2.1 Thermal Preservation - STD

Thermal Preservation
CLF203 Food Processing &

Preservation
Outline
Types
of Thermal Preservation
Blanching
Pasteurisation
Ultra Pasteurisation
Sous-vide Cook Chill Processing
Sterilisation
Selection
of Heat Treatments
Categories
Protective
of Heat Preservation Practices
Effects of Food Constituents

Preservation
Introduction
Among
all preservation methods, the use

of heat for preservation is most widely
used in the food industry.
Thermal
preservation includes simple

household practices such as cooking,
frying, grilling, broiling, roasting etc.
Commercial
practice of thermal
preservation is through controlled process
such as blanching, pasteurisation,
sterilisation (canning/retort).
Preservation
Thermal Preservation
Blanching
Pasteurisation
Ultra-Pasteurisation
Sous-Vide
Cook Chill Processing
Sterilisation

Preservation
Blanching
Blanching
is a mild thermal process used to

inactivate natural oxidative enzymes (e.g.
polyphenol oxidase [PPO], lipoxygenase)
in
fruits and vegetables to prevent loss of
colour/flavor/nutrient/texture during handling
and storage.
May
not
necessary
be
considered
as
Preservation method but it is a common
practice before further processing such as
freezing, canning, dehydration.
Blanching
time for most vegetables is about 1 to

5 min and influenced by :
Type of vegetable and size
Blanching Temperature
Method of heating (water, steam)
CLF203 Food
Processing &
Preservation
Table 1 : Inactivation temperatures of some enzymes

Enzyme
Effect
Inactivation temp. (C)
Lipoxygenase
rancidity
~ 80
Polyphenoloxidase
browning
~100
Peroxidase
deterioration
~135
Table 2: Example of Blanching Time for Vegetables

Vegetable
Recommended Water Blanching

Time (min)
Potato
35
Broccoli
(flowerets 11/2 inches across)
Carrots (Dice/Slice)
Green Peas
1.5
Cabbage (shredded)

Preservation1.5
6
Blanching
Under-blanching
stimulates enzymes activity

while over-blanching results in loss of flavour/
colour/ texture/ minerals.
Under-blanching
must be avoided because heat

may be just sufficient to cause disruption of
tissues which release the enzymes and
accelerate deterioration.
After
blanching, vegetable must be cooled

rapidly to stop the process to avoid overblanching which will result in excessive
softening of tissues.
Preservation
Blanching
Other
benefits of blanching:
Remove non-condensible tissue gases thus result in

better vacuum in cans and reduce oxygen which might
cause chemical reaction during storage
Preheat product prior process (i.e. increase bulk
temperature of tissues)
Facilitates packaging into cans by wilting tissues.
Cleanses the surface of dirt
Reduce microbial load
Common
Blanching Methods:
Conventional water blanching (immersion type / spray

type)
Steam blanching (preferred method)
CLF203 Food
Microwave blanching
Processing &
Preservation
Blanching
Adequacy
of blanching is usually based on

inactivation of heat resistant enzymes such
as
peroxidase/PPO/catalase.
Peroxidase
inactivation is taken as blanching adequacy
index.

Preservation
Typical Blanching System
=
SINGH. R.P, D.R. HELDMAN. 2009. Introduction to Food Engineering Fourth
Edition. China: Academic Press
Preservation
10
6 Zones
Infeed zone - 1000mm.

Preheating zone - 1500mm. 2 pumps 25M/h plus water curtain with pump.
Blanching zone - 4500mm. 4 pumps plus 1 CIP pump, water curtain with pump.
Air cooling zone - 4500mm, with ventilator.
Water cooling zone - 3700mm. 3 pumps 25M/h, 1 spray pipe for ice water plus
a bypass pump. Sealing between air cooling and water cooling with stainless steel
plate and rubber.
Outfeed zone - 700mm.

Preservation
11
Sous-Vide Cook Chill Processing

Sous
vide is French word for under vacuum
Sous-vide
cook chill process is known as the

cooking of raw material or par-cooked raw
materials under controlled conditions of
temperature and time inside vacuumised
pouches and cooled rapidly
It
is a pasteurization/cooking step that

reduces bacterial load but depending of
time/temperature combination, it may not be
sufficient to make the food shelf-stable
Preservation
12
Sous Vide Cook Chill Processing

Widely
used in catering/modern kitchen

to give superior product reproducibility,
better control of doneness, reduction of
pathogens at lower temperatures,
prevent
recontamination
through
vacuum packaging, minimise oxidation
and loss of nutrients to cooking medium

