2314533 2011 packaging for heat processed 1 food
TRANSCRIPT
PACKAGING FOR HEAT-PROCESSED FOOD
Heat Preservation
วั�ตถุ�ประสงค์� เพื่��อ ทำ��ให้�อ�ห้�รนุ่��มขึ้��นุ่ ย่�อย่ง��ย่ขึ้��นุ่ ทำ��ให้�อ�ห้�รอร�อย่ ม รสช�ต" กลิ่"�นุ่รสม�กขึ้��นุ่ ทำ��ลิ่�ย่ จุ�ลิ่"นุ่ทำร ย่� ทำ �ทำ��ให้�เก"ดโรค์ แลิ่ะ/ห้ร�อทำ��ให้�
อ�ห้�รเนุ่��เส ย่ แลิ่ะ enzyme เช�นุ่ Avidin ในุ่ไขึ้� แย่�งจุ�บ Biotin
ก�รให้�ค์วั�มร�อนุ่ม ห้ลิ่�ย่วั"ธี เช�นุ่ ต�ม ทำอด ผั�ด นุ่��ง ค์��วั ลิ่วัก ฯลิ่ฯ
อ�ห้�รทำ �ผั��นุ่ค์วั�มร�อนุ่จุะม อ�ย่�ก�รเก.บนุ่�นุ่กวั��
Degree of Heat Preservation
1. Sterilization2. Commercially Sterilization or
“sterile”3. Pasteurization4. Blanching
Degree of Heat Preservation
1. Sterilization complete destruction of microorganism จุ�ดม��งห้ม�ย่เพื่��อ ทำ��ลิ่�ย่จุ�ลิ่"นุ่ทำร ย่�ทำ �ม อย่/�ทำ� �งห้มด สปอร�ขึ้องแบค์ทำ เร ย่ด�วัย่
แลิ่ะเอนุ่ไซม� โดย่ทำ��วัไป อ�ณห้ภู/ม"ทำ �ใช�ส/งถุ�ง 121 องศ�เซลิ่เซ ย่ส แลิ่ะค์งทำ �อ�ณห้ภู/ม"นุ่ �เป4นุ่
เวัลิ่� 15 นุ่�ทำ (ขึ้��นุ่อย่/�ก�บชนุ่"ดอ�ห้�ร ลิ่�กษณะภู�ชนุ่ะบรรจุ� จุ��นุ่วันุ่จุ�ลิ่"นุ่ทำร ย่�เบ��องต�นุ่ แลิ่ะอ��นุ่ ๆ ) แลิ่�วัทำ��ก�รลิ่ดอ�ณห้ภู/ม"ลิ่ง
อ�จุใช�อ�ณห้ภู/ม"อ��นุ่ทำ �ต���กวั��นุ่ �ได� แต�จุะต�องให้�ม ผัลิ่ในุ่ก�รทำ��ลิ่�ย่จุ�ลิ่"นุ่ทำร ย่�ทำ��งห้มด จุ�งจุะเร ย่กวั��เป4นุ่ก�รสเตอร"ไลิ่เซช��นุ่
Low acid food (pH >4.6, aw >0.85) Clostridium botulinum 12 D process
High acid food (pH < 4.6, aw > 0.85) Bacillus thermoacidurans 5 D process
Degree of Heat Preservation
2. Commercially Sterilization or “sterile”
ก�รให้�ค์วั�มร�อนุ่ในุ่ก�รทำ��อ�ห้�รกระป7อง อ กช��อห้นุ่��งวั�� ก�รสเตอร"ไลิ่ลิ่�แบบก�รค์�� ซ��งห้ม�ย่ถุ�งระด�บก�รทำ��สเตอร"ไลิ่เซช��นุ่ทำ �ทำ��ลิ่�ย่จุ�ลิ่"นุ่ทำร ย่�ทำ �ทำ��ให้�เก"ดโรค์ แลิ่ะจุ�ลิ่"นุ่ทำร ย่�ทำ �สร��งส�รพื่"ษ รวัมทำ��งส"�งม ช วั"ตอ��นุ่ทำ �ส�ม�รถุทำ �จุะเจุร"ญได�ในุ่อ�ห้�รแลิ่ะทำ��ให้�อ�ห้�รเส ย่ได� เม��อเก.บอ�ห้�รไวั�ในุ่สภู�พื่แวัดลิ่�อมปกต"
ด�วัย่เห้ต�นุ่ �อ�ห้�รทำ �ผั��นุ่ก�รสเตอร"ไลิ่ลิ่�แบบก�รค์��จุ�งย่�งม สปอร�ขึ้องแบค์ทำ เร ย่ทำ �ส�ม�รถุทำนุ่ค์วั�มร�อนุ่ได� แต�สปอร�นุ่��นุ่ไม�ส�ม�รถุทำ �จุะงอกแลิ่ะเจุร"ญเพื่"�มจุ��นุ่วันุ่ในุ่ภู�ชนุ่ะบรรจุ�นุ่��นุ่ได�
Degree of Heat Preservation
3. Pasteurization Low order of heat treatment (generally
below boiling point of water) ม 2 วั�ตถุ�ประสงค์�
อ�ห้�รทำ �ม pH > 4.6 : เพื่��อฆ่�� pathogenic organisms เช�นุ่ในุ่นุ่ม ห้ร�อ ไขึ้�
อ�ห้�รทำ �ม pH < 4.6 : เพื่��อย่�ดอ�ย่� shelf life (จุ�ก spoilage จุ�ลิ่"นุ่ทำร ย่� แลิ่ะ enzyme) ขึ้องผัลิ่"ตภู�ณฑ์� เช�นุ่ beer, wine, fruit juices
Shelf life ไม�นุ่�นุ่ แลิ่ะต�องเก.บในุ่ต/�เย่.นุ่
Degree of Heat Preservation
3. Pasteurization (cont.) ม 2 แบบ
3.1 ก�รให้�ค์วั�มร�อนุ่ทำ �อ�ณห้ภู/ม"ส/งเวัลิ่�ส��นุ่ (High Temperature Short Time, HTST) จุะให้�ค์วั�มร�อนุ่จุนุ่นุ่���นุ่มม อ�ณห้ภู/ม" 72 องศ�เซลิ่เซ ย่ส แลิ่ะร�กษ�อ�ณห้ภู/ม"ทำ �อ�ณห้ภู/ม"นุ่ �นุ่�นุ่ 15 วั"นุ่�ทำ โดย่ทำ��วัไปแลิ่�วัจุะใช�ในุ่ระบบก�รผัลิ่"ตแบบต�อเนุ่��องซ��งเป4นุ่ก�รผัลิ่"ตในุ่ระบบอ�ตส�ห้กรรม
3.2 ก�รให้�ค์วั�มร�อนุ่ทำ �อ�ณห้ภู/ม"ต���เวัลิ่�นุ่�นุ่ (Low Temperature Long Time) ทำ��ให้�นุ่���นุ่มม อ�ณห้ภู/ม" 63 องศ�เซลิ่เซ ย่สเป4นุ่เวัลิ่� 30 นุ่�ทำ ก�รพื่�สเจุอร�ไรซ�แบบนุ่ �จุะใช�ก�บนุ่���นุ่มในุ่ห้ม�อต�ม ห้ร�อทำ��ในุ่บ��นุ่เร�อนุ่
Degree of Heat Preservation
4. Blanching เป4นุ่ pasteurization แบบห้นุ่��ง ใช�ก�บผั�ก/ผัลิ่ไม�เพื่��อ
inactivate natural food enzymes ซ��งจุะทำ��ลิ่�ย่จุ�ลิ่"นุ่ทำร ย่�ไปด�วัย่บ�งส�วันุ่
เป4นุ่ pre-treatment เทำ��นุ่��นุ่ โดย่ทำ��วัไปใช� นุ่���ร�อนุ่ ห้ร�อ steam
Degree of Heat Preservation
ข้�อควรระว�ง อ�ห้�รแต�ลิ่ะชนุ่"ด/ แต�ลิ่ะขึ้นุ่�ดบรรจุ�/ process ต��งก�นุ่ จุะ
ใช� เวัลิ่� แลิ่ะ อ�ณห้ภู/ม"ในุ่ก�รฆ่��จุ�ลิ่"นุ่ทำร ย่� เอนุ่ไซม�ไม�เทำ��ก�นุ่ ก�รเลิ่�อกใช� Time, temp ให้�ฆ่��ปร"ม�ณจุ�ลิ่"นุ่ทำร ย่�ได�พื่อ
เห้ม�ะ แลิ่ะส�ม�รถุร�กษ�ค์�ณภู�พื่อ�ห้�รเป4นุ่ส"�งส��ค์�ญ
Degree of Heat Preservation
