanasan)

+ tutup

Produk steril dalam wadah




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Heat Resistance of Microbial


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Heat Resistance of Microbial

D values of microorganisms of importance in heat processing

Spores

B. stearothermophilus C. thermosaccharolyticum D. nigrificans C. botulinum – proteolytic C. sporogenes B. coagulans B. Sporothermodurans

D 121.1

D140

(min)

(s)

4.0 - 5.0 3.0 - 4.0 2.0 - 3.0 0.1 - 0.23 0.1 - 1.5 0.01 - 0.1

0.9

3,4 -7.9


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Comparison of Z and Ea for Quality Attributes and Microbial Populations of importance in heat processing Reaksi

E (kJ/mole)

Z (oC)

Enzyme reactions Chlorophyl loss Ascorbic acid Non-enzymatic browning Lipid oxidation Spore destruction Veg. cell destruction Protein denaturation

0-33.5 21-113 21-167 37.7-167 41.9 251-335 209-628 335-502

26-142 11.8-142 8.7-11.8 4.7-14.2 5,9-8.9

PROCESS CALCULATIONS

• Lethal Rate (LR)= Lethal value (LV) • Time/Temp Process & LR • LR Curve for Thermal Process


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PROCESS CALCULATIONS 1

LR = LV = 10

T(t) - 121.1 z

= 10

121.1 - T(t) z

T(oC)

T(oF)

LR(z=10oC)

90 95 100 105 110 115 120 121,1 125 129

194 203 212 221 230 239 248 250 257 264

0,000776247 0,002454709 0,007762471 0,024547089 0,077624712 0,245470892 0,776247117 1,000000000 2,454708916 6,165950019

PROCESS CALCULATIONS Pemanasan pada suhu konstan, 121,1oC

140 120

0 1 2 3 4 5 6 7 8 9 10 11 12

121,1 121,1 121,1 121,1 121,1 121,1 121,1 121,1 121,1 121,1 121,1 121,1 121,1

1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0

100 Suhu

T(oC) LR(z=10oC)

80 60 40 20 0 0

1

2

3

4

5

6

7

8

9 10 11 12

Waktu

1,2 1,0 0,8 LR

t, min

1 unit sterilisasi 12 unit sterilisasi F0=12

0,6 0,4 0,2 0,0 0

1

2

3

4

5

6

7

8

9 10 11 12


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PROCESS CALCULATIONS Pemanasan pada suhu konstan, 100oC T(oC)

LR(z=10oC)

0 1 2 3 4 5 6 7 8 9 10 11 12

100 100 100 100 100 100 100 100 100 100 100 100 100

0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471 0,007762471

0,0080 LR

t, min

0,0100

0,0060 0,0040 0,0020 0,0000 0

1 2

3

4 5

6

7 8

9 10 11 12

Waktu

Total sterilitas

= 0.007762x12 unit = 0.10091 unit

hanya 0.00776 x pengaruh letal pada 121.1oC Total letalitas = F0 =??

F0 = Do log

N0 N





t

(LR)dt

0

F0 = LR.t


t = heating time (mini) T = Heating temperature, oC

F0 = 1  pemanasan selama 1 menit pada suhu 121.1oC


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PROCESS CALCULATIONS Diketahui :

Mikroba A; D0 = 0,21 menit dikehendaki proses 12 D

Pemanasan pada suhu 121.1oC ………> 12(0,21)=2.52 menit Pemanasan pada suhu 100oC  1/LR100C x 2.52 min = 1/0.00776 x 2.52=324.7 min (5.4 jam) Pemanasan pada suhu 129oC  1/LR129C x 2.52 min = 1/6,166 x 2.52=0.408 min (24.5 detik) Pemanasan pada suhu 50oC  1/LR50C x 2.52 min = 1/0. 000000078 x 2.52 = 32307692.31 menit = 747.8 bulan????!!!! Pada prakteknya :  efek letal panas untuk sterilisasi, umumnya mulai dianggap nyata setelah T>90oC  Teixeira (1992) : no appreciable lethality at T < 210oF(99oC)  suhu produk selama pemanasan tidak konstant …….> T=f(t)  Pemanasan produk dilakukan dalam retort  pengalengan  Pemanasan produk dilakukan dengan HE  aseptik  suhu produk diukur pada SHP/CP

PROCESS CALCULATIONS (for ”In-container sterilisation”)

Produk

Kaleng, botol, gelas, dll Pengisian

Sterilisasi (pemanasan)

+ tutup

Produk steril dalam wadah


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PROCESS CALCULATIONS (for ”In-container sterilisation”) Heat Penetration Test

• Scheduled Process: Venting and heating procedure • Come up time • Operator processing time • Cooling time, ETC

 TR = f(t)

PROCESS CALCULATIONS (for ”In-container sterilisation”) Heat Penetration Test  Tipikal kurva penetrasi panas untuk pangan kaleng dan perubahan suhu retort (TR) selama proses seterilisasi

• Suhu retort di”set” (mis: pada 250oF)

• t untuk mencapai TR : CUT

CUT Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.


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PROCESS CALCULATIONS (for ”In-container sterilisation”) Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan

SHP

SHP:

Slowest Heating Point = Coldest Point Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.


Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.


21

T(oC)

LR(z=10oC)

0 4 8 12 16 20 24

90 105 120 121 100 70 60

0,000776247 0,024547089 0,776247117 0,977237221 0,007762471 0,000007762 0,000000776

F0 = Do log

N0 N

=



t

(LR)dt

0

140 120 100 80 60 40 20 0 0

4

8

12 waktu

16

20

24

0

4

8

12 Waktu

16

20

24

1,2 1,0 LR

t, min

Suhu (C)


0,8 0,6 0,4 0,2 0,0

Fo = luas area di bawah kurva hubungan antara LR dan t Fo = jumlah area trapesium Luas trapesium =  LR1 + LR2  t 2  

 0.776 + 0.97   (12- 8) = 3.506 A = 7 2  


Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.


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PROCESS CALCULATIONS 2. Metoda Formula Persamaan perubahan suhu selama proses pemanasan : T - TR Ti - TR T-Tm Ti-Tm

=e

=

hA CpV

t = e-kt

TP-TR Ti-TR

= exp -(t/L2)

TR-TP TR-Ti

= exp -(k)t

Log(TR-TP)=Log(TR-Ti)-

k t (2,303)

PROCESS CALCULATIONS Dari kurva penetrasi panas : - Tentukan fh - Buat garis vertikal di t=0.6 CUT - Tentukan jI (baca di sumbu kanan Y) - (hitung/tentukan j  j = jI/I  I = RT - IT

Kasus 1 Menentukan nilai Fo; jika diketahui B ........hitung log g = log jI – (B/fh) ...... .dengan diketahui log g  cari fh/U ...... .hitung Fi = 10(250-TR)/z  Fo = fh/[(fh/U)Fi]


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PROCESS CALCULATIONS Dari kurva penetrasi panas : - Tentukan fh - Buat garis vertikal di t=0.6 CUT - Tentukan jI (baca di sumbu kanan Y) - (hitung/tentukan j  j = jI/I  I = RT - IT

Kasus 2 Menentukan nilai B; jika dikehendaki nilai Fo ...... .hitung Fi = 10(250-TR)/z ....... hitung fh/U = fh/(Fo*Fi) ...... .dengan diketahui fh/U  cari log g  B= fh(log jI – log g)

PROCESS ADEQUACY (for Safety Assurance)  Focus : Low Acid Canned Foods

Low Acid Food : a food, other than alcoholic beverages, where any component of the food has a pH > 4.6 and a aw > 0.85.


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Low Acid Canned Food : •= pH > 4.6 • Water Activity > 0.85 • COMMERCIALLY Thermally processed • STERILE Hermetically sealed container • Non-refrigerated

PROCESS ADEQUACY (for Safety Assurance)  Focus : Low Acid Canned Foods Operator Proses

Pengen -dalian Proses

= COMMERCIALLY STERILE Arsip proses


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PROCESS ADEQUACY (for Safety Assurance)  Focus : Low Acid Canned Foods  Perlu GMP yang disiplin Operator Proses

Pengen -dalian Proses

Faktor Kritis

= COMMERCIALLY STERILE Arsip proses


COMMERCIALLY STERILE Performance Standard (USFDA/USDA) :

The product must be processed to achieve commercial sterility and the container in which the product is enclosed must be hermetically sealed so as to be airtight and to protect the contents of the container against the entry of microorganisms during and after processing.


