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POST-PACKAGING PASTEURIZATION OF RTE MEAT PRODUCTS

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POST-PACKAGING PASTEURIZATION OF RTE MEAT PRODUCTS

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    1. March 28-30, 2006 POST-PACKAGING PASTEURIZATION OF RTE MEAT PRODUCTS Seth Pulsfus Alkar Technical Development

    2. March 28-30, 2006 The simplest way to safer RTE products

    3. March 28-30, 2006 The new FSIS rule mandates to control L. m in post-cooking processed RTE meats Post-packaging pasteurization comply with FSIS rule: Implement a final intervention step after cooking = “post lethality” treatment Reduce risks of potential recontamination by L. m Increase products shelf-life by destroying spoilage micro-organisms

    4. March 28-30, 2006 How to define the right process for you?

    5. March 28-30, 2006 OUTLINE

    6. March 28-30, 2006 Products characteristics affect process lethality Shape Surface “smoothness” Composition

    7. March 28-30, 2006 Products’ shape affects the dwell time

    8. March 28-30, 2006 Effect of shape: single layer hot dog packs are heat-treated in 8 min…

    9. March 28-30, 2006 While it requires 25 min for double layer hot dogs to reach the same temperature

    10. March 28-30, 2006 The smoother the surface, the more efficient the pasteurization process

    11. March 28-30, 2006 Rough surfaces need deeper heat penetration thus longer dwell time

    12. March 28-30, 2006 Because heat is transferred by conduction beyond the surface = less efficient

    13. March 28-30, 2006 Process lethality will vary depending on products’ surface roughness

    14. March 28-30, 2006 Highly injected products require longer processing times

    15. March 28-30, 2006 The presence of nitrite optimizes lethality

    16. March 28-30, 2006 OUTLINE

    17. March 28-30, 2006 Equipment design is instrumental in delivering an efficient process Products’ carrier design Heat transfer rate Temperature across the equipment Chilling capacity Process flexibility

    18. March 28-30, 2006 Carriers design must allow for all products’ sides to be treated evenly

    19. March 28-30, 2006

    20. March 28-30, 2006 Uniform temperatures throughout the equipment deliver safer products

    21. March 28-30, 2006 Pasteurized products need fast chilling to comply with FSIS guidelines

    22. March 28-30, 2006 And chilling back to 40?F can take a long time which must be included in overall process chilling time

    23. March 28-30, 2006 Example: crust freezing and equilibration process

    24. March 28-30, 2006 Lower initial core temperatures = shorter chilling time

    25. March 28-30, 2006 Alkar hot water tank Serpentine pasteurizer

    26. March 28-30, 2006 OUTLINE

    27. March 28-30, 2006 The new FSIS rule requires to validate the pasteurization process implemented

    28. March 28-30, 2006 Process lethality depends strongly on: Product characteristics Lethality established for a product can be extended only to similar products Equipment design Each equipment is characterized by its heat transfer rate Surface pasteurization is a specific process

    29. March 28-30, 2006

    30. March 28-30, 2006 Several factors influence the amount of purge released Process Chilling ? crust freezing increases purge Impingement ?less purge vs. non-impinged products Products’ shape and size Cut ends induce more purge than non cut ends Small products present higher purge percentage Products’ composition Binders like carrageenan, and soy protein isolates limit purge Level of injection Highly injected products: 1.8 to 2% purge Low injected products: 1 to 1.5% purge

    31. March 28-30, 2006 Surface pasteurization affects products and operations Products’ packaging Use of thicker, heat resistant bags Make shrink tunnel for bags optional Wet packages may affect labeling Products’ quality Generate more purge than in non-heat treated products Products shelf-life Increase shelf-life significantly

    32. March 28-30, 2006 In summary

    33. FLASH PASTEURIZATION TECHNOLOGY Surface pasteurization of hot dogs…without added purge? It’s possible!

    34. Shortcoming of current hotdog post packaging pasteurization Cook Chilling to packaging Seal Heat treatment Use pre-packaging pasteurization instead Cook Chilling to Packaging Flash pasteurization Seal Pasteurize before packing to avoid purge

    35. Integrate heat treatment into a packaging machine

    36. Eliminate handling between pasteurization and packing

    37. Flash pasteurization : The theory behind the patent The energy required to destroy bacteria = 1 to 12 kcal/mol vs. 50 to 100 kcal/mol to seriously damage muscles ? very quick heat transfer to surfaces preserve sensory characteristics Gas molecules are smaller than bacteria ? a gas can enter any cavity containing micro-organisms Saturated steam is a gas Steam releases a lot of energy when condensing

    38. SP Module: short process, high lethality

    41. RESULTS TO DATE

    42. CO-DEVELOPMENT PROJECT From Research to Commercialization

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