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Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Problem Solving in UHT Technology for Liquid Milk
Purwiyatno Hariyadiphariyadi.staff.ipb.ac.id
Departemen Ilmu dan Teknologi Pangan, Fakultas Teknologi Pertanian:Southeast Asian Food & Agricultural Science & Technology (SEAFAST) Center, LPPM,
INSTITUT PERTANIAN BOGOR
Purwiyatno [email protected]
Problem Solving in UHT Technology for Liquid Milk
Materi iniBisa diunduh dari
www.foodreview.co.id
SEMINAR “Better & Safer Dairy Technology”June 11, 2015
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Disukai oleh mikroba mudah rusak
• Bahan pangan yang “bergizi”• pH > 4.5 dan aw>0.85• Potensi Bahaya : Tinggi
SUSU
1. Teknologi Pengolahan Susu Cair
Purwiyatno [email protected]
1. Teknologi Pengolahan Susu Cair
• Pendinginan,• Pemanasan,• Pengeringan,• Penambahan gula,• Penambahan asam,• Penambahan
pengawet,• Dll
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
1. Teknologi Pengolahan Susu Cair
• Pendinginan,• Pemanasan,• Pengeringan,• Penambahan gula,• Penambahan asam,• Penambahan pengawet,• Pengendalian atmosfir,• Iradiasi• Dll
• Pendinginan,
• Pemanasan• Pengeringan,• Penambahan gu• Penambahan a• .........
Purwiyatno [email protected]
WadahPengisian &Penutupan
Sterilisasi(pemanasan)
Retort/pemasak
SUSU sterildalam wadah
SUSU
1. Teknologi Pengolahan Susu CairDengan panas (proses termal)
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
WadahPengisian &Penutupan
Sterilisasi(pemanasan)
Retort/pemasak
SUSU sterildalam wadah
SUSU
1840an: Susu dalam kaleng/botol mulai dijual komersial=AWET.Tantangan kerusakan zat gizi dan perubahan cita-rasa
1. Teknologi Pengolahan Susu CairDengan panas (proses termal)
Purwiyatno [email protected]
1850s:Pasteur; pemanasan susu pada T=63°C; t=30’ Pasteurization: membunuh pathogenTantangan:
• Tidak membunuh spora bacteri (tahan panas)
• Memerlukan penyimpanan dingin lemari es
1840an: Susu dalam kaleng/botol mulai dijual komersial=AWET.Tantangan kerusakan zat gizi dan perubahan cita-rasa
1. Teknologi Pengolahan Susu CairDengan panas (proses termal)
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Optimasi Proses Panas
Membunuh mikroba:Memperpanjang masa
kesegaran
~ aman, awet
Juga menyebabkanperubahan :
• Rasa• Warna, Tekstur• Flavor• Gizi, • Nilai Tambah• Fungsionalitas,
• dll
vs
1. Teknologi Pengolahan Susu CairDengan panas (proses termal)
Purwiyatno [email protected]
(2) Definisi Nilai D
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
(2) Definisi Nilai z
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Purwiyatno [email protected]
JenisMikroba
1. C. Botulinum2. C. Sporogenes3. B. Stearotherm.4. C. Thermosacch.5. B. Subtilis6. B. Coagulan7. C. pasteurianum
TR
(oC)
121121121121121121100
D(min)
0,251,505,004,000,400,070,50
Z(oC)
111110117108
D-Red
12555655
Produk
LAFs (pH >4,5)DagingSayuran & susuSayuranSusu & produk susu4,2 <pH<4,5, tomat4,2 <pH<4,5, pir
Referensi ; (Maroulis and Saravacos, 2003. Food Process Design. Thermal Destruction Data of Spoilage Microorganisms; p 312)
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Aspek Mutu(Nilai Tambah)
1. Vitamin C2. Tiamin3. Vitamin A4. KLorofil5. Dll
TR
(oC)
121121121121
?
D(min)
93125443,515,4
?
Z(oC)
17,825,420,045,0
?
