3-a. specified process parameters

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Section A:Section A:

Specified Process Parameters Affecting

Heat Penetration

Chapter 3: PROCESS ESTABLISHMENTChapter 3: PROCESS ESTABLISHMENT


“…“…. any property, characteristic, . any property, characteristic, condition, aspect, or other parameter, condition, aspect, or other parameter, variation of which may affect the variation of which may affect the scheduled process and the attainment scheduled process and the attainment of commercial sterility”of commercial sterility”

What are…

Specified Process Parameters?

DEFINITION #1...


“…“…any characteristic, condition or any characteristic, condition or aspect of a product, container, or aspect of a product, container, or procedure that affects the adequacy of procedure that affects the adequacy of the process schedule.”the process schedule.”

What are…

Specified Process Parameters?

DEFINITION #2...


The precise time/temperature profile The precise time/temperature profile at the product “cold-spot” depends at the product “cold-spot” depends

upon....upon....

Physical propertiesPhysical properties

Thermal propertiesThermal properties

Container size and shapeContainer size and shape

Process delivery systemProcess delivery system


Pre-Test ConsiderationsPre-Test Considerations

1.1. Retort or thermal process Retort or thermal process delivery considerationsdelivery considerations

2.2. Container considerationsContainer considerations

3.3. Product considerationsProduct considerations


RetortRetort oror

Thermal Process Thermal Process DeliveryDelivery

CONSIDERATIONSCONSIDERATIONS


Retort or Thermal Process Delivery Retort or Thermal Process Delivery ConsiderationsConsiderations

Initial Temperature (IT) Initial Temperature (IT) Uniform or StratifiedUniform or StratifiedCold or Hot Cold or Hot


Rotational SpeedRotational Speed generally target heat penetration test to that of at or slightly below commercial generally target heat penetration test to that of at or slightly below commercial

production “minimum” speedproduction “minimum” speed

Low RPM Low RPM oror

High RPMHigh RPM

Low RPMLow RPMoror

High RPMHigh RPM

End-Over-End

Axial



Venting/Ramp RateVenting is required in pure steam retorts to

remove air If General Method (GM) calculation to be used,

ramp slightly under the come-up profile in HP test and maintain exponential or linear ramp per production equipment capability

If Ball, Stumbo or NumeriCAL method of calculation to be used, bring test retort through vent and ramp to test processing temperature as quickly as possible



Come-Up TimeCome-Up Time same testing profile as for “vent/ramp”, same testing profile as for “vent/ramp”,

depending upon calculation method which depending upon calculation method which will be employedwill be employed



Other Retort Considerations:Other Retort Considerations:

Steam/Air Fraction (75/25 or better steam to air Steam/Air Fraction (75/25 or better steam to air ratio for proper heat transfer)ratio for proper heat transfer)

Overpressure (container dependent)Overpressure (container dependent)

Pump flow rate (fluids)Pump flow rate (fluids)

Air Flow (circulation air in hot water systems)Air Flow (circulation air in hot water systems)



ContainerContainer



““Cold-Spot” Thermocouple LocationCold-Spot” Thermocouple Location Conduction heating products – cylindrical containers (Geometric Center-GC)Conduction heating products – cylindrical containers (Geometric Center-GC)

Container ConsiderationsContainer Considerations


Cold Spot Study RequiredCold Spot Study Required

Thermocouple locations should be started at Thermocouple locations should be started at 33//44” (19.05 mm) ” (19.05 mm)

above the lowest side or bottom of the container (Above Side-above the lowest side or bottom of the container (Above Side-AS, Above Bottom-AB)AS, Above Bottom-AB)

Increase vertical height of thermocouple by Increase vertical height of thermocouple by 11//44” to ” to 33//88” (6.35 – ” (6.35 –

9.52 mm) until the Geometric Center (GC) is reached9.52 mm) until the Geometric Center (GC) is reached

