Factors Influence the Heat Resistance of Microbial

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ITP530

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)

ITP530/2015

Thermal Processing of Foods

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

Factors Influence the Heat

Resistance of Microbial

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H M

L

Characteristics of potentially hazardous foods:

M

4.5 0.85

0 1 a_w

pH

14 10

H M

L M

4.5 0.85

0 1 a_w

pH

14 10

Managing riks of potentially

hazardous foods: food processing

Salah satu teknik yang effektif adalah:

Pemanasan

=

Thermal Processing

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H M

L M

4.5 0.85

0 1 a_w

pH

14 10

Managing riks of potentially

hazardous foods: food processing

•Telah digunakan oleh manusia sejak manusia menemukan api

• Pemasakan (cooking)

• Penghangatan kembali (rewarming)

• Pelelehan (thawing)

• Blansir (blanching)

• Hot filling

• Pasteurisasi

• Sterilisasi

Better Thermal Processing??

• 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

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Better Thermal Processing??

~ Optimasi

Thermal Processing: Tujuan

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

Highly PHFs pH > 4.5 dan a_w>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

 Sterilisasi Komersial

Thermal Processing:  Kasus A

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Highly PHFs pH > 4.5 dan a_w>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

Medium ‐ PHFs pH > 4.5 dan a_w<0.85 pH < 4.5 dan a_w>0.85

 Awet (shelf stable), dengan/tanpa refrigerasi

 Bisa tanpa refrigerasi

 Contoh : Sari buah, sos tomat, jem/jelly, dll

Proses Pasteurisasi

&/atau Hot-fill-hold

Thermal Processing:  Kasus C

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Thermal Processing

Process Objectives (Process Criterias):

• to kill microorganisms

• to keep away microorganisms

Food Safety Objectives :

• Protect public health hazard

• (reduce economic spoilage)

• Hot-filling (Hot-fill-hold)

• Pasteurisasi

• Sterilisasi

Bagaimana mengevaluasi/

menilai keamanan produk pangan yang diproses panas?

?

Thermal Processing

• Pasteurisasi

• Sterilisasi

Ingredients Preparation:

cutting, etc Preparation of liquid

Ready made

CAN Filling

(particulates) Filling

(liquid) Closing Retorting Labelling Filled Can

In-Container Processing

1

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Produk Kaleng, botol,

gelas, dll

Produk steril dalam wadah

Sterilisasi (pemanasan)

In-container thermal processing

Pengi-

sian +

tutup

Thermal Processing

1

• Species of microorganisms.

• Acidity (pH)

• Water activity (a_w)

Factors Influence the Heat

Resistance of Microbial

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• Species of microorganisms.

• Acidity (pH)

• Water activity (a_w)

Factors Influence the Heat Resistance of Microbial

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 0.9 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

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Reaksi E Z

(kJ/mole) (^oC)

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 Comparison of Z and E_a 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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z 121.1 - T(t)

z T(t) -

121.1 10

10 LV 1

LR = = =

T(ôC) T(ôF) LR(z=10ôC)

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

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)

0 121,1

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^oC) 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 Pemanasan pada suhu konstan, 121,1^oC

1 unit sterilisasi

PROCESS CALCULATIONS

0 20 40 60 80 100 120 140

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

Suhu

12 unit sterilisasi F₀=12

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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=10^oC)

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

Total sterilitas = 0.007762x12 unit

= 0.10091 unit hanya

0.00776 x pengaruh letal pada 121.1^oC Total letalitas = F₀=??

F₀= D_olog ^



^t

0

(LR)dt N

N₀ F₀= LR.t

Pemanasan pada suhu konstan, 100^oC

PROCESS CALCULATIONS

t = heating time (mini)

T = Heating temperature, ^oC

F₀= 1

pemanasan selama 1 menit pada suhu 121.1^oC

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Diketahui : Mikroba A; D₀= 0,21 menit dikehendaki proses 12 D

Pemanasan pada suhu 121.1^oC ^………> 12(0,21)=2.52 menit Pemanasan pada suhu 100^oC

 1/LR_100Cx 2.52 min = 1/0.00776 x 2.52=324.7 min (5.4 jam)

Pemanasan pada suhu 129^oC

 1/LR_129Cx 2.52 min = 1/6,166 x 2.52=0.408 min (24.5 detik)

