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Adapting Novel Processing Technologies to Meat Operations Tatiana Koutchma, PhD

Adaptando novas tecnologias para o processamento da carne

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Page 1: Adaptando novas tecnologias para o processamento da carne

Adapting Novel Processing

Technologies to Meat Operations

Tatiana Koutchma, PhD

Page 2: Adaptando novas tecnologias para o processamento da carne

Outline

Safety Risks of Modern Food Production

Review of Novel Processing Technologies

Technology Assessment and Gaps in Knowledge

FSWG’s Survey :

Food Safety and Novel Technologies

Page 3: Adaptando novas tecnologias para o processamento da carne

Safety Risks of

Modern Food Production

Products

Higher quality - Mild treatment

Extended product shelf-life

“Fresher” quality,

RTE pre-cooked

Convenience

Low salt, sugar, fat

Globalization of food supply

New Risks

Incomplete microbial inactivation

Possible non respect of adequate

storage conditions and expiration

dates

Undercooking

Overcooking

Generation of stress-resistant

organisms

Emerging pathogens

Page 4: Adaptando novas tecnologias para o processamento da carne

Food Technologies

Branch of food science and engineering which deals with the actual

production processes to make foods.

5. Novel or emerging

technologies

Contemporary technical

innovations which represent

progressive developments within

a field for competitive advantage

Traditional processing concepts

1. Application of thermal energy to

elevate product temperatures to

achieve long term or extended

stability or preservation

2. Removal of thermal energy to

reduce product temperature and

extend shelf-life

3. Removal of water from products

structure and thus achieving of

extended shelf-life

4. Packaging or the step required to

maintain product properties

achieved during processing

Page 5: Adaptando novas tecnologias para o processamento da carne

Future Processing Trends

Improved Quality and Safety

Novel Foods

Transformation & Preservation

Novel Technologies

Novel Processes

Improved Product Quality

Traditional Foods

Improved Manufacturing Performance

Traditional Technologies

Improvements in Designs and Control. Redesign

vs

Page 6: Adaptando novas tecnologias para o processamento da carne

The Novel Foods

• Non-traditional foods with

no history of safe use and

manufactured, prepared,

preserved or packaged by

a process that has not

been previously applied to

that food

• Definitions available

in 6 countries

Page 7: Adaptando novas tecnologias para o processamento da carne

Key Drivers

Freshness & convenience & less preserved

Enhanced safety and extended shelf-Life

Heat labile functional ingredients

Engineering functional ingredients for

delivery of healthy foods

Lower carbon footprint

Reduce water volume used

Lower energy

Lower waste

Need for sound regulatory policy

U.S., Canada, EU

Page 8: Adaptando novas tecnologias para o processamento da carne

Novel Processing Options

Pressure - 6

Electromagnetic energy - 7

Electrical energy - 5

Sonication - 3

Chemical – 5

Plasma, magnetic field -2

Mechanical energy - 3

Total - more than 30 OPTIONS!

Page 9: Adaptando novas tecnologias para o processamento da carne

High Pressure

Hydrostatic

(HHP)

Pre-Packed Foods

2000

MPa

Hydrodynamic

(HDP)

Raw Meats 100

MPa

Hydrodynamic

Homogenization

(HDH)

Beverages 300

MPa

Pressure and CO2 Juices 100

MPa

Pressure Cycling

(HPC)

Extraction 300

MPa

Hyperbaric Fresh Produce 900

kPa

Page 10: Adaptando novas tecnologias para o processamento da carne

Novel Processing Technologies

Transform raw materials into food products

Preserve fabricated foods and raw ingredients during transportation, retailing and consuming foods

Control safety at different points of supply chain

With Potential

Provide Safety attributes HIGHER than those of raw products

Maintain Health and Quality attributes at least EQUAL to raw products

Enhance Functional properties or create New Products

Provide Broader Sustainable and Environmentally friendly benefits

Page 11: Adaptando novas tecnologias para o processamento da carne

UV Technology

Page 12: Adaptando novas tecnologias para o processamento da carne

Technology Assessment

Fundamental Physical Methods

Technology Performance

Technology Readiness

Risk Assessment

Regulatory Status

Life Time Cycle

Cost Efficacy

and

Page 13: Adaptando novas tecnologias para o processamento da carne

9 - Ready for full-scale commercialization

8 - Economic feasibility and regulatory issues addressed

7 - Economic feasibility demonstrated or regulatory issues addressed (but not both)

