Download - Optimized high-acid pasteurization

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

MS/2013-11 / 5

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

MS/2013-11 / 6

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

MS/2013-11 / 7

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

MS/2013-11 / 8

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

MS/2013-11 / 9

Verification of commercial sterility

Conclusion: Commercial sterility achieved

Results: No gas formation in 16 000 packages; no growth detected from 1043 streaked packages

MS/2013-11 / 10

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

MS/2013-11

MS/2013-11 / 12

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


MS/2013-11 / 13

Reduction of energy consumption and carbon footprint


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

MS/2013-11

MS/2013-11 / 15

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


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)

MS/2013-11 / 16


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

MS/2013-11 / 17


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


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

MS/2013-11 / 19

MS/2013-11 / 20

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