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forseafood&meatproducts
RomanBuckow|MichelleBull
23May2012
CSIROANIMAL,FOODANDHEALTHSCIENCES
Principlesofhighpressure
processing
2 | HPPseafood&meat|RomanBuckow
WhyHighPressureProcessing?
Features: Static
Application of high pressures can cause: High Pressure
Inactivation of Parasites, Plant cells
Vegetative
V t ti micro-organisms
i i
Some fungal spores
Many food borne viruses
Enzymes are selectively inactivated
Macro molecules can change conformation
Small molecules (eg flavours) are generally
unaffected
Food Systems as above plus equilibria may
change
EvolutionofHPPindustrialmachines
Source:Hiperbaric
Source:Hiperbaric
esinproduction
170
160 Oceania
150 5% Asia
140
15%
130
120
NumberofHHPindustrialmachine
110
100 America Europa
90 55% 25%
80
70
60
50
40
30
20
10
0
Verysmall<10
(number ofemployees)
Group>5000 6%
15%
1250<Very 10<Small<50
Large<5000 23%
12%
250<Large<1250
22% 50<Medium<250
22%
HighPressureProcessingofFoods Source:Hiperbaric
Source:Hiperbaric
Meatproducts
27%
Vegetable
products
32%
Seafoodandfish
16%
Juicesand
Otherproducts
beverages 14%
11%
~100Food Companies
~250.000t/aProducts in2011
Most Applications:
ColdPasteurisationinthefinalpackage
Whatisthepressureweneed?
Pressure [MPa]
Magnetic Compression
1000
Ultrasonics
Mariana Trench
100
Hydraulic Systems
295 (2002)
10
1
Thermal Autoclave
Effectofpressureonmicroorganisms
Highpressurecankillmicroorganismsbyinterruptingtheircellularfunctionwithout
theuseofheatthatcandamagethetaste,texture,andnutritionofthefood.
High Pressure Processing
-
- -
- Piston
Size CD
HPPoffood earlystudies1899
Hite1899:
Pressure(600MPa)
appliedatroom
li d
temperaturefor60min
canextendtheshelflifeof
rawmilkby4days
Pressurealsoaffects
somenativemilkenzymes
andproteins
SomeCoagulationoffat
andproteinsunder
pressure
CommercialapplicationofHPP pressurerange
CSIRO.
Volumecontractionandcompressionheating
Water
Propylene-Glycol
140 HDPE
PP
PTFE
120
100
Temperature / C
80
60
40
20
0
0 100 200 300 400 500 600 700
Pressure / MPa
Compression heating of water, propylene-glycol, HDPE
Compressibility of water and (High density polyethylene), PP (Polypropylene) and
carbon dioxide at 20C. PTFE (Polytetrafluoroethylene) at Tini = 10, 50, 90C.
Icemodificationsunderpressure
= 1.165 kg/L tetrag.
