itp530 thermal processing of foods -...
TRANSCRIPT
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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Purwiyatno Hariyadiphariyadi.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
ITP530
IntrinsicProperties of Foods
• Species of microorganisms.• Acidity (pH) • Water activity (aw)• 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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ITP530
HM
L
Characteristics of potentially hazardous foods:
M
4.5
0.85
0
1aw
pH1410
ITP530
HM
L M
4.5
0.85
0
1aw
pH1410
Managing riks of potentially hazardous foods: food processing
Salah satu teknik yang effektif adalah:
Pemanasan=
Thermal Processing
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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
HM
L M
4.5
0.85
0
1aw
pH1410
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
ITP530
Better Thermal Processing??~ Optimasi
• 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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ITP530
Better Thermal Processing??~ Optimasi
Thermal Processing: Tujuan
Mengoptimalkan yield dan produktivitas, meminimalkan kerusakan mutu (dan gizi)tanpa mengkompromikan persyaratan keamanan pangan
ITP530
Highly PHFspH > 4.5 dan aw>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
SterilisasiKomersial
Thermal Processing: Kasus A
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ITP530
Highly PHFspH > 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
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
ITP530
Medium ‐ PHFspH > 4.5 dan aw<0.85pH < 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
Awet (shelf stable), dengan/tanpa refrigerasi
Bisa tanpa refrigerasi Contoh : Sari buah, sos tomat,
jem/jelly, dll
ProsesPasteurisasi
&/atau Hot-fill-hold
Thermal Processing: Kasus C
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ITP530
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?
?
ITP530
Thermal Processing
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
IngredientsPreparation:cutting, etc
Preparationof liquid
Ready madeCAN
Filling(particulates)
Filling(liquid)
Closing Retorting Labelling Filled Can
In-Container Processing
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ITP530
Produk Kaleng, botol, gelas, dll
Produk steril dalam wadah
Sterilisasi(pemanasan)
In-container thermal processing
Pengi-sian +
tutup
Thermal Processing1
ITP530
• Species of microorganisms.• Acidity (pH) • Water activity (aw)• 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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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
• Species of microorganisms.• Acidity (pH) • Water activity (aw)• Food Oxygen (some of the spores
with high thermal resistance are anaerobic).
• Food composition
Factors Influence the Heat Resistance of Microbial
ITP530
Heat Resistance of Microbial
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ITP530
Heat Resistance of Microbial
ITP530
D values of microorganisms of importance in heat processing
Spores D 121.1 D140
(min) (s)
B. stearothermophilus 4.0 - 5.0 0.9C. thermosaccharolyticum 3.0 - 4.0D. nigrificans 2.0 - 3.0C. botulinum – proteolytic 0.1 - 0.23C. sporogenes 0.1 - 1.5B. coagulans 0.01 - 0.1B. Sporothermodurans 3,4 -7.9
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ITP530
Reaksi E Z(kJ/mole) (oC)
Enzyme reactions 0-33.5 -Chlorophyl loss 21-113 26-142Ascorbic acid 21-167 11.8-142Non-enzymatic browning 37.7-167 -Lipid oxidation 41.9 -Spore destruction 251-335 8.7-11.8 Veg. cell destruction 209-628 4.7-14.2Protein denaturation 335-502 5,9-8.9
Comparison of Z and Ea for Quality Attributes and Microbial Populations of importance in heat processing
ITP530
• Lethal Rate (LR)= Lethal value (LV)
• Time/Temp Process & LR
• LR Curve for Thermal Process
PROCESS CALCULATIONS
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ITP530
z121.1-T(t)
zT(t)-121.1 10
10
1LVLR ===
T(oC) T(oF) LR(z=10oC)
90 194 0,00077624795 203 0,002454709100 212 0,007762471105 221 0,024547089110 230 0,077624712115 239 0,245470892120 248 0,776247117121,1 250 1,000000000125 257 2,454708916129 264 6,165950019
PROCESS CALCULATIONS
ITP530
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)
0 121,11 121,12 121,13 121,14 121,15 121,16 121,17 121,18 121,19 121,110 121,111 121,112 121,1
LR(z=10oC)
1,01,01,01,01,01,01,01,01,01,01,01,01,0
Pemanasan pada suhu konstan,121,1oC
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
Su
hu
12 unit sterilisasiF0=12
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ITP530
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=10oC)
0 100 0,0077624711 100 0,0077624712 100 0,0077624713 100 0,0077624714 100 0,0077624715 100 0,0077624716 100 0,0077624717 100 0,0077624718 100 0,0077624719 100 0,00776247110 100 0,00776247111 100 0,00776247112 100 0,007762471
Total sterilitas = 0.007762x12 unit= 0.10091 unit
hanya 0.00776 x pengaruh letal pada 121.1oC
Total letalitas = F0 =??
