State of the art technology Optimized high-acid pasteurization MS/2013-11
Dec 05, 2014
State of the art technologyOptimized high-acid pasteurization
MS/2013-11
Dramatically lowered energy cost made possible through technology research
► Uncompromising food safety► Lower energy cost by 20%
− Improved environmental performance
► World-leading in heat transfer technology− Research study− Patent
MS/2013-11 / 2
MS/2013-11 / 3
80°C/15s
► New lower recommendation► Microbiology research study and lab test► PDC and customer field test
to verify result – proof► Pasteurization unit control
Progressing cutting-edge technology
Research study and customer site validation
MS/2013-11
JNSD pH<4.2
► The traditional recommended heat treatment of JNSD is 95°C/15 s
► Primary pasteurization immediately after squeezing to deactivate enzymes and kill microorganisms− 95-98°C for 10-30 s
► A second pasteurization is usually performed prior to filling
− Recontamination during bulk storage of NFC juice
− Contamination while juice reconstituted from concentrate
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Microorganisms of concern
Hea
t res
ista
nce
95-98°C/10-30 s
95°/15s
Possibility to reduce heat treatment
► Possibility to reduce heat treatment of JNSD
► Growth study on bacterial spores’ possibility to grow at pH<4.2
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Target organism
Hea
t res
ista
nce
72°C/15s
95°/15s
?
YeastMouldsAcid-tolerant bacteriaPathogenic bacteria
Yeast ascospores
Bacterial sporesSpores of heat-resistant moulds
Result: No growth at pH<4.2
► Orange and apple juice► Adjustment of pH to 3.5, 3.8, 4.0, 4.2► Inoculation with spores or vegetative cells of selected bacteria
− Spores: B. lichenformis, P. polymyxa, Cl. pasteurianum, Cl. butyricum − Vegetative cells: B. megaterium, B. coagulans, P. macerans
► 5 replicates for each juice/pH/species► Incubated at room temperature for 3 weeks
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Growth test with bacterial spores at low pH
Conclusion: The tested bacterial spores are not an issue in juice with pH<4.2
Result: No growth in any of the juices at any of the pH levels
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Calculations confirmed. Target 9 log reductions
Results and theoretical log reductions
Test results:
Temperature / time Sterile packages
65°C/15 s 0%
72°C/15 s 100%
80°C/15 s 100%
Conclusions: the test results confirm the theoretical log reduction calculations
Theoretical log reductions based on D and z values:
Optimized high-acid pasteurization
Temp 1
D63= 1.6 minz=5.4°C
Put & de Jong 2
D60= 22 minz=6.5°C
Tetra Pak 3
D65= 19 sz= 5.5°C
95/15 131 800 2 755 225 000
80/15 222 13.57 421
77/15 62,0 4.69 120
72/15 7.39 0,8 14.79
65/15 0.38 0,07 0.791 Apple juice, pH 3.5, 2013 2 Buffer solution, pH 4.5, 19823 Orange juice, pH 3.8, DR8671, 1997
Tested at Valio, Finland, June 2013
► 4000 litres orange juice− pH 4.0, 11.3°Brix, initial load: 90 CFU/ml
► Processed at 78°C/22 s (=80°C/9.5 s)► Packed in Tetra Prisma® Aseptic (250 ml), 16 000 packages► Incubated at ambient temperature (20-23°C) for 3 weeks► Inspected for gas formation► 1043 packages streaked (10 μl) at OSA at Tetra Pak®, Lund
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Verification of commercial sterility
Conclusion: Commercial sterility achieved
Results: No gas formation in 16 000 packages; no growth detected from 1043 streaked packages
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Prerequisites
► Turbulent flow required► Content of Alicyclobacillus – negative in 10 g / 10 ml► Content of Byssochlamys – negative in 10 g / 10 ml
Process recommendation
Product Set point* / holding time
Juice, second pasteurization, pH<4.2 80°C / 15 s
Juice, first pasteurization, enzyme deactivation 95-98°C / 10-30 s
Nectar, pH<4.2 80°C / 15 s if turbulent flow
Still drinks, pH<4.2 80°C / 15 sJNSD pH 4.2-4.6 123°C / 15 sJNSD pH>4.6 138°C / 4 sJuice with pulp 80°C / 15 s