H = - 68.2 kJ/kg
ICE III
H = - 19.0 kJ/kg
H = - 42.5 kJ/kg
ICE I
PressureTemperatureDiagramofInactivation
5 log10 reduction
in 60 s
HowHighPressureProcessing(HPP)works
HPPvesseldevelopments19802000
HPPindustrialequipment
Indirect compression system
Automatic
A i loading
l di /unloading
/ l di system
IndustrialHPPmachines
160 L vessel
420 L vessel
Avure Technologies
350 L vessel
HPPequipmentmanufacturer
HIPERBARIC AVURE MULTIVAC KOBELCO CHIC
Country Spain USA Germany Japan China
KobeSteel
CHICFresherTech
Hiperbaric,S.A. MULTIVAC ShinkoBuilding,
Avure Global Sales
GlobalSales
C/Condado de AustraliaPTY. 1026,
TechnologiesInc 19th Floor,GangTai
Trevio,6 LTD. Wakinohamach
2240866th Plaza
Address Pol.De 2McGregors o2chome,
AvenueSouth No700EastYanAn
Villalonquejar Drive Chuoku,Kobe
Kent,WA98032, Road
09001Burgos, 3042Tullamarine Hyogo651
U.S.A. Shanghai200001
Spain Australia 8585
P.R.China
Japan
+8178261
Phone +34947473874 +12539816350 +61383312800 +862153850085
5111
+8178261
Fax +34947473531 +12539816230 +61383312810 +862153850005
4123
IndustrialHPPsystemsinoperation
HPPsystemsatCSIRO
2mLkinetic,(700MPa)andtemp
300mL,pressure(800MPa)andtemp
2L,pressure(500MPa)
3L,pressure(800MPa)andtemp
( ) d
35L,pressure(690MPa)andtemp
2ml kinetic
3L Stansted
35 L Avure Technologies
RecentCSIROHPPpublications
Highpressureprocessing|RomanBuckow|Page22
Microbiologicalsafetyand
stability of HPP products
stabilityofHPPproducts
23 | HPPMicrobiology|MichelleBull
RiskManagement:FindingtheBalance
Traditional Innovative
Processing Processing
HPPMicrobiology|MichelleBull
2
Definingthemicrobialhazard
Infectious ppathogens
g
eg Listeria, Salmonella, Inactivate
E. coli O157
Thehurdleconcept
E h combination
Each bi ti off hurdles
h dl defines
d fi the
th
microbiological safety & stability of a food
MicrobialinactivationbyHPP
Lethaleffectsonmicroorganismsmayinclude
denaturationofproteins&enzymes
cchangesinthepermeabilityofmembranes=leakage&
a ges t e pe eab ty o e b a es ea age &
susceptibilitytootherhurdles
DifferencesinsensitivitytoHPP +HPP
Gramnegatives>Yeast/Mould>Grampositives>Spores
(onlywithheatalso)ruleofthumb
Productspecific:inactivationdependentonpH,water
y, ,
activity,saltconcentration,etc.
Processspecific:exposuretime,pressurelevel,etc.
CFNS|MichelleBull
2
Highpressureprocessing
Ambient temperature
moulds
vegetative pathogens various
Ambient stable
Chill stable
non-proteolytic proteolytic
e
C. botulinum C. botulinum
High temperature
CFNS|MichelleBull
2
BacterialinactivationindifferentP/Tdomains
Z. bailii:
Z b ilii Metwurst
M t t slurry,
l
Lori et al. (unpublished)
Presentationtitle|Presentername
3
VirusinactivationindifferentP/Tdomains
Presentationtitle|Presentername
3
Effectofhighpressure&storagetemperaturesonthe
microbiologicalqualityofcookedpoultrymeat
400MPa/1min/20oC 600MPa/10min/20oC
(Patterson, 2011)
Presentationtitle|Presentername
3
ImprovedsafetythroughHPP
HPP RTE meat Inactivation of Listeria monocytogenes
Numberofsamples
NaCl p
positiveforgrowth*
g
Product
(%wt/wt) aftertreatmentat600
MPafor
210s 300s
Chicken 2.1 0/5 0/5
ShavedChickenBreast 4.8 5/5 0/5
Turkey
Turkey 19
1.9 0/5 0/5
*via enrichment: limit of detection greater than 1 CFU in a 25g
sample (USDA), inoculum conc. ~104 cfu/g
no preservatives chemical-free
Youart et al. (2010)
salt-reduced
CFNS|MichelleBull
3
InpackpasteurisationbyHPP
Ready-to-eat meats processed at 600MPa
for 180s
Extension of refrigerated shelf-life from 45-50
days to >98 days
Approx. 4-log reduction of L. mono.