Referensi ; (Maroulis and Saravacos, 2003. Food Process Design. Thermal Destruction Data of Spoilage Microorganisms; p 312)
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Purwiyatno [email protected]
Aspek Mutu(Nilai Tambah)
Mikroba
1. Pathogenik
2. Mesofilik
3. Thermofilik
Aspek Mutu (nilai Tambah
1. Tiamin
2. Lisin
3. Asam Askorbat
TR
(oC)
75
120
120
120
120
120
D(min)
0,01
0,15
0,50
120
960
960
Z(oC)
9,5
10,0
10,5
30
20
18
D-Red
12
9
9
Referensi ; (Maroulis and Saravacos, 2003. Food Process Design. Thermal Destruction Data of Spoilage Microorganisms; p 312)
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Suhu Pemanasan(T)
Wak
tu (
lam
a) P
eman
asan
(t)
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Purwiyatno [email protected]
Suhu Pemanasan(T)
Wak
tu (
lam
a) P
eman
asan
(t)
115-121oC
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Suhu Pemanasan(T)
Wak
tu (
lam
a) P
eman
asan
(t)
135-140oC
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Purwiyatno [email protected]
135-140oC115-121oCSuhu Pemanasan(T)
Wak
tu (
lam
a) P
eman
asan
(t)
Pemanasan pada suhu lebih tinggi • Lebih efektif
membunuh mikroba• Minimal merusak
mutu dan gizi.
Pemanasan pada suhu lebih
rendah • Kurang
efektif membunuh
mikroba; • Signifikan
merusak mutu dan gizi
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
135-140oC115-121oCSuhu Pemanasan(T)
Wak
tu (
lam
a) P
eman
asan
(t)
Pemanasan pada suhu lebih tinggi • Lebih efektif
membunuh mikroba• Minimal merusak
mutu dan gizi.
Pemanasan pada suhu lebih
rendah • Kurang
efektif membunuh
mikroba; • Signifikan
merusak mutu dan gizi
PerluOPTIMASIKombinasi T (suhu) &t (waktu)
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Purwiyatno [email protected]
JaminanKeamanan,Kestabilan(keawetan)
JaminanMutu
(fungsionalitas)
Membunuh mikroba:Memperpanjang masa kesegaran ~ aman,
awet
Menyebabkan perubahan : Rasa, Warna,
Tekstur, Flavor, Gizi, dll
PerluOPTIMASIKombinasi T (suhu) &t (waktu)
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
JaminanKeamanan,Kestabilan(keawetan)
JaminanMutu
(fungsionalitas)
Membunuh mikroba:Memperpanjang masa kesegaran ~ aman,
awet
Menyebabkan perubahan : Rasa, Warna,
Tekstur, Flavor, Gizi, dll
UHT
Ultra HighTemperature
1. Teknologi Pengolahan Susu CairOPTIMASI PROSES PANAS– Kinetika Inaktivasi Mikroba
Purwiyatno [email protected]
Zona Aseptis
Produk steril dalam
kemasan
Pengisian produk steril kedalam kemasan
steril, dilakukan pada kondisi lingkungan
steril
2. Teknologi UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
USA, 1989(http://www.ift.org)
“…The most significantfood science innovation of the last 50 years.”
2. Teknologi UHT
Purwiyatno [email protected]
SUSU
2. Teknologi UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
1890s: Alat penukar panas tipe Pelat, pertama kali
dipatenkan di Jerman Proses pemanasan (pasteurusasi dan sterilisasi) bisa
dilakukan dengan suhu yang lebih tinggi
2. Teknologi UHT
Purwiyatno [email protected]
2. Teknologi UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
2. Teknologi UHT
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Malmgren, B, 2011. Aseptic process. External Partners Workshop, Singapore, 10-11 May 2011
1. Definisi Nilai F0
3. Kecukupan Panas UHT
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
3. Kecukupan Panas UHT
T(oC) LR t (sec) Fo121.1 1.0 180 3135 24.5 2 0.8
Purwiyatno [email protected]
3. Kecukupan Panas UHT
T(oC) LR t (sec) Fo121.1 1.0 180 3135 24.5 2 0.8135 24.5 8 3.3140 77.6 3 3.9
Revisi???
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Waktu Pengendalian Aliran- kecepatan dan profil laju aliran dalam Holding Tube (HT)
Purwiyatno [email protected]
3. Kecukupan Panas UHT
Waktu Pengendalian Aliran- kecepatan dan profil laju aliran dalam Holding Tube (HT)
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
V
LF
tF
Z
T
o
Z
T
o
ho
ho
210
10
121
min
121
L = panjang holding tubeTho : suhu diujung hilir holding tubeV = kecepatan rata2 aliran
3. Kecukupan Panas UHT
Waktu Pengendalian Aliran- kecepatan dan profil laju aliran dalam Holding Tube (HT)
Purwiyatno [email protected]
Nilai Fo :• Dipengaruhi oleh aliran bahan HT; (profile & kecepatan
aliran)• Kendalikan pompa :
• Pompa dipasang di bagian hulu sistim pemanasan• Positive displacement pump• Nilai Fo = ditentukan berdasarkan nilai Fo dari the fastest
moving particle• Untuk memastikan t tidak berubah fixed rate pump.• Jika digunakan pompa dengan variable speed
perubahan kecepatan hanya dibisa dilakukan oleh authorized personel yang sudah ditunjuk dan diberikan training memadai.