การเลื�อกใช้�ว�ธี� แลืะ ระยะเวลืา โดยทั่��วไปควรค�านึ�งถึ�ง ชนุ่"ดอ�ห้�ร/ขึ้นุ่�ดบรรจุ� Pretreatment ห้ร�อม วั"ธี ก�รในุ่ก�รลิ่ดปร"ม�ณจุ�ลิ่"นุ่ทำร ย่� (ลิ่��ง
ห้��นุ่) ห้ร�อไม� Shelf life ทำ �ต�องก�ร ลิ่�กษณะขึ้องก�รเก.บร�กษ� (Room temp VS cool storage
VS frozen storage) ปร"ม�ณ แลิ่ะชนุ่"ดขึ้องจุ�ลิ่"นุ่ทำร ย่�ในุ่อ�ห้�ร ห้�กม ก�รใช�วั"ธี ก�รร�กษ�อ�ห้�รอ��นุ่ ๆ เช�นุ่ก�รค์วับค์�ม ปร"ม�ณ
นุ่���ต�ลิ่ เกลิ่�อ นุ่��� ค์วั�มเป4นุ่กรด ฯลิ่ฯ ร�วัมด�วัย่จุะช�วัย่ให้�ไม�ต�องใช�ค์วั�มร�อนุ่ทำ �ร�นุ่แรงม�กเก"นุ่ไป
Packaging for thermally-processed products
I. Retort PackagingII. Hot-fill PackagingIII. Sous Vide PackagingIV. Aseptic PackagingV. Microwavable Packaging
In-package heat treatment
heat treatment prior to packagingIn-package heat
treatment
I. Retort
The technology of preserving foods in cans was developed at the nineteenth century by Nicolas Appert won his prize for demonstrating that foods which had been heated in air-tight (hermetic) metal cans, did not spoil, even when they were stored without refrigeration.
Principle of Canning
Nicolas Appert (1749-1841), French inventor of airtight food preservation. Appert, known as the “father of canning”
I. Retort
Retort Processing: Non-sterile food product is filled and
hermetically sealed into non-sterile containers
Food product is then thermally processed within the container in the retort to achieve sterility of the food and the inside of the container
Principle of Canning
I. Retort
Containment Protection Communication Convenience Minimal environmental impact
Packaging Requirements/Functions
Available Packaging Technology Metal Can
Glass jar/bottle
Composite rigid/semi-rigid containers Plastics Plastics and Aluminum foil Plastics, paper board, Alu foil
Composite flexible packaging Plastics Plastics and Alu foil
•Majority of canned food•Perceived as old fashion, lower grade•Used for specialty packs
•Becoming more common alternative to metal cans
I. Retort
Available in different metals, as pre-forms Tin plate Tin-free steel Aluminium alloy
Available Pkg – Metal Can
I. Retort
Tin plate Tin plate is steel sheet coated with a thin
layer of tin on each surface Because of its strength and rigidity tin plate
forms an ideal material for food containers In addition to the benefits of its bright
appearance and ease of soldering, the major function of the tin layer is to protect the base steel from corrosion
Available Pkg – Metal Can
I. Retort
Tin Plate The main factors of importance
Chemical composition and physical properties of the base plate
Thickness of tin coating Application of protective coatings Relative corrosivity of the product which is to
be canned
Available Pkg – Metal Can
I. Retort
Tin Plate Low carbon steel is used for can manufacture The chemical composition of the base steel plate is
of primary importance in obtaining adequate service-life for corrosive, products
The most critical element is phosphorus, but other elements such as copper nickel, chromium and silicon may also affect the corrosion resistance of the plate
For low-acid products, such as fish the steel type has no important influence on corrosion and any of the available types may be used
Available Pkg – Metal Can
I. Retort
Tin-free steel (TFS) The tin-free steel is one of the newer can-
making materials Un-tinned steel on which very thin layers of
chromium-oxide have been electrodeposited is resistance to corrosion and discolouration
Disadvantages are that the plate must be coated on both sides and that it cannot be soldered
Available Pkg – Metal Can
I. Retort
Aluminum alloys Aluminium alloys are finding increasing use
in the can making industry Advantages of aluminium include the light