Preservation
13
Figure 1: Chicken eggs cooked for 60 minutes at various

Preservation
14
ovomucoid
conalbumi
n
70 C
61.5 C
livetin
64.5 C

Preservation
15
Pasteurisation
The
process of Pasteurisation was named

after Louis Pasteur.
Mild
thermal process (generally below

water boiling point) with purpose to
inactivate enzymes AND eliminate selected
pathogenic m/o to extend product shelf life.
Does
not destroy all vegetative bacteria

and spore-former so pasteurised food have
to be stored in combination with other
preservation
methods
e.g.
refrigeration/chemical preservative / MAP to
minimize microbial growth.
Preservation
16
Pasteurisation
Sensory
characteristic and nutritional value of

food are minimally affected.
Severity
of heat treatment and storage period

are dependent on pH condition, resistance of
test m/o, type of heat application, heat
sensitivity of food etc.
Majority
of pasteurisation involves liquid such

as milk, beer, juice etc. However, recently
minimally processed vacuum packaged food
are pasteurised offering convenience and
quality.
Preservation
17
Pasteurisation
Common
liquid product pasteurisation :
Batch pasteurisation
Use vat pasteurizer (indirect ~ jacketed with circulating

water/steam or direct ~ water or steam)
High Temperature
pasteurisation
Short
Time
(HTST)
continuous
Consist of heat exchangers (for product heating/cooling),

holding tube, pumps and flow diversion valve
Examples
of typical pasteurisation conditions:
Fruit juice ~ inactivation of enzymes ~ 88 for 15s

Beer ~ Destruction of m/o and residual yeast ~ 65-68 for 20min
Milk ~ Destruction of pathogen ~ 71.5 for 15s
Preservation
18
Pasteurisation
Adequacy of raw milk pasteurization is done using

Alkaline Phosphatase test. Alkaline Phosphatase is
an enzyme naturally present in all raw milk and
its heat stability is greater than target pathogens
(e.g. Mycobacterium tuberculosis) in milk. Thus,
inactivation of alkaline phosphatase is used as an
indicator of proper milk pasteurization.
Testing of alkaline phosphatase activity

mandatory for raw milk pasteurization.
http://
www.cdrfoodlab.com/food-analysis/alkalinephosphatase-cow-milk.html
Preservation
is
19
Ultra-Pasteurisation
Pasteurisation
at a higher temperature to
extend product shelf life under normal
refrigerated conditions through destruction of
greater proportion of spoilage m/o
Generally
to effect a minimum 6-log reduction

of viable spores of non-proteolytic Cl botulinum
under normal refrigerated conditions
E.g. 137.7 (280 ) for about 2 seconds or longer

for extended shelf life (ESL) of about 6-8 weeks
under chilled conditions

Preservation
20
Table 3: Pasteurization Definition
Source: International Dairy Foods

Association

Preservation
21
UHT Processing
UHT
(ultra-high temperature or ultra heat treated)
is the sterilisation of food before packaging

followed by filling into pre-sterilized containers
and airtight sealed in a sterile environment
Sterilisation
of the product via rapid heating to

temperature about 135 ~ 140 holding for several
seconds (2 5 sec) followed by rapid cooling.
Statutory
regulations for some UHT products
Eg. UHT Milk temp. not less than 135 for a min. of 2
seconds (Singapore Sale of Food Act)

Preservation
22
UHT Processing
Method
of UHT Treatment
Direct heating systems ( steam injection, steam infusion)
Indirect heating systems (plate, tubular, scraped surface
heat exchanger)
Methods
of aseptic packaging
Fill and seal
Form, fill and seal
Erect, fill and seal
Thermoform, fill and seal
Blow mold, fill and seal
NOTE:
Products that are UHT heat treated but not

aseptically packaged gives a longer shelf life at refrigeration
temperatures compared to pasteurized products, However,
it does NOT produce a shelf-stable product at ambient
temperatures, due to the possibility of recontamination
post-processing.
Preservation
23

Preservation
24

Preservation
25
UHT Packaging System

Preservation
26
Sterilisation
More
severe heat treatment to eliminate both

spoilage and pathogenic m/o.
Sterilisation
imply complete destruction of m/o.

Nonetheless, in food it is not necessary to be
completely sterile to have long shelf life.
Typically
in food, we only need to achieve

commercially sterility. Commercial sterile refers
to degree of sterilisation whereby all pathogenic
and toxin forming m/o are destroyed and those
remaining will not grow and result spoilage under
normal storage condition.
Preservation
27
Sterilisation
Example
of typical industrial practices:
5D process ~ used for acid canned foods (pH <4.6) to

reduce B. sterothermophilus population by 5 log cycle
12D process ~ used for low acid canned food (pH >4.6)
to reduce Cl. botulinum spore population by 12 log cycle
Minimum botulinum cook ~ heating at 121 for 3 min
measured at the slowest heating point
Sterilisation
process takes into account of the

heat resistance property and growth sensitivity
to oxygen, pH or temperature of m/o
System
for commercial sterilisation includes :
Batch (e.g. still retort)

