Better Thermal Processing of Foods: In Container Processing · Penggaraman, dll (aw controlled) Pengasaman (pH controlled) Managing riks of potentially hazardous foods: food processing

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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id

Purwiyatno Hariyadiphariyadi.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)

Better Thermal Processing of Foods:

In Container Processing

“potentially hazardous foods” (PHF)

“high risk foods (HRF)

Introduction

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“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.

Introduction

3


Potentially hazardous foods are foods that meet both the criteria below:

• they might contain the types of food-poisoning bacteria that need to multiply tolarge 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 dairy-based desserts such as

• cheesecakes and custard tarts;• seafood (excluding live seafood) including seafood

salad, patties, fish balls, stews containing seafood and fish stock;

Introduction


4


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

Introduction


• Species of microorganisms.• Acidity (pH) • Water activity (aw)• Food Oxygen (some of the spores

with high thermal resistance are anaerobic).

• Food composition

Factors Influence the Heat Resistance of Microbial

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HM

L

Characteristics of potentially hazardous foods:

M

4.5

0.85

0

1aw

pH1410

6


HM

L M

4.5

0.85

0

1aw

pH1410

Pengeringan,Penggaraman, dll

(aw controlled)

Pengasaman(pH controlled)

Managing riks of potentially hazardous foods: food processing

HM

L M

4.5

0.85

0

1aw

pH1410

Managing riks of potentially hazardous foods: food processing

Heating=

Thermal Processing

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• 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

Better Thermal Processing??~ Optimasi

• 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


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Better Thermal Processing??~ Optimasi


Mengoptimalkan yield dan produktivitas, meminimalkan kerusakan mutu (dan gizi)tanpa mengkompromikan persyaratan keamanan pangan

Highly PHFspH > 4.5 dan aw>0.85

Terkemas/tertutup dengan kedap (hermetis)

Awet pada suhu ruang (shelf stable)

Tidak memerlukan refrigerasi Contoh : Sardine, tuna dalam

kaleng, susu steril, dll

Proses Panas

SterilisasiKomersial

Thermal Processing: Kasus A

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Highly PHFspH > 4.5 dan aw>0.85


Hanya beberapa hari pada suhu refrigerasi

Harus refrigerasi Contoh : Susu pasteurisasi,

daging udang, kepiting, dan hasil laut lainnya

Proses Panas

Pasteurisasi

Thermal Processing: Kasus B

Highly PHFspH > 4.5 dan aw<0.85pH < 4.5 dan aw>0.85


Awet (shelf stable), dengan/tanpa refrigerasi

Bisa tanpa refrigerasi Contoh : Sari buah, sos tomat,

jem/jelly, dll

ProsesPasteurisasi

&/atau Hot-fill-hold

Thermal Processing: Kasus C

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Thermal Processing

• Hot-filling (Hot-fill-hold)

• Pasteurisasi

• Sterilisasi

Thermal Processing

Process Objectives (Process Criterias):

• to kill microorganisms• to keep away microorganisms


• Pasteurisasi

• Sterilisasi

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Thermal Processing



Food Safety Objectives :• Protect public health hazard• (reduce economic spoilage)


• Pasteurisasi

• Sterilisasi

Thermal Processing



Food Safety Objectives :• Protect public health hazard• (reduce economic spoilage)


• Pasteurisasi

• Sterilisasi

Bagaimana mengevaluasi/menilai keamanan produk pangan yang diproses panas?

?