3. Kecukupan Panas UHT
Waktu Pengendalian Aliran- kecepatan dan profil laju aliran dalam Holding Tube (HT)
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Holding Tube :
• Posisi HT dibuat miring self draining• HT standar disain saniter (sanitary design);
• pemukaan pipa yang halus• komponen mudah diurai dan dirakit kembali,• kualitas pengelasan (welding) yang baik CIP
• HT dikonstruksi pada area yang kering dan tidak lembab;
• Tekanan di dalam HT perlu dipertahankan tinggi:
menghindari terjadinya proses mendidih/flashing.
• Suhu HT (Tho) dicatat sebagai suhu outlet HT.
Waktu Pengendalian Aliran- kecepatan dan profil laju aliran dalam Holding Tube (HT)
3. Kecukupan Panas UHT
Purwiyatno [email protected]
2. Definisi Nilai Pemasakan(C-value)
Malmgren, B, 2011. Aseptic process. External Partners Workshop, Singapore, 10-11 May 2011
3. Kecukupan Panas UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Malmgren, B, 2011. Aseptic process. External Partners Workshop, Singapore, 10-11 May 2011
3. Definisi Nilai B*
3. Kecukupan Panas UHT
Purwiyatno [email protected]
Malmgren, B, 2011. Aseptic process. External Partners Workshop, Singapore, 10-11 May 2011
4. Definisi Nilai C*
3. Kecukupan Panas UHT
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Faktor kritis untuk Umur Simpan susu Steril UHT• Colour• Smell• Taste• Texture• Stability
3. Kecukupan Panas UHT
Purwiyatno [email protected]
1985 di Italy1990 di Jerman
• Problems of non-sterility of UHT-milk products.
• Caused by the presence of ultra heat resistant bacterial spores belonging to the genus Bacillus.
• Massive non-sterility
mesophilic/thermofilik spores present in theinitial milk might have survived the UHT-treatment.
germinate, multiply
4. Permasalahan Teknologi UHT- Case of Non-Sterility
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
• Molecular investigations of these sporeformers showed that a new Bacillus species is involved (Klijn et al., 1994),
• Identified as Bacillus sporothermodurans by Petterson et al. (1996) .
• HHRS : Highly Heat-Resistant Spore-former
4. Permasalahan Teknologi UHT- Case of Non-Sterility
Purwiyatno [email protected]
4. Permasalahan Teknologi UHT- Case of Non-Sterility
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
4. Permasalahan Teknologi UHT- Case of Non-Sterility
Purwiyatno [email protected]
B. Stearothermophilus: D140-value ~ 0.9 s)
B. Sporothermodurans: D140-value ~ 3.4 - 7.9 s)
Zvalue:
B. Sporothermodurans: 13.1-14.2oC and B. Stearothermophilus: 9.1oC
4. Permasalahan Teknologi UHT- Case of Non-Sterility
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Factors? Cleaning
"4T" law: the success of CIP depends on:
1. the correct cleaning Time
2. the right Temperature
3. the Turbulence
4. the Titration of cleaning solution
4. Permasalahan Teknologi UHT- Case of Non-Sterility
Purwiyatno [email protected]
Factors?
Reprocessing of UHT milk.
Waiting time (delay of processing) at warm temperature
4. Permasalahan Teknologi UHT- Case of Non-Sterility
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
4. Permasalahan Teknologi UHT- Case of Gelation
Purwiyatno [email protected]
Age gelation of UHT Milk (Kocak, H. R. and Zadow, J. G., 1985, Age gelation of UHT whole milk as in uenced by storage temperature, Aust J Dairy Technol, 40(1): 14–21)
In general, gelation occurs more readily at room temperatures(~20–25°C) than at low (~4°C) and high (~35–40°C)
4. Permasalahan Teknologi UHT- Case of Gelation
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
4. Permasalahan Teknologi UHT- Case of Gelation
Purwiyatno [email protected]
Gelasi (penggumpalan) pada susu UHT selama penyimpananerat berkaitan dengan reaksi proteolisis.