107
2472
2655
106 2657
2345
2340
105 2343
2542
2341
104 2342
CFU/ml
103
102
101
100
0 10 20 30 40 50 60 70
T im e (s )
Marinatedbeefloin
1315days Somegreyingofmeat Garriga etal.(2004)
(raw)
Shelf-life
Bloodsausage extension by HPP meat products
28days Nonementioned Diez etal.(2008)
(fresh)
upto66days
Nodeleteriouseffects
Cookedslicedham dependingon Slongo etal.(2009)
onquality
HPPlevel
ImprovedsafetywithHPP seafood
5log10 reduction
Live oysters V. parahaemolyticus 350 MPa / 2 min Kural et al. (2008)
(1 35C)
1.6-log10 reduction
Oysters Hepatitis A Grove et al. (2009)
425 MPa / 1 min
Coloureffectsand
2dayswithHPPalone,6
Atlanticsalmon(fresh) rancidityforHPP+MA Amanatidou etal.(2000)
dayswithHPPandMA
withlongerstorage
y
Oysters upto21daysdepending
p y p g Increasedcutting
g CruzRomeroetal.
(live) onHPPlevel strengthwithHPP (2008)
Salmon Littlechangeinodour,
22days Medinaetal.(2009)
(coldsmoked) somecolourchange
Applications&opportunities
38 | HPPseafood&meat|RomanBuckow
Effectsofhighpressureonproteins
Aggregation
Schemeoftheellipticphasediagramof
proteins.Thearrowsmarkedbythelettersp,
h,cshowthespecificdenaturationways
knownaspressure,heatandcold
denaturation.
CSIRO.
Effectofhighpressureonmuscularstructures
Turkey breast (M. pectoralis superficialis) after 1 min at 0.1-500 MPa and 25C.
25C
Minced Meat
e.
Ref 0.5
0 5s 15 s 30 s
0.5 s 10 s 20 s 30 s
05s
0.5 10 s 20 s 30 s
InactivationofE.coli infreshfermentedsausage
E. coli
0
30 C
-1
1
Log Reduction [-]
-2
-3 5000 bar
-4
-5
5
6000 bar
-6
0 20 40 60 80 100 120
Time [s]
HPPCommercialMeatProducts
Shelflifeincrease
Destructionofpathogens:Listeria,Salmonella,coliforms
Stabilisationofpreservativefreeorlowsaltcontentproducts
Country Year Products
Spain 1998 Slicedcookedhamandtapas
USA 2001 Slicedcookedproductsandproscuittoham
USA 2001 Poultryproducts
USA 2002 Precookedchickenandbeefstrips
Spain 2002 Slicedcookedmeatsproducts,Serranocuredham
Italy 2003 Proscuittoham,salami&pancetta
Germany 2004 Curedandsmokedslicedanddicedham
Japan 2004 Nitritesfreebacon,sausagesandslicedmeat
USA 2005 Readytoeatmeatbasedproducts
Spain 2005 Curedmeatproducts&Serranoham
Canada 2006 Cured&cookedmeatproducts
USA 2006 Wholeroastedchicken
USA 2006 Slicedcookedturkeyandchicken
Canada 2006 Readytoeatmeatmeals
USA 2007 Chickensausages
USA 2008 Cookedpork&beefslicedproducts
USA 2008 Petfood
Canada 2008 Sausagesandbacon
Canada 2009 Germanstylecookedmeatproducts
USA 2009 SlicedRTEmeats
Canada 2010 Proscuittohamandcuredmeats
Australia 2010 Slicedanddicedpreservativefreepoultryproducts
Switzerland 2011 Cookedporkslicedproducts and sausages
USA 2011 Proscuittohamandcuredmeats
USA 2011 RTEslicedmeats
Rumania 2011 RTEporkproducts
Spain 2011 Serranohamandcuredmeats
WhydoesthemeatindustryuseHPP?
Non thermalpostpackagingpasteurization(approvedbyFSISinUSA)
Efficiency
Safestalternativeforslicedmeatproducts
Significantshelflifeextension
Nosize/volumeeffect:whole,sliced,stripped&dicedmeatproducts
SuitableforvacuumpackedorMAP
8
FU / g)
8
U FC /
6 6 6
Log (C F
4
g)
4 4
Log (U
2 2 2
0 0
0
0 20 40 0 20 40 0 20 40
Storing days at + 6 C Storing days at + 6 C Storing days at + 6 C
HPPtreatmentofslicedcookedhamat500MPa for8minat+8C
WhydoesthemeatindustryuseHPP?