Continuous (e.g. hydrostatic sterilisation)
UHT with aseptic packaging

Preservation
28
Hydrostatic Retort
Water in the inlet
and outlet legs
which balance the
pressure in the
steam dome hence
give this style of
retorts their name.
14
m
The severity of the

process depends
upon the residence
time that the cans
are in the dome
(which is controlled
by chain speed and
chain length)
Preservation
29
Hydrostatic Sterilizer Containment

Structure

Preservation
30
Sterilisation
Inoculated
pack studies are used to

determine adequacy of thermal processing
to achieve commercial sterility.
Known substantial population of heat resistant food
spoilage m/o (e.g. Clostridium sporogenes PA 3679)
is inoculated into cans of food and processed in a
retort. After processing, the cans are stored at
temperature that favours growth of surviving
spores. Cans are periodically examined for physical
appearance (bulging cans) and m/o testing.

Preservation
31
Selection of Heat
Treatments
Prior
to selection of preservation treatment we need
to know :
1. Time-temperature combination for inactivation of most
heat resistant pathogen/spoilage m/o found in the food.
Destruction of Cl. botulinum in low acid food are equally
effective at the following time-temperature combination :
0.78 min at 127
2.78 min at 121
10 min at 116
330 min at 100
2. Heat Penetration characteristics (e.g. mode of heat

CLF203 Food
transfer, packaging) of the food.
Processing &
Preservation
32
Category of Heat Preservation

Practices
Broadly it can be divided into two broad categories:
Heating Food in Containers
Produce reasonably acceptable quality food
Less technical sophistication, less concern of
contamination after thermal processing
E.g. Still Retort, Agitating Retorts, Hydrostatic Cookers
and Cooler, In-package Pasteurisation
Heating Food Prior to Packaging

Less damaging to food quality since food can be
subjected to rapid heat exchange
Need to prevent/minimise recontamination after
thermal processing
E.g. Batch pasteurisation, HTST Pasteurisation, Aseptic
Packaging, Hot Filling
Preservation
33
In-package
Pasteurisation
Courtesy of Thong Siek Food Industry

34
Pte Ltd
Protective Effects of Food

Constituents
Some food constituents in food have varying

degree to protect m/o against heat:
E.g. Sugar/starch and protein protects bacterial spores.

Thus, canned fruits with high sugar concentration needs
higher temperature or longer time.
E.g. Fat/oil can protect m/o and their spores by interfering
with penetration of wet heat. M/o in liquid phase is killed
more rapidly than in oil-phase.
Other than direct protective effects to m/o, food

constituents may result in indirect effect against
thermal processing.
E.g. Fat is poorer heat conductor than water.
E.g. High native starch product may thicken during
processing and convert heating from convection to
conduction.
Preservation
35

Preservation
36

Preservation
37

2.1 Thermal Preservation - STD

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Thermal Preservation

CLF203 Food Processing &

of Heat Preservation Practices

Effects of Food Constituents

all preservation methods, the use

preservation includes simple

Cook Chill Processing

CLF203 Food Processing &

is a mild thermal process used to

time for most vegetables is about 1 to

Table 1 : Inactivation temperatures of some enzymes

Inactivation temp. (C)

Table 2: Example of Blanching Time for Vegetables

Recommended Water Blanching

CLF203 Food Processing &

stimulates enzymes activity

must be avoided because heat

blanching, vegetable must be cooled

Remove non-condensible tissue gases thus result in

Conventional water blanching (immersion type / spray

of blanching is usually based on

CLF203 Food Processing &

Typical Blanching System

Infeed zone - 1000mm.

CLF203 Food Processing &

Sous-Vide Cook Chill Processing

vide is French word for under vacuum

cook chill process is known as the

is a pasteurization/cooking step that

Sous Vide Cook Chill Processing

used in catering/modern kitchen

CLF203 Food Processing &

Figure 1: Chicken eggs cooked for 60 minutes at various

CLF203 Food Processing &

CLF203 Food Processing &

process of Pasteurisation was named

thermal process (generally below

not destroy all vegetative bacteria

characteristic and nutritional value of

of heat treatment and storage period

of pasteurisation involves liquid such

Use vat pasteurizer (indirect ~ jacketed with circulating

Consist of heat exchangers (for product heating/cooling),

of typical pasteurisation conditions:

Fruit juice ~ inactivation of enzymes ~ 88 for 15s

Adequacy of raw milk pasteurization is done using

Testing of alkaline phosphatase activity

to effect a minimum 6-log reduction

E.g. 137.7 (280 ) for about 2 seconds or longer

CLF203 Food Processing &

Table 3: Pasteurization Definition

Source: International Dairy Foods

CLF203 Food Processing &

(ultra-high temperature or ultra heat treated)

is the sterilisation of food before packaging

of the product via rapid heating to

regulations for some UHT products

CLF203 Food Processing &

Products that are UHT heat treated but not

CLF203 Food Processing &

CLF203 Food Processing &

UHT Packaging System

CLF203 Food Processing &