6 – Systems available commercially

5 - System or prototype demonstration in relevant environment (pilot scale)

4 - Component validation in relevant environment

3 - Analytical and experimental critical function and/or characteristic proof of concept

2 - Technology concept and/or application formulated

1 - Basic principles observed and reported

NASA Assessment Te

ch

no

log

y D

eve

lop

me

nt

Emerged

Under

development

Emerging

Page 14: Adaptando novas tecnologias para o processamento da carne

Thermal Processing Technologies

Traditional

Retorting

Aseptic

Pasteurization

Hot, Cold-Fill

Sous vide

Emerging

Pressure + Heat (8) Microwave dielectric (8) High frequency or RF (5-6) Infrared (6-7) Ohmic (6-7)

Under Development

Conductive

Heating

Page 15: Adaptando novas tecnologias para o processamento da carne

Non-thermal

Processing Technologies

Emerged

Irradiation (9)

High Hydrostatic Pressure (8-9)

Filtration (9)

Ozone (8-9)

Emerging

Pulsed Electric Fields (6-7)

UV light (6)

Pressure and CO2 (6)

Under Development

Cold Plasma (3-4)

Electrolyzed water (5)

Sonication (5)

Low dose e-beams (5)

Page 16: Adaptando novas tecnologias para o processamento da carne

Technology Knowledge

Traditional/Thermal

Established organism of public

health concern

Understood destruction

kinetics/mathematics

Knowledge of products heating in

given processing systems

Relationships between the

organism of public health concern

and spoilage

Equivalent safety of different

processing systems express in

“Lethality” terms

Novel

Target organisms of concerns and

surrogates has to be determined

Detailed knowledge of microbial

dose-response behavior

Complete representation of

distribution of the lethal agent

Process uniformity

Process monitoring &verification

Process Equivalency (FSO)

Chemical safety

Risk assessment

Page 17: Adaptando novas tecnologias para o processamento da carne

What Understanding is Needed when

Establishing a Novel Process?