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Thermal Processing


• Pasteurisasi

• Sterilisasi

Aseptic/Continuous Processing

Ingredients CuttingAddition of

Liquid, Mixing

Heating(sterilizing/

Pasteurizing)

FormingPackagingMaterial

Sterilizing AsepticFilling

CodingAsepticClosing Filled Pack

Thermal Processing


• Pasteurisasi

• Sterilisasi

IngredientsPreparation:cutting, etc

Preparationof liquid

Ready madeCAN

Filling(particulates)

Filling(liquid)

Closing Retorting Labelling Filled Can

In-Container Processing

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Produk Kaleng, botol, gelas, dll

Produk steril dalam wadah

Sterilisasi(pemanasan)

In-container thermal processing

Pengi-sian +

tutup

Thermal Processing





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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 D 121.1 D140

(min) (s)

B. stearothermophilus 4.0 - 5.0 0.9C. thermosaccharolyticum 3.0 - 4.0D. nigrificans 2.0 - 3.0C. botulinum – proteolytic 0.1 - 0.23C. sporogenes 0.1 - 1.5B. coagulans 0.01 - 0.1B. Sporothermodurans 3,4 -7.9

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Reaksi E Z(kJ/mole) (oC)

Enzyme reactions 0-33.5 -Chlorophyl loss 21-113 26-142Ascorbic acid 21-167 11.8-142Non-enzymatic browning 37.7-167 -Lipid oxidation 41.9 -Spore destruction 251-335 8.7-11.8 Veg. cell destruction 209-628 4.7-14.2Protein denaturation 335-502 5,9-8.9

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

• Lethal Rate (LR)= Lethal value (LV)

• Time/Temp Process & LR

• LR Curve for Thermal Process

PROCESS CALCULATIONS

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z121.1-T(t)

zT(t)-121.1 10

10

1LVLR ===

T(oC) T(oF) LR(z=10oC)

90 194 0,00077624795 203 0,002454709100 212 0,007762471105 221 0,024547089110 230 0,077624712115 239 0,245470892120 248 0,776247117121,1 250 1,000000000125 257 2,454708916129 264 6,165950019


0,0

0,2

0,4

0,6

0,8

1,0

1,2

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

LR

t, min T(oC)

0 121,11 121,12 121,13 121,14 121,15 121,16 121,17 121,18 121,19 121,110 121,111 121,112 121,1

LR(z=10oC)

1,01,01,01,01,01,01,01,01,01,01,01,01,0

Pemanasan pada suhu konstan,121,1oC

1 unit sterilisasi12 unit sterilisasi

F0=12

0

20

40

60

80

100

120

140

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

Waktu

Su

hu


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0,0000

0,0020

0,0040

0,0060

0,0080

0,0100

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

Waktu

LRt, min T(oC) LR(z=10oC)

0 100 0,0077624711 100 0,0077624712 100 0,0077624713 100 0,0077624714 100 0,0077624715 100 0,0077624716 100 0,0077624717 100 0,0077624718 100 0,0077624719 100 0,00776247110 100 0,00776247111 100 0,00776247112 100 0,007762471

Total sterilitas = 0.007762x12 unit= 0.10091 unit

hanya 0.00776 x pengaruh letal pada 121.1oC

Total letalitas = F0 =??

F0 = Do log t

0(LR)dt

N

N0

F0 = LR.t

Pemanasan pada suhu konstan,100oC



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

F0 = 1 pemanasan selama 1 menit pada suhu 121.1oC

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Diketahui : Mikroba A; D0 = 0,21 menitdikehendaki 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


Produk Kaleng, botol, gelas, dll

Produk steril dalam wadah

Sterilisasi(pemanasan)

Pengi-sian +

tutup

PROCESS CALCULATIONS(for ”In-container sterilisation”)

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Heat Penetration Test

• Scheduled Process:Venting and heating procedure

• Come up time• Operator processing

time• Cooling time, ETC

TR = f(t)


Tipikal kurva penetrasi panas untuk pangan kaleng dan perubahan suhu retort (TR) selama proses seterilisasi

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

CUT

• t untuk mencapai TR : CUT


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

Heat Penetration Test

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Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan



SHP

SHP:Slowest Heating Point=Coldest Point




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0,0

0,2

0,4

0,6

0,8

1,0

1,2

0 4 8 12 16 20 24

WaktuL

R

t, min T(oC) LR(z=10oC)

