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Commercial Sterility

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Jannelle Migabon
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14 views39 pages

Commercial Sterility

Uploaded by

Jannelle Migabon
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Commercial

sterility and the


validation of
thermal processes
• Define commercial sterility.

• Explain the areas to be considered in a retort survey.

• Discuss the importance of calculating D and z-values.

• Illustrate the first-order or logarithmic survivor curve for the


calculation of D and z-values.

• Calculate the lethality of the process.


Thermal processing

• Goal – ensure safety of food


produced without compromising
the quality of the end product
Validation methods: Objectives
and principles
• Goal – establish the worst-case conditions
which can be from
• Product
• Container
• Retort or processing system
• Determined by a Thermal Process Authority
Validation methods: Objectives
and principles
• Two processes
1. Temperature distribution (TD
tests)
2. Heat penetration or HP Test
Temperature
distribution
• Locating the retort cold
point
• Ideally, 1C variation during
hold phase with no cold
points
Heat penetration test
Goal – determine heating and cooling
behavior of a specific product

Stages
• Location of the product cold point in
the container
• Establish the process conditions to
have a scheduled process
Heat penetration test
When is it carried out?
• Before commencing production of a
new product, process or package
• Changes to any of the criteria above
Heat penetration test

• Cold points are dependent on the geometry


and characteristics of the food product
• Fish based – cold point is at the geometric
center
Heat
penetration
test

Conduction heating
Heat
penetration
test

Convection heating
Heat penetration test

Changes in the cold point location for a freely-moving liquid such as water, a mixed liquid such as a
soup, and for a conduction heating product such as corned beef
Heat penetration test

Number of replicates?
• Open for discussion
• Depends
• 3x3 and 2 x 10 – common approaches
Heat penetration test

Establishing the scheduled process time and temperature

• Data obtained is called heat penetration data


• In calculating process schedule
• Use the thermal resistance data for the target microorganism
• Use the heat penetration data for the product
• Use of a scientific method to calculate the process schedule for the
product
Microbiological parameters
Microbiological
parameters
• D-value / Decimal reduction time (DT)

• Time (minutes) required to reduce the number of


microorganisms at a constant temperature by a factor of 10
(90% reduction or 1 log reduction)

• D value = 1 minute at 90C, what does it mean?


Microbiological parameters
At 72C, the D value for
microorganisms is 14 minutes
• How long will it require to
decrease microbe from 10,000
to 100 cells?
• What does it mean to have a
higher D value?
• If the D-value at 80 degree Celsius is 0.3
minutes for spores of C. botulinum, the time
taken to reduce 10^9 spores to one spore is
___ minutes
Determine the D-value of a m.o from the following data obtained at 116C )

Time (min) Number of survivors


0 2001050
5 210220
10 19988
15 2000
20 199

1. Obtain the log of the # of survivors per time data


2. Plot time versus Log N using a scatter plot
3. Show equation and get the slope (m)
4. Y = mx + b
5. Calculate D value from the slope (D = -1/slope)
Microbiological parameters
Microbiological
parameters
• Z-value (thermal resistance
constant)
• Measures the effect of
temperature on the D value
• Increase in temperature to
reduce the D value by one log
cycle or a factor of 10
• At 110C, D value is 100 minute,
at __, D value is 10 minute
Determine the z-value for a spore suspension if the following D- values were
obtained at different temperature

Temperature (c) D-value (min)


100 28
103 15.4
106 7.8
109 3.9
111 2.3

1. Obtain the log D per data


2. Plot Log D versus temperature
3. Show equation and get the slope (m)
4. Y = mx + b
5. Calculate z value from the slope (Z = -1/slope)
Microbiological
parameters
• F-value (thermal death time)
• Minutes required to achieve a desired reduction in
microorganisms at specific temperature
• Multiples of D
• D value times the number of required log reductions of the target
m.o
• 12D for C. botulinum (0.23 min x 12 = 2.76 or 3 minutes)
• Pasteurization process = 6D
Microbiological
parameters • For C. botulinum, the target is 12
log reductions, therefore the target
process is:

• DT – decimal reduction time at a fixed


temperature
• N final – final number of m.o after exposure
to elevated temp
• N initial – initial no. of m.o • The target process for a
commercially safe product is 3
minutes at 121.1 of F value of 3
minutes
Determining process schedules

1. General Method or graphical method


2. Formula method
Determining process schedules

General Method
• Converts measured time and temperature
to F-values from accumulated lethal rates
• Lethal rate – microorganisms killing effect
at a measure temperature to one minute
at a reference temperature
Determining process schedules

L – lethality achieved
T – product temperature
Tref – reference temp for the given m.o
Z – z value for the reference m.o
Determining process schedules

Sample problem: a sterilization process wherein the


temperature of the product is at 116C

Exposing the product to 116 for 1 min =


121C at 0.309 min
Determining process schedules

Sample problem: a sterilization process wherein the


product was exposed to 30 seconds at a 116C
temperature

Exposing the product to 116 for 30 sec


or 0.5min = 121C at 0.155 min
• Develop a detailed HACCP Plan for a specific
thermally processed fish product
• E.g. Spanish sardines, canned tuna (hot and
spicy flavor)
• Critical limits and control points can be identified
based on literatures

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