weight of the material, resistance to atmospheric corrosion and to sulfide-bearing products. Disadvantages include difficulties in closing the body seam by soldering
Available Pkg – Metal Can
I. Retort
Enamel Coatings Enamel coatings are used to protect tin plate
aluminium alloys and TFS The coatings can be applied to sheets and coils
either before and after cans are made. In some cases, coatings make it possible to use more lightly coated grades of tin plate or tin-free steel
The enamels or lacquers were originally prepared from polymerized fish oil but today lacquers are made from synthetic materials which provide better performance
Available Pkg – Metal Can
Available Pkg – Metal Can
1st Function: Containment Pkg material integrity; in terms of
production speed/difficulties/capital Steel Cans: perform well in retort environment Aluminum Cans: need special handling to avoid
collapse
I. Retort
Available Pkg – Metal Can
Remembering retort? Still retort
I. Retort
Available Pkg – Metal Can
Remembering retort? Still retort Agitation retort
I. Retort
Available Pkg – Metal Can
Remembering retort? Still retort Agitation retort Hydrostatic retort
I. Retort
Available Pkg – Metal Can
1st Function: Containment Pkg material integrity production
speed/difficulties/capital Steel Cans: perform well in retort environment Aluminum Cans: need special handling to avoid
collapse Limited migration/interaction
Enamel coating (esp. high acid food) Soldering material Bleaching effect
I. Retort
Available Pkg – Metal Can
2st Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage Hermetically sealed by
Double seam
Side seam
I. Retort
Available Pkg – Metal Can
2st Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage
Shelf life Total barrier (w/o pinholes) generally 3 years+
I. Retort
Available Pkg – Metal Can
2st Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage
Shelf life Total barrier (w/o pinholes) generally 3 years+
Tamper evidence
I. Retort
I. Retort
3rd Function: Communication
Available Pkg – Metal can
I. Retort
3rd Function: Communication
Available Pkg – Metal can
I. Retort
3rd Function: Communication
Available Pkg – Metal can
I. Retort
4th Function: Convenience Easy-to-open features
Metal can Easy-open ring-pull lids Easy-open peel-seam
Available Pkg – Other functions
I. Retort
4th Function: Convenience Easy-to-open features Easy-to-hold shape Easy-to-use
Self – heating/cooling
Available Pkg – Metal can
I. Retort
4th Function: Convenience Easy-to-open features Easy-to-hold shape Easy-to-use Reclosable features
Available Pkg – Metal can
I. Retort
5th Function: Minimal environmental impact All metal can are 100 % recyclable
Self-cooling/heating can?
Available Pkg – Metal can
I. Retort
Available in jar, bottle, tubler as pre-forms The principles of processing with glass are
substantially the same as for cans, except that there are some modifications necessary because of the sealing mechanism used and the thermal characteristics of the glass
Available Pkg – Glass
I. Retort
1st Function: Containment Pkg material integrity; in terms of production
speed/difficulties/capital need special handling to avoid glass fracture and
seal loss counter balanced retort slower handling and heat transfer speed than metal containers
Available Pkg – Glass
I. Retort
1st Function: Containment Pkg material integrity
Good for home canning
Available Pkg – Glass
I. Retort
1st Function: Containment Glass is innert limited
migration/interaction with food As glass is resistant to all food products no
internal surface treatment is required. The metal closures however must be protected from corrosion and for this reason are internally and externally lacquered
Available Pkg – Glass
I. Retort
2nd Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage Hermetically sealed by pressed-on twist-off