0 90 0,0007762474 105 0,0245470898 120 0,77624711712 121 0,97723722116 100 0,00776247120 70 0,00000776224 60 0,000000776

F0 = Do log =t

0

(LR)dtN

N0

Fo = luas area di bawah kurva hubungan antara LR dan t

Fo = jumlah area trapesium

Luas trapesium t2

LR2LR1

+=

020406080

100120140

0 4 8 12 16 20 24waktu

Su

hu

(C

)

3.5068)(122

0.977

0.776A =-

+=





23






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T-Tm TP-TR=

Ti-Tm Ti-TR

= exp -(t/L2)

TR-TP

TR-Ti

= exp -(k)t

Log(TR-TP)=Log(TR-Ti)- t(2,303)

k

2. Metoda Formula

T - TR

Ti - TR

= e

hA

CpV- t

= e-kt

Persamaan perubahan suhu selama proses pemanasan :


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

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]

Kasus 1


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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

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)


Kasus 2

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.

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

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Low Acid Canned Food :

• pH > 4.6• Water Activity > 0.85• Thermally processed• Hermetically sealed container• Non-refrigerated

=COMMERCIALLYSTERILE

Low Acid Canned Food :


Ope-rator

Proses

Pengen-dalianProses

Arsipproses



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Ope-rator

Proses

Pengen-dalianProses

Arsipproses

Perlu GMP yang disiplin


Faktor Kritis


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.

Performance Standard (USFDA/USDA) :COMMERCIALLY STERILE


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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.

Performance Standard (USFDA/USDA) :COMMERCIALLY STERILE


• C. botulinum

• DBot,250F = 0.21 menit

• 12-log10 reduction C. botulinum Fo = 2.52 menit

Performance Standard (USFDA/USDA) :

COMMERCIALLY STERILE

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Dalam prakteknya …

10 Ovals Sliced meat in gravy12-15 All Meats in gravy6-8 Up to A1 Mushrooms in butter

8-10 A1 Mushrooms in brine3-4 A2 Celery6-8 A2 to A10 4-6 Up to A2 Green beans in brine3-4 All Carrots6-8 A2 to A10 6 Up to A2 Peas in brine

4-6 All Beans in tomato sauce3-5 babyfood Babyfoods

Fo values Ukuran KalengsProduk

Beberapa nilai-Fo pangan steril komersial di pasar UK

COMMERCIALLY STERILE

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 39 41 43 45 47 49 51 53 55 149

Calculated F Value

Fre

qu

ency

3 < Fo< 15

UK

• Jumlah data terkumpul= 93 (dari 23 FCE)• Kisaran : 1.9 < Fo <148.4

COMMERCIALLY STERILE di INDONESIA

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• 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

02468

101214161820

25 30 35 40 45 50 55 602)

Calculated PU-values

Pre

quen

cy

PASTEURIZED PRODUCTS di INDONESIA

Industri perlu melakukan evaluasi untuk pemastian :

i. Good Manufacturing Practices?

ii. Kinerja alat pengolahan/retort?

iii. Kecukupan panas (nilai-Fo)?

KONDISI INDONESIA?

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0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 39 41 43 45 47 49 51 53 55 149

Calculated F Value

Fre

qu

ency

7 < Fo< 19

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

Berlebihan?

KONDISI INDONESIA?

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 SYARATPENGALENGAN PANGAN SUKSES :

1. Perlakuan pemanasan yang cukup : tercapainya sterilitas komersial

2. Wadah/kaleng tertutup secara hermetislakukan 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 akanmasuk kembali dan mencemari produk yang telah

Disterilisasi integritas sambungan dan penutupan adalah faktor penting

Terimakasih

phariyadi.staff.ipb.ac.id

Documents

Better Thermal Processing of Foods: In Container Processing · Penggaraman, dll (aw controlled) Pengasaman (pH controlled) Managing riks of potentially hazardous foods: food processing