Noeffectonsensorialquality
Qualiity
Keepfreshtaste
Keep fresh taste
Maintainnutritionalvalue
Removechemicalpreservatives
Colour
10
Fibrous Sliced
5
Non processed
Juicy 0 Adhesiveness
HPP
Tenderness Crunchy
Elasticity
HPPtreatmentofslicedcookedhamat500MPa for8minat+8C
Espua Spain
forsanitizationofreadytoeatmealsandcuredmeatproducts
Campofro Spain
sliced cooked ham andboneless cured ham (Export to
USAofcured ham Listeriafree)
VueltayVueltarange:gross slices ofham,turkey,
andchicken (meat taste,less additives,longer shelf life
: 8 weeks)
:8weeks)
Sanissimo(Super Healthy !):cooked ham with
Omega3&noadded salt
VueltayVueltamarinated chicken andturkey ready
to eat products
InfantisFreshpress Greece
www.freshpress.gr
Hormel USA
HPPdrycuredhamintheUSmarketsince2001
LargerangeofHPPslicedRTEham,turkeyandbeef
VacuumpackedandMAP
Label
Label True
TrueTasteTechnology
Taste Technology
InfoonHPPinthewebsiteandflyer
Hormel USA
http://www.hormelnatural.com/
KraftFoods USA
slicedRTEpreservativefreemeats
MapleLeaf Canda
RTEpreservative freemeals andsalads
CSIRO.
Zwanenberg TheNetherlands
Shelflifeextentionofpreservativefreesteaktartare
MRM Spain
preservativefreeRTEmealsandsausages
Applegate USA
Organicuncuredsausages
Stella&Chewys(USA)
OrganicPetfood
Cargill USA
FressureTM beefpatties
Shelf life of21days vs10days ofthe nonHPPequivalent
Patented
P d process
MoiraMacsFineFood Australia
HPPCommercialSeafoodProducts
Shelflifeincrease
Shuckingbivalves
Easyshellfishextraction
DestructionofVibrio
Country Year Products
USA 1999 Oysters
USA 2001 Oysters
USA 2001 Oysters
USA 2001 Oysters
USA 2003 Crab
Canada 2004 Seafood
Canada 2004 Lobsters
N.Zealand 2004 Musselsshuckingformeds
Italy 2004 Desaltedcod
USA
USA 2005 Lobsters
Canada 2006 Seafood
Japan 2007 Shellfish
USA 2008 Crab
Spain 2009 RTEfishmeals
USA 2010 Oysters
Canada 2010 Lobsters
NewZealand 2010 Greenmussels
France 2011 Losters&clams
EffectofHPPonappearanceofseafood
HPPofsalmon shorttimetreatment
EffectofcookingmethodfollowingHPP
Highpressuretreatmentofoysters
Usuallyeatenraworlightlycooked
Potentialforpathogenicbacteria
Differentbacteriaandspoilage
mechanisms(highglycogen)
HPP
Shucking
Appearanceimproves
Increasedmoistureretention
Bacterialinactivation
Extendedshelflife
Changeinmicroflora
Change in microflora packaging
Lipaseincreases~7d
OceanChoice Canada
extractionofrawlobstermeat
Mitsunori Japan
clamsshucking
http://www.youtube.com/watch?v=OYSbc1_l7tM
HPPPackaging&Costs
66 | HPPseafood&meat|RomanBuckow
Packagingrequirements
Flexible packaging (>15%
volume contraction)
Extra tight seals
Rounded & reinforced edges
Minimal head space
MAP possible
Tear strength, puncture
resistance, surface smoothness
generally not affected by HPP
Often flexible pouches or bottles
are inserted in secondary
cardboard containers or sleaves
after processing
ConventionalHPPprocessingoftypicalMAPproducts
Delamination of packaging film
Micro defects
Bending and delamination
(white spots)
of packaging film
Damagescouldoccurwheninsufficientpackagingand
processingisused
Inparticularmodifiedatmospherepacks
(MAP)havebeencritical.