cap or lug-type twist-off cap
Available Pkg – Glass
plastisol lining compound that acts as a sealant between the glass and the metal cap
I. Retort
2nd Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage
Glass containers are processed under water in a counter-balanced retort
The water prevents thermal shock breakage as steam enters the retort while the counter-balancing air transmits pressure through the water ensuring that at all times the pressure in the retort is greater than that in the sealed containers
Available Pkg – Glass
over-pressure applications
I. Retort
2nd Function: Protection Integral packaging Shelf life Tamper evidence
Available Pkg – Glass
I. Retort
3rd Function: Communication
Available Pkg – Glass
I. Retort
4th Function: Convenience Microwavable
Available Pkg – Glass
I. Retort
5th Function: Minimal environmental impact 100% Recyclable Reusable
Available Pkg – Glass
I. Retort
Available in both In-line forming and Pre-form Reduced wt. and storage space
Available Pkg – Composite containersFlexible (aka retort pouch)
I. Retort
1st Function: Containment Pkg material integrity; in terms of
production speed/difficulties/capital Similar to rigid and semi-rigid composite
container Need counter-balanced retort with overriding
pressure application need special handling and machine to avoid collapse and seal loss
Slower heat transfer than metal container Longer processing time (compared at same dimension)
Available Pkg – Composite containers Flexible (aka retort pouch)
I. Retort
1st Function: Containment Pkg material integrity; in terms of
production speed/difficulties/capital Thin-profile packages
Shortened processing times Improved food quality Energy conservation and space utilization
Available Pkg – Composite containers
Potter and Hotchkiss, 1995
q = -k A dT/dx q = h A (Ts - Tcp )ColdPoint
ColdPoint
Flexible (aka retort pouch)
I. Retort
1st Function: Containment Limited migration/interaction
Migration Potential of plasticizer/additive of plastic to food Potential of flavor scalping by plastic layer
Available Pkg – Composite containersFlexible (aka retort pouch)
I. Retort
2nd Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage Heat seal by impulse sealer
Heating temperature and time Pressure Dwell or cooling down time
Need counter-balanced retort with overriding pressure application need special handling and machine to avoid collapse and seal loss
Available Pkg – Composite containers Flexible (aka retort pouch)
I. Retort
2nd Function: Protection Shelf life
Lower barrier properties (comparing to metal/glass containers) shorter shelf life
Need physical protection from 20 pkg Combination of materials depending on converters
Constructed of layers of plastic and/or aluminum Development of multi-layer plastic pouches Pouches collapse/compress tightly around food when
vacuum applied before sealing US military has been a pioneer in development and
application
Available Pkg – Composite containersFlexible (aka retort pouch)
I. Retort Available Pkg – Composite containers
Flexible (aka retort pouch)
I. Retort Available Pkg – Composite containers
Flexible (aka retort pouch)
I. Retort
3rd Function: Communication
Available Pkg – Composite containers
VS
Flexible (aka retort pouch)
I. Retort
3rd Function: Communication
Available Pkg – Composite containers Flexible (aka retort pouch)
I. Retort
4th Function: Convenience Lighter weight Easy-to-open features
Flexible Packaging tear notch
“V”, “U”, “C” notch/cut
Easy-to-use Dispense and reclosable
Available Pkg – Composite containersFlexible (aka retort pouch)
4th Function: Convenience Example: Meal-Ready-to-Eat (MRE)
Developed by US Soldier Systems Center (SSC-Natick)