(i) protease alami pada susu (plasmin) (ii) proteinase yg diproduksi oleh bakteri psikrotrop
(kontaminant) protease ekstraseluler.
4. Permasalahan Teknologi UHT- Case of Gelation
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
4. Permasalahan Teknologi UHT- Case of Gelation
Purwiyatno [email protected]
Law, B. A., Andrews, A. T. And Sharpe,M. E., 1977, Gelation of ultrahightemperature-sterilized milk by proteinases from a strain of Pseudomonas uorescens isolated from raw milk, J Dairy Res, 44(1): 145–148.
4. Permasalahan Teknologi UHT- Case of Gelation
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
4. Permasalahan Teknologi UHT- Case of Gelation
Purwiyatno [email protected]
• Tingkat/intensitas pemanasan yang diterima oleh susu dan produk-produk susu laktulosa sebagai indikator.
4. Permasalahan Teknologi UHT- Index of Heating : Lactulose
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
• Laktulosa secara alami tidak terdapat pada susu segar; terbentuk selama proses pemanasan; sebagai hasil isomerisasi dari laktosa khas pada susu
• The European Union (EU) : indikator untuk menentukan intensitas pemanasan susu, untuk membedakan antara susu pasteurisasi, susu steril dalam wadah, atau pu susu steril-UHT
(EU Milk Hygiene Directive, 1992).
4. Permasalahan Teknologi UHT- Index of Heating : Lactulose
Purwiyatno [email protected]
Lactulose contents in milks of different heat-processes:
• PAST=fresh pasteurized milk; • HT PAST=high temperature• pasteurized milk; • IND UHT=indirect UHT-treated• milk; • INJ UHT=direct UHT-treated milk
using an injection system;• INF UHT=direct UHT-treated milk
using an infusion system;• STER=In-container sterilized milk.
() Number of samples per class.
4. Permasalahan Teknologi UHT- Index of Heating : Lactulose
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
4. Permasalahan Teknologi UHT- Index of Heating : Lactulose
Purwiyatno [email protected]
Terimakasih
Email: [email protected]
Web: phariyadi.staff.ipb.ac.id
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Notes:
Purwiyatno [email protected]
Mudah rusak krn pertumbuhan
mikroba87
4.84.1 3.4 0.7
Air
Laktosa
Lemak
Protein
Mineral
Susu segar
• Sumber gizi• pH > 4,6• aw > 0.85
• berasal dari ternak
1. Karakteristik produk Kondisi mutu awal
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
Mudah rusak krn pertumbuhan
mikroba
Susu segar
• Sumber gizi• pH > 4,6• aw > 0.85
• berasal dari ternak
SNI 3141 1 2011 Susu Segar
1. Karakteristik produk Kondisi mutu awal
Bozena Malmgren (2013). Dairy Processing: Dairy raw materials, Tetra Pak
Purwiyatno [email protected]
Mudah rusak krn pertumbuhan
mikroba
Susu segar
• Sumber gizi• pH > 4,6• aw > 0.85
• berasal dari ternak
SNI 3141 1 2011 Susu Segar
1. Karakteristik produk Kondisi mutu awal
Bozena Malmgren (2013). Dairy Processing: Dairy raw materials, Tetra Pak
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
SNI 3141 1 2011 Susu Segar
TPC < 1 x 106
1. Karakteristik produk Kondisi mutu awal
Susu segar Indonesia
Purwiyatno [email protected]
1. Karakteristik produk Kondisi mutu awal
Bozena Malmgren (2013). Dairy Processing: Dairy raw materials, Tetra Pak
Kriteria Mutu bahan baku susu segar (untuk sterilisasi UHT)
Better & Safer Dairy TechnologyJune 11, 2015
Purwiyatno [email protected]
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.
1. Karakteristik produk Kondisi mutu awal
Kriteria Mutu bahan baku susu segar (untuk sterilisasi UHT)
Berkaitan dengan:
Standard Performansi (USFDA/USDA) STERIL KOMERSIAL:
Purwiyatno [email protected]
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.
1. Karakteristik produk Kondisi mutu awal
Kriteria Mutu bahan baku susu segar (untuk sterilisasi UHT)
Berkaitan dengan:
Standard Performansi (USFDA/USDA) STERIL KOMERSIAL: