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

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1 Better Thermal Processing of Foods: In Container Processing 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 ( Anggota Institute for Thermal Process Specialist (IFTPS)-USA ( Introduction potentially hazardous foods (PHF) high risk foods (HRF) 1

2 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. 2

3 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; 3

4 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 (a w ) Food Oxygen (some of the spores with high thermal resistance are anaerobic). Food composition 4

5 Factors Influence the Heat Resistance of Microbial Species of microorganisms. Acidity (ph) Water activity (a w ) Food Oxygen (some of the spores with high thermal resistance are anaerobic). Food composition Characteristics of potentially hazardous foods: a w M H L M 0 ph

6 Managing riks of potentially hazardous foods: food processing a w M Pengasaman H (ph controlled) Pengeringan, Penggaraman, dll (a w controlled) L M ph Managing riks of potentially hazardous foods: food processing a w M H Heating = L Thermal Processing M ph 6

7 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 7

8 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 a w >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 8

9 Thermal Processing: Kasus B Highly PHFs ph > 4.5 dan a w >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 a w <0.85 ph < 4.5 dan a w >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 9

10 Thermal Processing Hot-filling (Hot-fill-hold) Pasteurisasi Sterilisasi Thermal Processing Hot-filling (Hot-fill-hold) Pasteurisasi Sterilisasi Process Objectives (Process Criterias): to kill microorganisms to keep away microorganisms 10

11 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) 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? 11

12 Thermal Processing Hot-filling (Hot-fill-hold) Pasteurisasi Sterilisasi Ingredients Cutting Addition of Liquid, Mixing Heating (sterilizing/ Pasteurizing) Aseptic/Continuous Processing Packaging Material Forming Sterilizing Aseptic Filling Aseptic Closing Coding Filled Pack Thermal Processing Hot-filling (Hot-fill-hold) Pasteurisasi Sterilisasi Ingredients Preparation: cutting, etc Preparation of liquid In-Container Processing Ready made CAN Filling (particulates) Filling (liquid) Closing Retorting Labelling Filled Can 12

13 Thermal Processing In-container thermal processing Produk Pengisian + tutup Kaleng, botol, gelas, dll Sterilisasi (pemanasan) Produk steril dalam wadah Factors Influence the Heat Resistance of Microbial Species of microorganisms. Acidity (ph) Water activity (a w ) Food Oxygen (some of the spores with high thermal resistance are anaerobic). Food composition 13

14 Factors Influence the Heat Resistance of Microbial Species of microorganisms. Acidity (ph) Water activity (a w ) Food Oxygen (some of the spores with high thermal resistance are anaerobic). Food composition Heat Resistance of Microbial 14

15 Heat Resistance of Microbial D values of microorganisms of importance in heat processing Spores D D 140 (min) (s) B. stearothermophilus C. thermosaccharolyticum D. nigrificans C. botulinum proteolytic C. sporogenes B. coagulans B. Sporothermodurans 3,

16 Comparison of Z and E a for Quality Attributes and Microbial Populations of importance in heat processing Reaksi E Z (kj/mole) ( o C) Enzyme reactions Chlorophyl loss Ascorbic acid Non-enzymatic browning Lipid oxidation Spore destruction Veg. cell destruction Protein denaturation ,9-8.9 PROCESS CALCULATIONS Lethal Rate (LR)= Lethal value (LV) Time/Temp Process & LR LR Curve for Thermal Process 16

17 PROCESS CALCULATIONS 1 LR = LV = = T(t) 10 z T(t) z T( o C) T( o F) LR(z=10 o C) , , , , , , , , , , , PROCESS CALCULATIONS Pemanasan pada suhu konstan, 121,1 o C t, min T( o C) 0 121, , , , , , , , , , , , ,1 LR(z=10 o C) 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 Suhu LR Waktu 1,2 1,0 0,8 0,6 0,4 0,2 1 unit sterilisasi 12 unit sterilisasi F 0 =12 0,

18 PROCESS CALCULATIONS Pemanasan pada suhu konstan, 100 o C t, min T( o C) LR(z=10 o C) , , , , , , , , , , , , , LR 0,0100 0,0080 0,0060 0,0040 0,0020 0, Waktu Total sterilitas = x12 unit = unit hanya x pengaruh letal pada o C Total letalitas = F 0 =?? F 0 = D o log F 0 = LR.t N 0 N t 0 (LR)dt PROCESS CALCULATIONS t = heating time (mini) T = Heating temperature, o C F 0 = 1 pemanasan selama 1 menit pada suhu o C 18