Micro defects
Source: Tobias Richter, Multivac
(white spots)
ExamplesforasuitableHPPpackagingconcept
optimalfilling degree
perfect package solution
(filmthickness,form,depth)
no delamination
no product
d d
damage
no white spots
Source: Tobias Richter, Multivac
Highpressuretreatment:600MPafor3min
Optimisepackaging
ProcessingCosts Hours / d
Process pressure
Starting temperature
16
600
5
16
600
90
h/d
MPa
C
Vessel size 325 125 L
Number of vessels 1 1 U
Cycle time 8.0 8.0 min
Vessel=325L
V l 325 L Packs / a
Cycles / d
35 100
35,100
120.0
13 500
13,500
120.0
1000/a
1/d
Electric power 63 69 kWh/m product
Water 0.765 0.765 m/m product
Facility 1,896,120 1,738,110 USD
Extra pumps (if required) 260,717 284,418 USD
HighPressureThermalSterilisation Accessories 27,968 30,180 USD
Installation / Commissioning 94,806 94,806 USD
(orange): Duty 22,796 21,475 USD
Freight 31,602 31,602 USD
SensitivityAnalysis
SensitivityAnalysis
?
?
Conclusions
Generally,theprocesscostsforHighPressure
ThermalSterilisationareconsiderablyhigherthan
thoseforHighPressureLowTemperatureprocessing
ThecostsforHPLTandHPTSfor600MPa/3min
processcanbeestimatedtobe0.15and0.25AUD
perkgproduct,respectively
Sensitivityanalysis:capitalcost,fillingdegree
efficiency,productionhours,depreciationperiod,and
cycletimegreatlyaffectedtheprocessingcosts
Manningandenergycostsonlyhadarelativeminor
impactontheprocesscost.
Conclusions
Consumers: HPPisaconsumeracceptable,environmentalfriendly,
scientificallyrecognised methodtoachievehigherqualityincertainfoods
Processing: Pressuretransmissionisinstantaneousanduniform(notheat
transfercontrolled,noshadow,depth,orunevendistributioneffect) rapid,
shortprocessingtimes,assuredsafetyinwholepack,suitableforsolidsand
liquids
Quality: retainsflavour andnutrition
Environmentally: safeandnoprocessbyproducts,noemissions
Packaging:
Packagedesign,geometryandformatshouldbetailoredforHPP,Packaging
filmsandlaminatestructuregenerallysurviveHPPwell,butMAPandHPPat
hightemperaturecancausedelamination anddefects
OTRandWVTRcanbeaffectedbyHPP
InternationalNonthermal Food
ProcessingWorkshop FIESTA2012
1617October2012,MelbourneAustralia
Innovative processes for sustainable safe and healthy foods
Innovativeprocessesforsustainable,safeandhealthyfoods
www.innovativefoods2012.com
PosterabstractscloseJuly15
SupportedbytheInstituteofFoodTechnologysNonthermal ProcessingDivision,
theEuropeanFederationofFoodScienceandTechnology
andtheAustralianInstituteofFoodScienceandTechnology.
Presented by the Food Innovation Emerging Science and Technology Applications
PresentedbytheFoodInnovationEmergingScienceandTechnologyApplications
(FIESTA)Conferenceseries.
Thankyou
ProcessEngineeringScience FoodMicrobiology
RomanBuckow MichelleBull
ResearchGroupLeader StreamLeader
t +61397313270
+61 3 9731 3270 t +61397313270
+61 3 9731 3270
e roman.buckow@csiro.au e michelle.bull@csiro.au
w www.csiro.au/fns w www.csiro.au/fns
CSIROFOODANDNUTRITIONALSCIENCES