Need to “bracket” or isolate the cold-spot location as Need to “bracket” or isolate the cold-spot location as determined from resulting HP test datadetermined from resulting HP test data

Thermocouple locationThermocouple location -- Convection or Broken Heating Convection or Broken Heating



Thermocouple location- exampleThermocouple location- example Convection or Broken Heating - Convection or Broken Heating - Vertical OrientationVertical Orientation

1” AB25.4 mm

1-1/4” AB31.75 mm

1-1/2” AB38.1 mm

3/4” AB19.05 mm



Thermocouple location- exampleThermocouple location- example Convection or Broken Heating - Convection or Broken Heating - Horizontal OrientationHorizontal Orientation


3/4” AS19.05 mm

1” AS25.4 mm

1-1/4” AS31.75 mm

1-1/2” AS38.1 mm


Container Container OrientationOrientation During the Retort Process During the Retort Process


VerticalVertical HorizontalHorizontal AngledAngled

Lid-UpLid-Up Lid-DownLid-Down


Container “nesting” or stacking will often retard heat transfer and process effects need to be determined Container “nesting” or stacking will often retard heat transfer and process effects need to be determined “ “Necked-In” CansNecked-In” Cans 2-pc “shelf-stackable” cans (e.g. pet food, tuna)2-pc “shelf-stackable” cans (e.g. pet food, tuna) Odd-shaped rectangular cans (e.g. fish, prawns, tuna) Odd-shaped rectangular cans (e.g. fish, prawns, tuna)



Container Material Type and Shape- Container Material Type and Shape- Plastic containers slow heat transfer compared to metal and glassPlastic containers slow heat transfer compared to metal and glassCold-spot locations are unique to plastic mould design (e.g. trays, bowls, cups)Cold-spot locations are unique to plastic mould design (e.g. trays, bowls, cups) Special thermal process calculation factors are unique to packaging type and shapeSpecial thermal process calculation factors are unique to packaging type and shape

CanCanGlass JarGlass JarPouchPouchPlastic BowlPlastic Bowl



Headspace- most influencing to heat transfer in agitating processes, also important Headspace- most influencing to heat transfer in agitating processes, also important in glass processes (e.g. product expansion/closure performance)- must have an in glass processes (e.g. product expansion/closure performance)- must have an associated measurement temperatureassociated measurement temperature


76.7oC 60oC


Residual Gas- greater in-gas volumes generally slow Residual Gas- greater in-gas volumes generally slow heat transfer within horizontally oriented pouchesheat transfer within horizontally oriented pouches

10 cc’s of Residual Gas10 cc’s of Residual Gas

50 cc’s of Residual Gas50 cc’s of Residual Gas 10 cc’s10 cc’s 50 cc’s50 cc’s



Container Vacuum- too little vacuum may Container Vacuum- too little vacuum may retard heat transfer (e.g. vacuum pack corn)retard heat transfer (e.g. vacuum pack corn)



ProductProduct



Specific Gravity- specific gravity of the some Specific Gravity- specific gravity of the some products may affect the rate of heat transferproducts may affect the rate of heat transfer

Product ConsiderationsProduct Considerations

100

90

80

70

60

50

40302010


Fat Content- fat may insulate product components and retard the rate Fat Content- fat may insulate product components and retard the rate of heat transfer into that product location and protect microorganismsof heat transfer into that product location and protect microorganisms



Fill & Net Weight- the higher the particle fill (e.g. peas, corn, beans) or Fill & Net Weight- the higher the particle fill (e.g. peas, corn, beans) or net weight (e.g. evaporated milk), the slower the rate of heat transfernet weight (e.g. evaporated milk), the slower the rate of heat transfer



Drained Weight & Product Settling- layering and compaction (e.g. Drained Weight & Product Settling- layering and compaction (e.g. whole leaf spinach, Vienna sausage) can influence heat transferwhole leaf spinach, Vienna sausage) can influence heat transfer



1. Weigh out all dry ingredients.

2. Blanch pasta until 2x hydration.

3. After blanch is complete, cool for 10 minutes with ambient temperature water. Drain after cooling.

3. Mix all spices with tomato paste in steam-jacketed kettle. Turn on agitation, low speed, and heat to 200°F (93.3°C).

4. In slurry kettle mix all Brand X starch with 20 gallons of 70°F (21.1°C) water. Constant agitation at medium speed is required. Mix for 20 minutes.

