hpp: high-pressure processing€¦ · ppt file · web view2011-09-23 · hydrostatic pressure....
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HPP: HIGH-PRESSURE PROCESSING
MODERATOR Mike Fielding
Managing Editor of Technical Content,
Meatingplace
HOST Bill Kinross
Publisher, Meatingplace
FUNDAMENTALS AND PACKAGING ASPECTS
Tatiana Koutchma, PhD. Research Scientist
Agriculture and Agri-Food Canada
Poll Question
What research topics should federal government scientists focus on to assist faster implementation of HPP technology in the meat industry?
1. Microbial safety2. Nutritional considerations3.Chemical/Toxicological considerations4. Raw meats functionality5. HPP for control of emerging pathogens
Why High Hydrostatic Pressure Independent of product mass,
size and geometry Minimizing treatment time and scale up Inactivates all vegetative bacteria and spores Destroys enzymes Minimal impact on quality and nutrition
Commercially economical processes Emerged as a post-lethality treatment Emerging as a pre-treatment before cooking
Regulatory Status of HHPUSA• USDA has approved High Hydrostatic Pressure as an
intervention method for Listeria contaminated pre-packed ready-to-eat (RTE) meat products
• U.S Food and Drug Administration (FDA) has accepted the commercial use of pressure-assisted thermal sterilization (PATS) processes for application in the production of low acid foods (LAF) ( February 2009)
Canada Use of High Hydrostatic Pressure for Processing Ready to
Eat (RTE) Meat-containing Entrees, Meat-containing Salads and Meat Products (Maple Leaf, December 2006)
Use of High Hydrostatic Pressure for the Control of L. monocytogenes in Ready to Eat (RTE) Meats and Poultry (Santa-Maria, Foods, October 2006)
Principles of High Hydrostatic Pressure (
Listeria
HPP systems design
Vertical vessel Horizontal vessel
Commercial HPP systems
Vessel layout – horizontal
Automatic loading / unloading
• Wave 6000 / 55 L• Wave 6000 / 135L • Wave 6000 / 300T L• Wave 6000 / 420 L
• Maximum pressure – 87,000 PSI• Pressure Hold Time – 3 min
Photo courtesy of NC Hyperbaric
Commercial HPP systems
• Wide range of HHP systems – 100 L - 600– 215 L - 600– 350 L - 600– 687 L - 300
• 7 contract services facilities
Photos courtesy of Avure
Product and process conditions for establishment of HPP preservation
HPP pasteurization HPP sterilization
Product parameters
pH, aw 3.5 <pH<4.6; pH<3.5 pH>4.6; aw >0.86
Process parameters
Temperature, oC ≤ 45 > 100
Pressure, MPa ≤ 600 > 700
Target microorganisms
Pathogenic E. coli; Listeria; Salmonella C. botulinum spores Spoilage Lactic bacteria, yeasts, molds Geobacillus spp.
Bacillus cereusStorage Refrigerated conditions Ambient temperaturePackaging Hermetically sealed
flexible containersHermetically sealed flexible containers
Product Development Issues• Product selection• Product formulation• Food safety/regulatory• Pre & post pressure processing
• Packaging
• Product storage temperature
• Shelf-life
HPP In-Container Principles• Product is generally treated in its final primary package
• Food and its packaging are treated together
• Entire package remains a “secure unit” until the consumer opens it
• Packaging must withstand a change of volume up to 18% followed by return to its original size
– Without loosing package integrity– Seal integrity– Barrier properties
• Packaging under vacuum or modified atmosphere
Food Packaging Materials
• In general, traditional packaging materials are not intended to have any technical effect in the food, and considered as food additives because their components can migrate into the food that contacts the packaging
• In the case of active and intelligent packaging, sometimes the package may be designed to deliver a chemical to the food for the purpose of exerting some technical effect in the food.
