Factors Influence the Heat Resistance of Microbial

ITP530/2015

Thermal Processing of Foods Purwiyatno Hariyadi phariyadi.staff.ipb.ac.id

• Department of Food Science and Technology, IPB • Southeast Asian Food & Agricultural Science & Technology (SEAFAST) Center, Bogor Agricultural University, BOGOR, Indonesia (www.seafast.ipb.ac.id) • Member of Institute for Thermal Process Specialist (IFTPS)-USA (www.iftps.org)

ITP530

Factors Influence the Heat Resistance of Microbial

Intrinsic Properties of Foods

• • • •

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

ITP530 Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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Characteristics of potentially hazardous foods: 1

aw M

0.85

H

L

M

pH

0 4.5

10

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Managing riks of potentially hazardous foods: food processing 1

aw M

H

Salah satu teknik yang effektif adalah:

0.85

Pemanasan M = Thermal Processing L

pH

0 4.5

10

14


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Managing riks of potentially hazardous foods: food processing 1 0.85

aw M H •Telah digunakan oleh manusia sejak manusia menemukan api • • • L• • • •

Pemasakan (cooking) Penghangatan kembali (rewarming) Pelelehan (thawing) Blansir (blanching) M Hot filling Pasteurisasi Sterilisasi

pH

0 4.5

10

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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 Better Thermal Processing?? ~ Optimasi ITP530 Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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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 ITP530

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

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Thermal Processing:  Kasus C Medium ‐ 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

Food Safety Objectives : • •

Protect public health hazard (reduce economic spoilage)

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

ITP530

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Ingredients

Preparation: Preparation cutting, etc of liquid

Ready made Filling CAN (particulates)

Filling (liquid)

In-Container Processing

Closing

Retorting

Labelling

Filled Can


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1

Thermal Processing In-container thermal processing

Produk Pengisian

Sterilisasi (pemanasan)

Kaleng, botol, gelas, dll + tutup

Produk steril dalam wadah

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Factors Influence the Heat Resistance of Microbial • • • •



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Factors Influence the Heat Resistance of Microbial • • • •


ITP530

Heat Resistance of Microbial


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Heat Resistance of Microbial

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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

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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

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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

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

F0 = 1  pemanasan selama 1 menit pada suhu 121.1oC ITP530 Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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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????!!!!

ITP530

PROCESS CALCULATIONS 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


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PROCESS CALCULATIONS (for ”In-container sterilisation”)

Produk Pengisian

Kaleng, botol, gelas, dll + tutup

Sterilisasi (pemanasan)

Produk steril dalam wadah

ITP530

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) ITP530 Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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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

ITP530

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

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

ITP530

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

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

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ITP530


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

ITP530

Luas trapesium =  LR1 + LR2  t 2  

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

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

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

=e

=

hA CpV

TP-TR Ti-TR

t = e-kt

= exp -(t/L2)

= exp -(k)t

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

k t (2,303)


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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 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]

ITP530

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)


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2


Ingredients

Packaging Material

Cutting

Forming

Heating (sterilizing/ Addition of Liquid, Mixing Pasteurizing)

Sterilizing

Aseptic Filling

Aseptic/Continuous Processing

Aseptic Closing

Coding

Filled Pack

ITP530

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Aseptic/Continuous Processing: Contoh : Susu Cair

Zona Aseptis Pengisian

SUSU steril kedalam kemasan steril, dilakukan pada kondisi lingkungan steril

SUSU steril dalam kemasan


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ITP530 ITP530 Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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

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

ITP530

PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods Faktor-faktor yang perlu dikendalikan Operator Proses

Pengen -dalian Proses

= COMMERCIALLY STERILE Arsip proses ITP530 Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods Faktor-faktor yang perlu dikendalikan  perlu SOP dan GMP ketat Operator Proses

Pengen -dalian Proses

Faktor Kritis

= COMMERCIALLY STERILE Arsip proses ITP530

PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods 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. ITP530 Purwiyatno Hariyadi Email: [email protected] Web: phariyadi.staff.ipb.ac.id

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PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods 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. ITP530

PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods 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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PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods Dalam prakteknya … Beberapa nilai-Fo pangan steril komersial di pasar UK Produk Babyfoods Beans in tomato sauce Peas in brine Carrots Green beans in brine

ITP530

Celery Mushrooms in brine Mushrooms in butter Meats in gravy Sliced meat in gravy

Ukuran Kalengs

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

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

Terimakasih More on Thermal Processing of Food Go to  ITP730 phariyadi.staff.ipb.ac.id


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Factors Influence the Heat Resistance of Microbial

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