Available Pkg – Composite containersI. Retort
Flexible (aka retort pouch)
I. Retort
I. Retort
5th Function: Minimal environmental impact
Available Pkg – Composite containers Flexible (aka retort pouch)
I. Retort
Plastic cans, jars, tubs, cups, trays, bowl, bottles
Comprise of semi-rigid or rigid body with sealable flexible or semi-rigid lid
Tubs and trays produced by thermoforming
Cans produced by injection blow molding
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
1st Function: Containment Pkg material integrity; in terms of production
speed/difficulties/capital Thermoforming process In-line form
reduce pkg storage space Easier to fill than pouches
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
1st Function: Containment Pkg material integrity; in terms of production
speed/difficulties/capital Injection molding Pre-form (Co) Extrution blow molding Pre-form
same pkg storage space as metal and glass container
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
1st Function: Containment Pkg material integrity; in terms of
production speed/difficulties/capital Need counter-balanced retort with overriding
pressure application need special handling and machine to avoid collapse and seal loss
Slower heat transfer than metal container Longer processing time (compared at same dimension)
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
1st Function: Containment Limited migration
Migration Potential of plasticizer/additive of plastic to food Potential of flavor scalping by plastic layer
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
2nd Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage Sealable flexible or semi-rigid lid peelable lid Need counter-balanced retort with overriding
pressure application need special handling and machine to avoid collapse and seal loss
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
2nd Function: Protection Shelf life
Lower barrier properties (comparing to metal/glass containers) shorter shelf life
Combination of materials depending on converters
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
2nd Function: Protection Shelf life
Available Pkg – Composite containers Rigid and Semi-rigid
www.constantia-flexibles.com
I. Retort
2nd Function: Protection Tamper evidence
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
3rd Function: Communication
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
4th Function: Convenience Lighter weight Various sizes and shapes Easy-open feature peelable lid Microwavable
Available Pkg – Composite containers Rigid and Semi-rigid
VS
I. Retort
4th Function: Convenience Multi-compartment trays have potential for
whole dinners Self-heating system (aka Hot Meal Solution)
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
5th Function: Minimal environmental impact
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
Retortable Cartons Paperboard combined with aluminum and
PP Need special handling to avoid collapse and
seal loss
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
1st Function: Containment Pkg material integrity; in terms of
production speed/difficulties/capital Form-fill-seal In-line form
reduce pkg storage space
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
1st Function: Containment Limited migration
Migration Potential of plasticizer/additive of plastic to food Potential of flavor scalping by plastic layer
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
2nd Function: Protection Integral packaging hermetically seal, seal
strength through production, distribution, storage Heat seal by impulse sealer
Heating temperature and time Pressure Dwell or cooling down time