JNSD with particles Based on particle size
Pasteurization at lower temperature
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Same quality with unique control
► Pasteurization unit (PU) control− International patent pending on total heat load control− Each product has its own PU value and
by controlling this we secure the right pasteurization
Pasteurization at lower temperature
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Reduction of energy consumption and carbon footprint
Pasteurization at lower temperature
Tetra Therm® Aseptic DrinkProduct: Orange juice, 12°BrixCapacity: 10 000 l/h Production scenario: two shifts, 5 days/week, 50 weeks/yearProduction: 15 hours/day
Heat treatment process 95°C/15 s* 80°C/15 s* Difference
Heating load kW 182 153 -16%
Cooling load kW 70 40 -43%
Production cost per year kEUR/year 42 34 -17%
Production cost per 1000 litre EUR/1000 litre 1.11 0.92 -0.19 EUR/1000 litre
Carbon footprint kg CO2/1000 litre 7.1 6,0 -16%
* Reduced from PU value similar to 95°C/15 s to 80°C/15 s
Impact of process temperature and increased dT
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Process temperature 80°C or 95°C and dT 3-25° C
► Taste− Process temperature and increased dT
do not impact taste of orange juice made from concentrate
► Colour− Process temperature and increased dT
do not impact colour of orange juice made from concentrate
► Vitamin C− Process temperature and increased dT
do not impact Vitamin C degradation of orange juice made from concentrate
Impact of process temperature and increased dT
Taste
► External taste panel by IPSOS Marketing, Kristianstad, Sweden− 6 weeks storage at ambient temperature− 80°C/dT=3°C vs. 95°C/dT=25°C (extreme values)− 95°C/dT=5°C vs. 95°C/dT=12°C (reference process vs. increased dT)− 95°C/dT=5°C vs. 95°C/dT=25°C (reference process vs. further increased dT)
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Impact of process temperature and increased dT
BA
A
Conclusion: Process temperature (80-95°C) and increased dT do not impact taste of orange juice made from concentrate
Result: No significant difference in taste in any of the three tested pairs
3 months 7 monthsColour
► Visual appearance evaluated once a month► Photographed using DigiEye
(consistent light conditions) after 3 and 7 months
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Impact of process temperature and increased dT
Conclusion: Process temperature (80-95°C) and increased dT do not impact colour of orange juice made from concentrate
Results: The juice was overall darker after 7 months storage than after 3 months.
At each evaluation point no difference could be detected between the samples
Vitamin C reduction
► Vitamin C content was analyzed by HPLC at Eurofins after 3.5 and 6 months storage
MS/2013-11
Impact of process temperature and increased dT
0 1 2 3 4 5 6 7300310320330340350360370380
Vitamin C content of orange juice during am-bient storage
80°C/dT=3°C80°C/dT=15°C95°C/dT=5°C95°C/dT=12°C95°C/dT=25°C
Storage time (months)
Vita
min
C c
onte
nt (m
g/l)
* Initial Vitamin C content measured on frozen raw material 3.5 months after processing
*
Conclusion: Process temperature (80-95°C) and increased dT do not impact
Vitamin C degradation of orange juice made from concentrate
/ 18
Results: Normal Vitamin C decrease due to OTR and anaerobic degradation
Conclusions
► Second pasteurization of orange juice with pH<4.2 can be reduced from 95°C/15 s to 80°C/15 s
► dT of orange juice can be increased from 5°C up to 25°C without impact on taste, colour or Vitamin C content
► Increased flexibility as more products can be run with the same configuration
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Dramatically lowered energy cost made possible through technology research
► Uncompromising food safety► Lower energy cost by 20%
− Improved environmental performance
► World leading in heat transfer technology− Research study− Patent