Pemanasan pada suhu 50^oC

 1/LR_50Cx 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^oC

Teixeira (1992) :

No appreciable lethality at T < 210^oF(99^oC)

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

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Produk Kaleng, botol,

gelas, dll

Produk steril dalam wadah

Sterilisasi (pemanasan)

Pengi-

sian +

tutup

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

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

•Suhu retort di”set”

(mis: pada 250^oF)

CUT

•t untuk mencapai T_R: CUT

PROCESS CALCULATIONS

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

Heat Penetration Test

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

PROCESS CALCULATIONS

SHP

SHP:

Slowest Heating Point

= Coldest

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PROCESS CALCULATIONS

0,0 0,2 0,4 0,6 0,8 1,0 1,2

0 4 8 12 16 20 24

Waktu

LR

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

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

F₀= D_olog = ^t

0

(LR)dt N

N₀

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

Luas trapesium t

2 LR₂ LR₁



 



 +

=

0 20 40 60 80 100 120 140

0 4 8 12 16 20 24

waktu

Suhu (C)

3.506 8) 2 (12

0.97 7 0.776

A  - =



 



 +

=

PROCESS CALCULATIONS

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PROCESS CALCULATIONS

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PROCESS CALCULATIONS

T-T_m T_P-T_R

T_i-T_m = T_i-T_R = exp -(t/L²)

T_R-T_P

T_R-T_i = exp -(k)t

Log(T_R-T_P)=Log(T_R-T_i)- t (2,303)k

2. Metoda Formula

T - T_R T_i- T_R ^{= e}

hA - CpV t

= e^-kt

Persamaan perubahan suhu selama proses pemanasan :

PROCESS CALCULATIONS

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Dari kurva penetrasi panas : - 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]

Kasus 1

PROCESS CALCULATIONS

Dari kurva penetrasi panas : - 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 CALCULATIONS

Kasus 2

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Thermal Processing

• Pasteurisasi

• Sterilisasi

Aseptic/Continuous Processing

Ingredients Cutting Addition of Liquid, Mixing

Heating (sterilizing/

Pasteurizing)

Forming

Packaging

Material Sterilizing _Aseptic

Filling Aseptic Coding

Closing Filled Pack

2 Aseptic/Continuous Processing:

Contoh : Susu Cair

Zona Aseptis

SUSU steril dalam kemasan Pengisian

SUSU steril kedalam kemasan steril, dilakukan pada kondisi lingkungan steril

2

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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.

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

=

COMMERCIALLY STERILE

Low Acid Canned Food :

PROCESS ADEQUACY (for Safety Assurance)

Focus : Low Acid Canned Foods

=

COMMERCIALLY STERILE

Ope- rator Proses

Pengen -dalian Proses

Arsip proses

PROCESS ADEQUACY (for Safety Assurance)

Focus : Low Acid Canned Foods

Faktor-faktor yang perlu dikendalikan

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Ope- rator Proses

Pengen -dalian Proses

=

COMMERCIALLY STERILE

Arsip proses Faktor Kritis

PROCESS ADEQUACY (for Safety Assurance)

Focus : Low Acid Canned Foods

Faktor-faktor yang perlu dikendalikan  perlu SOP dan GMP ketat

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

PROCESS ADEQUACY (for Safety Assurance)

Focus : Low Acid Canned Foods

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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^-9that there are spores of C.

botulinumin 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

• C. botulinum

• D_Bot,250F= 0.21 menit

• 12-log10 reduction C. botulinum

F_o= 2.52 menit

PROCESS ADEQUACY (for Safety Assurance)

Focus : Low Acid Canned Foods

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Dalam prakteknya …

10 Ovals

Sliced meat in gravy

12-15 All

Meats in gravy

6-8 Up to A1

Mushrooms in butter

8-10 A1

Mushrooms in brine

3-4 A2

Celery

6-8 A2 to A10

4-6 Up to A2

Green beans in brine

3-4 All

Carrots

6-8 A2 to A10

6 Up to A2

Peas in brine

4-6 All

Beans in tomato sauce

3-5 babyfood

Babyfoods

F_ovalues Ukuran Kalengs

Produk

Beberapa nilai-F_opangan steril komersial di pasar UK