F0 = Do log t
0(LR)dt
N
N0
F0 = LR.t
Pemanasan pada suhu konstan,100oC
PROCESS CALCULATIONS
ITP530
PROCESS CALCULATIONS
t = heating time (mini)T = Heating temperature, oC
F0 = 1 pemanasan selama 1 menit pada suhu 121.1oC
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ITP530
Diketahui : Mikroba A; D0 = 0,21 menitdikehendaki proses 12 D
Pemanasan pada suhu 121.1oC ………> 12(0,21)=2.52 menit
Pemanasan pada suhu 100oC
1/LR100C x 2.52 min = 1/0.00776 x 2.52=324.7 min (5.4 jam)
Pemanasan pada suhu 129oC
1/LR129C x 2.52 min = 1/6,166 x 2.52=0.408 min (24.5 detik)
Pemanasan pada suhu 50oC
1/LR50C x 2.52 min = 1/0. 000000078 x 2.52
= 32307692.31 menit
= 747.8 bulan????!!!!
PROCESS CALCULATIONS
ITP530
Pada prakteknya :
Efek letal panas untuk sterilisasi, umumnya mulai dianggap nyata setelah T>90oC
Teixeira (1992) :
No appreciable lethality at T < 210oF(99oC)
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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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Produk Kaleng, botol, gelas, dll
Produk steril dalam wadah
Sterilisasi(pemanasan)
Pengi-sian +
tutup
PROCESS CALCULATIONS(for ”In-container sterilisation”)
ITP530
Heat Penetration Test
• Scheduled Process:Venting and heating procedure
• Come up time• Operator processing
time• Cooling time, ETC
TR = f(t)
PROCESS CALCULATIONS(for ”In-container sterilisation”)
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ITP530
Tipikal kurva penetrasi panas untuk pangan kaleng dan perubahan suhu retort (TR) selama proses seterilisasi
• Suhu retort di”set” (mis: pada 250oF)
CUT
• t untuk mencapai TR : CUT
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
Heat Penetration Test
ITP530
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
SHP
SHP:Slowest Heating Point=Coldest Point
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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
ITP530
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=10oC)
0 90 0,0007762474 105 0,0245470898 120 0,77624711712 121 0,97723722116 100 0,00776247120 70 0,00000776224 60 0,000000776
F0 = Do log =t
0
(LR)dtN
N0
Fo = luas area di bawah kurva hubungan antara LR dan t
Fo = jumlah area trapesium
Luas trapesium t2
LR2LR1
+=
020406080
100120140
0 4 8 12 16 20 24waktu
Su
hu
(C
)
3.5068)(122
0.977
0.776A =-
+=
PROCESS CALCULATIONS
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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
ITP530
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
ITP530
T-Tm TP-TR=
Ti-Tm Ti-TR
= exp -(t/L2)
TR-TP
TR-Ti
= exp -(k)t
Log(TR-TP)=Log(TR-Ti)- t(2,303)
k
2. Metoda Formula
T - TR
Ti - TR
= e
hA
CpV- t
= e-kt
Persamaan perubahan suhu selama proses pemanasan :
PROCESS CALCULATIONS
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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Dari kurva penetrasi panas :
- Tentukan fh
- 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 Fo; jika diketahui B
........hitung log g = log jI – (B/fh)
...... .dengan diketahui log g cari fh/U
...... .hitung Fi = 10(250-TR)/z
Fo = fh/[(fh/U)Fi]
