/2015 Thermal Processing of Foods 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) Factors Influence the Heat Resistance of Microbial Intrinsic Properties of Foods Species of microorganisms. Acidity (ph) Water activity (a w ) Food Oxygen (some of the spores with high thermal resistance are anaerobic). Food composition 1
Characteristics of potentially hazardous foods: 0.85 1 a w M H L M 0 4.5 10 ph 14 Managing riks of potentially hazardous foods: food processing 0.85 1 a w M H Salah satu teknik yang effektif adalah: 0 L Pemanasan M = Thermal Processing 4.5 10 ph 14 2
Managing riks of potentially hazardous foods: food processing 0.85 1 0 a w M H Telah digunakan oleh manusia sejak manusia menemukan api Pemasakan (cooking) Penghangatan kembali (rewarming) Pelelehan (thawing) L Blansir (blanching) M Hot filling Pasteurisasi Sterilisasi 4.5 10 14 ph 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 3
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 4
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 Medium 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 5
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? 1 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 6
1 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 7
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 8
Heat Resistance of Microbial D values of microorganisms of importance in heat processing Spores D 121.1 D 140 (min) (s) B. stearothermophilus 4.0-5.0 0.9 C. thermosaccharolyticum 3.0-4.0 D. nigrificans 2.0-3.0 C. botulinum proteolytic 0.1-0.23 C. sporogenes 0.1-1.5 B. coagulans 0.01-0.1 B. Sporothermodurans 3,4-7.9 9
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 0-33.5 - Chlorophyl loss 21-113 26-142 Ascorbic acid 21-167 11.8-142 Non-enzymatic browning 37.7-167 - Lipid oxidation 41.9 - Spore destruction 251-335 8.7-11.8 Veg. cell destruction 209-628 4.7-14.2 Protein denaturation 335-502 5,9-8.9 PROCESS CALCULATIONS Lethal Rate (LR)= Lethal value (LV) Time/Temp Process & LR LR Curve for Thermal Process 10
PROCESS CALCULATIONS 1 LR = LV = = 10 121.1 -T(t) 10 z T(t)-121.1 z T( o C) T( o F) LR(z=10 o C) 90 194 0,000776247 95 203 0,002454709 100 212 0,007762471 105 221 0,024547089 110 230 0,077624712 115 239 0,245470892 120 248 0,776247117 121,1 250 1,000000000 125 257 2,454708916 129 264 6,165950019 PROCESS CALCULATIONS Pemanasan pada suhu konstan, 121,1 o C t, min T( o C) 0 121,1 1 121,1 2 121,1 3 121,1 4 121,1 5 121,1 6 121,1 7 121,1 8 121,1 9 121,1 10 121,1 11 121,1 12 121,1 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 140 120 100 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 0,6 0,4 0,2 12 unit 1 unit sterilisasi sterilisasi F 0 =12 0,0 0 1 2 3 4 5 6 7 8 9 10 11 12 11
PROCESS CALCULATIONS Pemanasan pada suhu konstan, 100 o C t, min T( o C) LR(z=10 o C) 0 100 0,007762471 1 100 0,007762471 2 100 0,007762471 3 100 0,007762471 4 100 0,007762471 5 100 0,007762471 6 100 0,007762471 7 100 0,007762471 8 100 0,007762471 9 100 0,007762471 10 100 0,007762471 11 100 0,007762471 12 100 0,007762471 LR 0,0100 0,0080 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 121.1 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 121.1 o C 12
PROCESS CALCULATIONS Diketahui : Mikroba A; D 0 = 0,21 menit dikehendaki proses 12 D Pemanasan pada suhu 121.1 o C > 12(0,21)=2.52 menit Pemanasan pada suhu 100 o C 1/LR 100C x 2.52 min = 1/0.00776 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 = 1/0. 000000078 x 2.52 = 32307692.31 menit = 747.8 bulan????!!!! PROCESS CALCULATIONS 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 13
PROCESS CALCULATIONS (for In-container sterilisation ) Produk Pengisian + tutup Kaleng, botol, gelas, dll Sterilisasi (pemanasan) Produk steril dalam wadah 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) 14
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, 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 Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng. 15
PROCESS CALCULATIONS (for In-container sterilisation ) Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng. PROCESS CALCULATIONS t, min T( o C) LR(z=10 o C) 0 90 0,000776247 4 105 0,024547089 8 120 0,776247117 12 121 0,977237221 16 100 0,007762471 20 70 0,000007762 24 60 0,000000776 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 140 120 100 80 60 40 20 0 0 4 8 12 16 20 24 waktu 1,2 1,0 0,8 0,6 0,4 0,2 0,0 0 4 8 12 16 20 24 Waktu 0.776 + 0.97 A = 7 (12-8) = 3.506 2 16
PROCESS CALCULATIONS (for In-container sterilisation ) Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan 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 17
PROCESS CALCULATIONS (for In-container sterilisation ) Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan 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 18
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 ] 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) 19
2 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 2 Aseptic/Continuous Processing: Contoh : Susu Cair Zona Aseptis Pengisian SUSU steril kedalam kemasan steril, dilakukan pada kondisi lingkungan steril SUSU steril dalam kemasan 20
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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 a w > 0.85. 29
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 Faktor-faktor yang perlu dikendalikan Operator Proses Pengen -dalian Proses = COMMERCIALLY STERILE Arsip proses 30
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 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. 31
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. PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods COMMERCIALLY STERILE Performance Standard (USFDA/USDA) : C. botulinum D Bot,250F = 0.21 menit 12-log10 reduction C. botulinum F o = 2.52 menit 32
PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods 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 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 33