5. Combine starch slurry with spice/tomato paste mix in steam-jacketed kettle, and reheat to 200°F (93.3°C)

6. Add pasta to sauce mix

Formulation- preparation, batching order, time & temperature, hydration, starch Formulation- preparation, batching order, time & temperature, hydration, starch dispersion /setting dispersion /setting



Ingredients - Frozen, Fresh, Canned-Ingredients - Frozen, Fresh, Canned-

““Variations”Variations” microbial loading microbial loading moisture moisture starch loadingstarch loading product initial temperatureproduct initial temperature



Impaled Particle- > 3/8” (9.52 mm) in size recommended…special Impaled Particle- > 3/8” (9.52 mm) in size recommended…special techniques secure the particle in the product “cold-spot” locationtechniques secure the particle in the product “cold-spot” location



Sliced vs. Diced vs. Whole?Sliced vs. Diced vs. Whole?

1/2” cubes, 3/4” cubes, 1” cubes?1/2” cubes, 3/4” cubes, 1” cubes?(12.7 mm)(12.7 mm) (19.05 mm) (19.05 mm) (25.4 mm) (25.4 mm)

Particle Style or Type and SizeParticle Style or Type and Size



Ingredient Maturity, Grade, ConditionIngredient Maturity, Grade, Condition Moisture (greater moisture loss in more mature product)Moisture (greater moisture loss in more mature product) More “fines” generated in poorer quality (#3) mushroomsMore “fines” generated in poorer quality (#3) mushrooms Microbial load (often greater number and more heat resistant in more mature product)Microbial load (often greater number and more heat resistant in more mature product)

#1 vs. #2 vs. #3 Mushrooms?#1 vs. #2 vs. #3 Mushrooms?

Fresh vs. Stored Field Peas?Fresh vs. Stored Field Peas?



Dispersion, Hydration and Rehydration- affects starch loading, heat transfer, and microbial heat resistance factorsDispersion, Hydration and Rehydration- affects starch loading, heat transfer, and microbial heat resistance factors

RiceRice

BeansBeans

PastaPasta

Vegetable Protein (TVP, HVP)Vegetable Protein (TVP, HVP)

StarchesStarches

GumsGums



Total Solids- greater % solids may retard heat transfer in liquid Total Solids- greater % solids may retard heat transfer in liquid products (e.g. chocolate milk, infant formula, dietary beverages)products (e.g. chocolate milk, infant formula, dietary beverages)

Evaporated Milk

23% Milk Solids

Light Cream

18 - 30% Milkfat

Heavy Cream

>36% Milkfat



Viscosity- increased viscosities generally retard heat transferViscosity- increased viscosities generally retard heat transfer

5 cm

10 cm

Example of Bostwick Measurement

Other Viscometers include devices such as Brookfield, Starchmaster, and Brabender and should be matched to the product

application



Brix or Soluble Solids- RefractometerBrix or Soluble Solids- Refractometer

Typically applies to sugar and tomato based products

Courtesy of MISCO, Cleveland, OH



It is important to understand all specified process It is important to understand all specified process parameters for:parameters for:• RetortRetort• ProductProduct• ContainerContainer

These Specified Process Parameters are required These Specified Process Parameters are required to properly design the heat penetration test.to properly design the heat penetration test.

SUMMARY….

Specified Process Parameters


This Completes the section........This Completes the section........

Specified Process Specified Process Parameters Parameters

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