19 PROCESS CALCULATIONS Diketahui : Mikroba A; D 0 = 0,21 menit dikehendaki proses 12 D Pemanasan pada suhu o C > 12(0,21)=2.52 menit Pemanasan pada suhu 100 o C 1/LR 100C x 2.52 min = 1/ x 2.52=324.7 min (5.4 jam) Pemanasan pada suhu 129 o C 1/LR 129C x 2.52 min = 1/6,166 x 2.52=0.408 min (24.5 detik) Pemanasan pada suhu 50 o C 1/LR 50C x 2.52 min = 1/ x 2.52 = menit = bulan????!!!! Pada prakteknya : efek letal panas untuk sterilisasi, umumnya mulai dianggap nyata setelah T>90 o C Teixeira (1992) : no appreciable lethality at T < 210 o F(99 o C) 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 Pengisian + tutup Kaleng, botol, gelas, dll Sterilisasi (pemanasan) Produk steril dalam wadah 19

20 PROCESS CALCULATIONS (for In-container sterilisation ) Heat Penetration Test Scheduled Process: Venting and heating procedure Come up time Operator processing time Cooling time, ETC T R = f(t) PROCESS CALCULATIONS (for In-container sterilisation ) Heat Penetration Test Tipikal kurva penetrasi panas untuk pangan kaleng dan perubahan suhu retort (T R ) selama proses seterilisasi Suhu retort di set (mis: pada 250 o F) t untuk mencapai T R : CUT CUT Teixera, Thermal Process Calculation. Handbook of Food Eng. 20

21 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, 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 Teixera, Thermal Process Calculation. Handbook of Food Eng. 21

22 PROCESS CALCULATIONS t, min T( o C) LR(z=10 o C) , , , , , , , F 0 = D o log N 0 N = t 0 (LR)dt Fo = luas area di bawah kurva hubungan antara LR dan t Fo = jumlah area trapesium Luas trapesium LR 1 + LR = 2 2 t Suhu (C) LR waktu 1,2 1,0 0,8 0,6 0,4 0,2 0, Waktu A = 7 (12-8) = PROCESS CALCULATIONS (for In-container sterilisation ) Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan Teixera, Thermal Process Calculation. Handbook of Food Eng. 22

23 PROCESS CALCULATIONS (for In-container sterilisation ) Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan PROCESS CALCULATIONS (for In-container sterilisation ) Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan 23

24 PROCESS CALCULATIONS 2. Metoda Formula Persamaan perubahan suhu selama proses pemanasan : T-T R T i -T R = e - ha t CpV = e -kt T-T m T P -T R = = exp -( t/l 2 ) T i -T m T i -T R T R -T P T R -T i = exp -(k)t Log(T R -T P )=Log(T R -T i )- k (2,303) t PROCESS CALCULATIONS Dari kurva penetrasi panas : Kasus 1 - Tentukan f h - 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 F o ; jika diketahui B...hitung log g = log ji (B/f h )....dengan diketahui log g cari f h /U....hitung F i = 10 (250-TR)/z F o = f h /[(f h /U)F i ] 24

25 PROCESS CALCULATIONS Dari kurva penetrasi panas : Kasus 2 - Tentukan f h - 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 F o....hitung F i = 10 (250-TR)/z... hitung f h /U = f h /(F o *F i )....dengan diketahui f h /U cari log g B= f h (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 a w >

26 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 PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods Operator Proses Pengen -dalian Proses = COMMERCIALLY STERILE Arsip proses 26

27 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 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. 27

28 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. COMMERCIALLY STERILE Performance Standard (USFDA/USDA) : C. botulinum D Bot,250F = 0.21 menit 12-log10 reduction C. botulinum F o = 2.52 menit 28

29 COMMERCIALLY STERILE Dalam prakteknya Beberapa nilai-f o pangan steril komersial di pasar UK Produk Babyfoods Beans in tomato sauce Peas in brine Carrots Green beans in brine 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 F o values COMMERCIALLY STERILE di INDONESIA Jumlah data terkumpul= 93 (dari 23 FCE) Kisaran : 1.9 < F o <148.4 Frequency UK < F o < 15 Calculated F Value 29

30 PASTEURIZED PRODUCTS di INDONESIA Pangan dgn proses panas minimal (minimally heat processed food): PASTEURISASI Dinyatakan dalam PU (F 185 (z=16) ) Dari 67 data : Nilai PU 23 < PU < 60 Umumnya berhub dgn keawetan Prequency ) Calculated PU-values KONDISI INDONESIA? Industri perlu melakukan evaluasi untuk pemastian : i. Good Manufacturing Practices? ii. Kinerja alat pengolahan/retort? iii. Kecukupan panas (nilai-f o )? 30

31 KONDISI INDONESIA? Frequency Indonesia? < F o < 19 Optimisi Mutu Penentuan T-t optimum Otomatisasi pengendalian suhu? Pelatihan Operator Calculated F Value Berlebihan? 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) 31

32 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 32