Definition
Available Packaging Materials• Plastic-laminated materials
– nylon/coextruded EVOH– nylon/PP– PET/AlOx/CPP– PET/PE
• Aluminum foil-laminated pouches – PET/Al/CPP– nylon/Al/PP
• Deposited coatings of SiOx
• Blends of polymers
• Nanocomposite materials
Physical Compression• Compression forces act on
– Food– Air– Packaging materials
• Decompression– Food package system undergoes a
reversible return to its initial volume – Except for porous structures
– where Vo and Bo are the polymer volume and the bulk modulus at atmospheric pressure for each polymer, respectively, p is pressure and C is a polymer dependent constant
ln (V/V0) = ln[1 - C ln(1 + p/CB0)]
Compression of Packaging Materials• 5% of the vessel is full of packaging material
• Polypropylene (PP) and polyethylene (PE) undergo compression heating (CH)
• CH was greater than water under– HP-LT (10ºC and 50ºC)– HP-HT (90ºC) conditions up to 750 Mpa
• CH was non-linear
• “Warmer” layer may be formed surrounding the food
Temperature elevation due to pressurization
0 100 200 300 400 500 600 7000
20
40
60
80
100
120
140
Pressure / MPaTe
mpe
ratu
re /
°C
0 100 200 300 400 500 600 7000
20
40
60
80
100
120
140
Pressure / MPa
Tem
pera
ture
/ °C
WaterPropylene-GlycolHDPEPPdata5PTFEdata7data8data9data10data11data12data13data14data15data16
0 100 200 300 400 500 600 7000
20
40
60
80
100
120
140
Pressure / M Pa
Tem
pera
ture
/ °C
WaterP ropylene-GlycolHDPEPPdata5PTFEdata7data8data9data10data11data12data13data14data15data16
(MPa)(°
C)
Ardia et al., 2004 Knoerzer and Versteeg, 2009
Requirements for HPP Packaging Materials
• Flexibility
• Visual integrity
• Gas barrier
• Material and seal strength
• Head space
• Aging and printability
Integrity requirement1
(maximum expected pressure/temperature)
HP-LT(600 MPa/80ºC)
HP-HT(800 MPa/133ºC)
Retort2
(0.2 MPa/ 133ºC)
Visual integrity no delamination or blistering
no delamination or blistering
no delamination or blistering
Oxygen permeability (maximum deviation 12%)
product dependent 0.06 for US military or 0.5-1.0 g/m²/day for
some commercial products
0.06 for US military or 0.5-1.0 g/m²/day for some commercial
products
Water permeability (maximum deviation 12%)
product dependent 0.01 g/m²/day or product dependent
0.01 g/m²/day or product dependent
Seal strength properties (maximum deviation 25%)
material dependent material dependent seal strength, 2-3.5 kg/100 mm; bond strength 150 150-500 g/10 ml; burst test 7.5 kg/15 mm seal
Physical strength (tensile, elongation, elasticity modulus; maximum deviation
25%)
material dependent material dependent material dependent
Global migration of packaging components to food simulants
< 10 mg/dm2 < 10 mg/dm2 < 10 mg/dm2
Maximum headspace3,4 up to 30% up to 30% up to 30%
High thermal conductivity4 not required (with exceptions)
required required
Polymer Oxygen permeability at 23C 50% or 0% RH (ml/m2/day)
Water vapour permeability at 23C 85% RH (g/m2/day)
Ethylene vinyl alcohol (EVOH)
0.001-0.01 (dry) 1-3
Poly(vinylidene chloride) (PVDC)
0.01-0.3 0.1
Poly(vinyl alcohol) (PVAL)
0.02 (dry) 30
Polyamide (PA) or nylon 0.1-1 (dry) 0.5-10Poly(ethylene naphthalate) (PEN)
0.5 0.7
Poly(ethylene terephthatlate) (PEF)
1-5 0.5-2
Poly(vinyl chloride) (PVC)
2-8 1-2
Polypropylene (PP) 50-100 0.2-0.4Polyethylene (PE) 50-200 0.5-2Polystyrene (PS) 100-500 1-4
Residual Headspace• Residual headspace in certain packages has been shown to
influence package integrity by causing delamination
• Headspace must be minimized not only to maximize vessel use capacity but also to maintain integrity
• Further work must be done in order to establish a minimum headspace value acceptable to maintain package integrity at both HP-LT and HP-HT conditions
Summary• Integrity criteria has to be met by a packaging material after HPP
processing at mild and high temperature – visual integrity, gas permeability, seal and physical strength properties,
and global migration of packaging components into the food
• Reported EVOH-based materials showed no deviations after HP-LT in terms of visual integrity, permeability, and physical properties.