Kasus 1
PROCESS CALCULATIONS
ITP530
Dari kurva penetrasi panas :
- Tentukan fh
- 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 Fo
...... .hitung Fi = 10(250-TR)/z
....... hitung fh/U = fh/(Fo*Fi)
...... .dengan diketahui fh/U cari log g
B= fh(log jI – log g)
PROCESS CALCULATIONS
Kasus 2
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Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Thermal Processing
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
Aseptic/Continuous Processing
Ingredients CuttingAddition of
Liquid, Mixing
Heating(sterilizing/
Pasteurizing)
FormingPackagingMaterial
Sterilizing AsepticFilling
CodingAsepticClosing Filled Pack
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ITP530
Aseptic/Continuous Processing:Contoh : Susu Cair
Zona Aseptis
SUSU steril dalam
kemasan
PengisianSUSU steril
kedalam kemasan steril, dilakukan pada
kondisi lingkungan steril
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ITP530ITP530
ITP530
Low Acid Food :
a food, other than alcoholic beverages, where any component of the food has a pH > 4.6 and a aw > 0.85.
PROCESS ADEQUACY (for Safety Assurance)Focus : Low Acid Canned Foods
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ITP530
Low Acid Canned Food :
• pH > 4.6• Water Activity > 0.85• Thermally processed• Hermetically sealed container• Non-refrigerated
=COMMERCIALLYSTERILE
Low Acid Canned Food :
PROCESS ADEQUACY (for Safety Assurance)Focus : Low Acid Canned Foods
ITP530
=COMMERCIALLYSTERILE
Ope-rator
Proses
Pengen-dalianProses
Arsipproses
PROCESS ADEQUACY (for Safety Assurance)Focus : Low Acid Canned Foods
Faktor-faktor yang perlu dikendalikan
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ITP530
Ope-rator
Proses
Pengen-dalianProses
=COMMERCIALLYSTERILE
Arsipproses
Faktor Kritis
PROCESS ADEQUACY (for Safety Assurance)Focus : Low Acid Canned Foods
Faktor-faktor yang perlu dikendalikan perlu SOP dan GMP ketat
ITP530
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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ITP530
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.
Performance Standard (USFDA/USDA) :COMMERCIALLY STERILE
PROCESS ADEQUACY (for Safety Assurance)Focus : Low Acid Canned Foods
ITP530
• C. botulinum
• DBot,250F = 0.21 menit
• 12-log10 reduction C. botulinum Fo = 2.52 menit
Performance Standard (USFDA/USDA) :COMMERCIALLY STERILE
PROCESS ADEQUACY (for Safety Assurance)Focus : Low Acid Canned Foods
33
Purwiyatno HariyadiEmail: [email protected]: phariyadi.staff.ipb.ac.id
ITP530
Dalam prakteknya …
10 Ovals Sliced meat in gravy12-15 All Meats in gravy6-8 Up to A1 Mushrooms in butter
8-10 A1 Mushrooms in brine3-4 A2 Celery6-8 A2 to A10 4-6 Up to A2 Green beans in brine3-4 All Carrots6-8 A2 to A10 6 Up to A2 Peas in brine
4-6 All Beans in tomato sauce3-5 babyfood Babyfoods
Fo values Ukuran KalengsProduk
Beberapa nilai-Fo pangan steril komersial di pasar UK
PROCESS ADEQUACY (for Safety Assurance)Focus : Low Acid Canned Foods
ITP530
Terimakasih
More on Thermal Processing of FoodGo to ITP730
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