Need counter-balanced retort with overriding pressure application need special handling and machine to avoid collapse and seal loss
Tamper evident
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
2nd Function: Protection Shelf life
Lower barrier properties (comparing to metal/glass containers) shorter shelf life
Combination of materials PP/Paperboard/PP/Aluminum/PP structure
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
3rd Function: Communication
Available Pkg – Composite containers Rigid and Semi-rigid
VSVS
Billboard surfaces
I. Retort
4th Function: Convenience Lighter weight Various sizes Easy-open feature
Available Pkg – Composite containers Rigid and Semi-rigid
I. Retort
5th Function: Minimal environmental impact
Available Pkg – Composite containers Rigid and Semi-rigid
Not recyclableNot resealable
Available Pkg - Comparison
Metal Can
Glass jar/bottle
Plastic container
Retortable Pouch
Retortable Carton
Containment- Heat transfer (fast/slow)-Seal (difficulty, integrity)-Migration
Protection-Shelf life (at shelf stable)-Tamper evident
Communication
Convenience
Environmental impact
Principle of Hot-Filling
Process Batch or continuous food sterilization (or pasteurization)
Food heat-sterilized by batch heating in steam-jacketed kettle, or
Food heat-sterilized by continuous pumping through heat-exchanger
Hot food filled & sealed into (not necessarily sterile) package
Metal, glass, plastic or paperboard laminate
Shelf stable product
Refrigerated product
II. Hot Fill
Heat of food sterilizes (or pasteurize) inside of the package
Hot food held for definite temperature and time in sealed container before cooling
Used for acid food (pH < 4.6) which can be sterilized at temperature < 100 0C (atmospheric pressure)
Used commercially with acid fruit and vegetable products
Principle of Hot-Filling II. Hot Fill
Advantages Compared to Retort Sterilization
Less time and energy used for heat sterilization of food
Higher quality food (not as overcooked) Packaging need not withstand retort conditions
Compared to Aseptic Processing Does not require separate aseptic container
sterilization Does not require aseptic filling and sealing
Principle of Hot-Filling II. Hot Fill
Disadvantages Compared to Retort Sterilization
Applicable only to high-acid foods Food must be pumpable
Compared to Aseptic Processing More time and energy for heat sterilization
of food Lower quality food Limited to packaging that can withstand
hot-fill temperatures
Principle of Hot-Filling II. Hot Fill
II. Hot Fill
Any packagings for retort OK Less extreme heat/pressure
condition Common Pkg
Metal less common because of the high acidity
Glass containers Plastic containers Composite containers
Available Packaging Technology
II. Hot Fill
1st Function: Containment Pkg material integrity production
speed/difficulties/capital Withstand vacuum at warm to chill
temperature Limited migration/interaction
Potential of plasticizer/additive of plastic to food
Potential of flavor scalping by plastic layer
Packaging requirements/functions
II. Hot Fill
2nd Function:Protection Integral packaging hermetically seal,
seal strength through production, distribution, storage Vacuum and heat sealed by vacuum, impulsed
sealer Vacuum time Heat sealing time and temperature Cool down time
Shelf life 4 hours at room temperature or chill for 10
days Tamper evidence
Available Packaging Technology
II. Hot Fill
3rd Function: Communication 4th Function: Convenience 5th Function: Environmental impact
Available Packaging Technology
Similar to retort pouch
II. Hot Fill
Example
Available Packaging Technology
II. Hot Fill
Example
Available Packaging Technology
Old design- Form-fill-seal pouch
New design- Thermoform tray
II. Hot Fill
Example
Available Packaging Technology