• Information gaps for certain properties, including global migration, must be provided for a complete assessment of the suitability of some reported materials
Future Trends• Further research is required in screening new materials that are finding applications in
thermal processing (hot fill or retort) for their potential use in HPP processes
• Transparent materials are desirable due to higher consumer preference
– Thin vacuum deposited coatings of SiOx on PET, PP or PA which are transparent, water-resistant, retortable microwaveable options
– New barrier polymers currently used as discrete layers with an oxygen permeability value 50-100 times lower than PET.
• Biodegradable polymers are being developed with oxygen barrier properties resembling those of EVOH, with heat sealability and resistance to grease.
• Blends of barrier polymers and standard polymers have been developed, including EVOH in PP, PE or PA; PA in PP or PET, and LCP in PET and PE
• Nanocomposite materials, or polymers filled with small (100-1000 nm) inorganic particles, may improve barrier properties by a factor of 50 or higher.
26
GFRC PILOT PLANT: CL-02 Certified Facility
20092010
2011PHAC
certification
McCormick Place, Chicago, ILWednesday, November 22:30-3:30 PMThe Promises and Challenges of Applying High Pressure Pasteurization (HPP) for RTE Food Products
Presented by Dr. Tobias RichterDr.-Ing., Dipl.-Kfm., M.Sc.
MULTIVAC Sepp Haggenmueller GmbH & Co. KG, Germany
NEXT-GENERATION HPP:
BEYOND SHELF-LIFE EXTENSION
Dr. Phil Minerich Vice President of Research and Development
Hormel Foods
Agenda
• Applications– Natural Meats– Produce – Fresh Meats– Harvest Processing
• Conclusion
Poll Question
What product features are achieved by using High-Pressure Processing?
1. Minimally processed 2. Extended shelf-life 3. Post-package pasteurization 4. All of the above
Application: Natural Meats
• U.S. Department of Agriculture definition– A product containing:
• No artificial or synthetic ingredient• No chemical preservative• No coloring ingredient• Only minimally processed
• Hormel® Natural Choice® products– HPP benefits
• Post-package pasteurization– Inactivates harmful microbes in foods
• Extends shelf-life
Sourse: http://www.fsis.usda.gov/factsheets/meat_&_poultry_labeling_terms/index.asp
Application: Produce
• Food safety assurance• Stabilizes enzyme activity• Preserves and enhances:
– Natural flavor– Color – Texture– Other quality attributes
• Extends shelf-life
Application: Fresh Meats
• Raw beef patties• Stops post-mortem glycolysis
– Improves meat quality for consumers• Stabilizes pH >6.0
– Improves color– Increases water-holding capacity– Decreases shear force– Increases tenderness
eating experience– Increases overall liking
Application: Harvest Processing
• Hair/feather removal– Loosens hair/feather follicles from skin– Eliminates scald tank
• Toenail removal– Loosens toenails from hoof
• Reduces fecal contamination
Conclusion
• HPP fits a variety of applications:– Allows ready-to-eat meats to meet the
USDA natural definition– Enhances quality attributes for produce products– Enhances quality for fresh meats– Improves harvest processing
• Future outlook– ???
HOW TO ENTER THE MARKET WITH AN ADVANTAGE
Justin Segel – PresidentGreg Zaja – Vice President
American Pasteurization Company
Poll Question
Besides food safety, what is driving your interest in high-pressure processing?• Clean labels• Longer shelf life• Risk management (raw materials/finished
product)• Regulatory compliance
Basic Concept of Toll vs. In-house
Capital costs • Hidden costs
Operations Coordinating volume stream
First Steps
Initial product testing • Product evaluation • Identify quality & food safety measures • Validation
• Inoculation studies• Shelf studies
• Packaging
Process Implementation
Integration between establishments• USDA approval for transferring product• Product specification overview • HACCP plan
Typical Tolling Process
Documentation of all records• Receiving • Processing• Certification of HPP• Pre-shipment reviews
What to Expect from a Toll Processor
Final product inspection Final packaging solutions Storage and distribution needs Supply chain integration Redundancy of equipment
QUESTIONS & ANSWERS
FOR MORE INFORMATIONDr. Tatiana Koutchma: [email protected] L. Minerich: [email protected]
Justin Segel: [email protected] Zaja: [email protected]
Jerry Hirsh: [email protected]
Bill Kinross: [email protected] Fielding: [email protected]
Webinar recording and PowerPoint presentation will be emailed to you within 48 hours. For more information:
www.meatingplace.com/webinars