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COMMERCIALLY STERILE Performance Standard (USFDA/USDA) : For a low-acid Produk that receives thermal or other sporicidal lethality processing, that processing must be validated to achieve : • a probability of 10-9 that there are spores of C. botulinum in a container of the produk that are capable of growing, or, • a 12-log10 reduction of C. botulinum, assuming an initial load of  1000 spores per container.

COMMERCIALLY STERILE Performance Standard (USFDA/USDA) : • C. botulinum • DBot,250F = 0.21 menit • 12-log10 reduction C. botulinum  Fo = 2.52 menit


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COMMERCIALLY STERILE Dalam prakteknya … Beberapa nilai-Fo pangan steril komersial di pasar UK Produk Babyfoods Beans in tomato sauce Peas in brine

Fo values 3-5 4-6 6 6-8 3-4 4-6 6-8 3-4 8-10 6-8 12-15 10

Ukuran Kalengs

babyfood All Up to A2 A2 to A10 All Up to A2 A2 to A10 A2 A1 Up to A1 All Ovals

Carrots Green beans in brine Celery Mushrooms in brine Mushrooms in butter Meats in gravy Sliced meat in gravy

COMMERCIALLY STERILE di INDONESIA • Jumlah data terkumpul= 93 (dari 23 FCE) • Kisaran : 1.9 < Fo <148.4 15

UK

14 13 12 11

Frequency

10 9 8 7 6 5 4 3 2 1 0 3

5

7

<

9

11

13

<

3 Fo 15

15

17

19

21

23

25

27

29

31

33

35

39

41

43

45

47

49

51

53

55

149

Calculated F Value


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PASTEURIZED PRODUCTS di INDONESIA

Prequency

• Pangan dgn proses panas minimal (minimally heat processed food): PASTEURISASI • Dinyatakan dalam PU (F185(z=16)) • Dari 67 data : • Nilai PU  23 < PU < 60 • Umumnya berhub dgn keawetan 20 18 16 14 12 10 8 6 4 2 0 2)

25

30

35

40

45

50

55

60

Calculated PU-values

KONDISI INDONESIA? Industri perlu melakukan evaluasi untuk pemastian : i. Good Manufacturing Practices? ii. Kinerja alat pengolahan/retort? iii. Kecukupan panas (nilai-Fo)?


30

KONDISI INDONESIA? Indonesia?

15

Optimisi Mutu • Penentuan T-t optimum • Otomatisasi pengendalian suhu? • Pelatihan Operator

14 13 12 11

Frequency

10 9 8

Berlebihan?

7 6 5 4 3 2 1 0 3

5

7

9

11

13

<

15

17

19

21

23

25

<

7 Fo 19

27

29

31

33

35

39

41

43

45

47

49

51

53

55

149

Calculated F Value

KECUKUPAN PANAS?

• Bandingkan dengan target • Ingat “performance criteria” • Identifikasi titik kritis • Buat “scheduled process” = SOP • Kendalikan titik kritis (next discussion) • Training operator • Maintenance • Perlu authorized person(s)


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3 SYARAT PENGALENGAN PANGAN SUKSES : 1. Perlakuan pemanasan yang cukup : tercapainya sterilitas komersial

2. Wadah/kaleng tertutup secara hermetis lakukan prosedur pengisian dan penutupan kaleng dengan benar

3. Penanganan kaleng dengan baik : Sebelum, selama dan setelah pemanasan memastikan bahwa integritas sambungan dan penutupan tetap terjaga

Selalu ada kemungkinan bahwa bakteri akan masuk kembali dan mencemari produk yang telah Disterilisasi  integritas sambungan dan penutupan adalah faktor penting

Terimakasih phariyadi.staff.ipb.ac.id


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Better Thermal Processing of Foods: In Container Processing. phariyadi.staff.ipb.ac.id

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