A

Process Design Validation

Hazard

Analysis Regulatory

Acceptance

B Ingredients Product

Process

A B

B

Page 18: Adaptando novas tecnologias para o processamento da carne

Challenges of Novel Processing

Safety Equivalence

Traditional Foods Vs Novel Foods

• Nutritional, Allergenicity, Toxicological, Chemical

&

Traditional Process Vs Novel Process

• Performance Objective, Food Safety Objective

• Validation, Verification, Monitoring

O

O O

OH

=

Page 19: Adaptando novas tecnologias para o processamento da carne

Safety of Novel Processes

Technology Microbial Risks Chemical Risks Other

HPP Incomplete

microbial

inactivation,

recovery

Chemical reactions Spore inactivation

at elevated

temperature

PEF No spore

inactivation

Electrochemical

reactions

Metal transfer from

electrodes

Non homogeneity

arcing

UV light and pulsed

light

Repair Photo oxidation

reactions

Non-homogeneity

Ohmic heating Survivors Metal transfer from

electrodes

under/over heating

Microwaves Survivors Chemical reactions Non-homogeneity

Possible reduction

of power

Page 20: Adaptando novas tecnologias para o processamento da carne

Risk Assessment of Novel Foods

• Details of novel process

• Dietary Exposure

• History of organism

• Nutritional considerations – Dietary intakes

• Toxicology considerations

• Allergenicity considerations

• Chemical considerations

O

O

O

OH

Page 21: Adaptando novas tecnologias para o processamento da carne

Microbiological Assessment

Product • Raw ingredients

– Contamination

• Semi-finished/

– pH, Aw, composition, ToC

• Finished

– Packaging/Storage

• Predictive modelling of

growth/death/survival

– Indigenous flora

– Shelf-life

– Safety in terms of target

pathogens of concern

Food Chain • Production

– Local/Imported

• Food Processing

• Transportation

• Storage & Distribution

– Food Services/Retail

• RTE

• Consumption

– Preparation

Page 22: Adaptando novas tecnologias para o processamento da carne

Chemical Hazards

Product

• Natural - Endogenous toxicants

• Trypsin

• Mycotoxins

• Synthetic

Produced, through contamination of food material or processing environment

• Pesticide residues in fruits and vegetables

• Heavy metals, nitrites

• Drug residues in foods of animal origin

• Allergens

Process

• Formed during food processing

Migration

from packaging Biphenols

Acrylamide

Furans

Lipid oxidation products

Maillard reaction

Page 23: Adaptando novas tecnologias para o processamento da carne

Global Regulations

Novel Foods

European Union

United Kingdom

New Zealand

Australia

Canada

China

No Definition

USA

Japan

India

Page 24: Adaptando novas tecnologias para o processamento da carne

USA

No definition can not be found

• US FDA considers food ingredients as novel that have not been previously used

• New dietary compounds (NDI)

• As food additives under existing law, the principal law being the Federal Food, Drug and Cosmetic Act.

• The ‘Generally Recognised as Safe’ or GRAS concept is the bench mark by which all foods, including novel foods, are assessed.

• GRAS substances are: substances used before 1958 (excluding prior sanctioned food ingredients); and substances for which there is scientific evidence of safety as determined by competent experts and by published and available safety information.

Page 25: Adaptando novas tecnologias para o processamento da carne

US Approvals of Novel Processes

• 2001, Code 21 CFR Part 179.39 was published to improve the safety of fresh juice products: Source of UV radiation (LPM at 254 nm) defined as a food additive

• 2004, USDA has approved High Hydrostatic Pressure as

an intervention method for Listeria contaminated pre-packed ready-to-eat (RTE) meat products

• 2008, 73 FR 49593 The FDA published a final rule that allows the use of irradiation for fresh iceberg lettuce and fresh spinach

• 2009, the US FDA approved a petition for the commercial use of Pressure Assisted Thermal Sterilization process (PATS) for application in the production of LAF

2010, US FDA first time approved novel sterilization processing using 915 MHz microwave energy (MATS) for producing pre-packaged, LAF

Page 26: Adaptando novas tecnologias para o processamento da carne

26

Novel Food Decisions in Canada • Use of High Hydrostatic Pressure for Processing Ready to Eat

(RTE) Meat-containing Entrees, Meat-containing Salads and Meat Products (Maple Leaf, December 2006)

• Use of High Hydrostatic Pressure for the Control of L. monocytogenes in Ready to Eat (RTE) Meats and Poultry (Santa-Maria, Foods, October 2006)

• Use of the Rinse and Chill Process as a Slaughter Process Technology (MPSC Inc. of St. Paul, MN , October 2006)

• Applesauce and Applesauce/Fruit Blends Treated by High Hydrostatic Pressure (Orchard Inc., Franklin Centre, QC, in November of 2004)

• Ultraviolet light treatment of apple juice/cider using the CiderSure 3500 (Moore Orchards, July 15, 2003 )

Page 27: Adaptando novas tecnologias para o processamento da carne

Why High Hydrostatic Pressure

Independent of product mass,

size and geometry

Minimizing treatment time and scale up

Inactivates all vegetative bacteria and spores

Destroys enzymes

Minimal impact on quality and nutrition

Commercially economical processes

Emerged as a post-lethality treatment

Emerging as

Harvesting treatment

Pre-treatment before cooking

Sterilization of Low Acid Foods

Page 28: Adaptando novas tecnologias para o processamento da carne

HIGH HYDROSTATIC PRESSURE

Preservation Transformation Value Added

Sterilization

Pasteurization Shelf-life

extension

Meat

Protein

PATS

LAF

RTE

meals

RTE meats

Raw meats

Seafood

Page 29: Adaptando novas tecnologias para o processamento da carne

HHP process parameters

• Process Pressure

• Constant holding pressure

• >700 MPa – “sterilization”

• 200-600 MPa – “pasteurization”

• <300 MPa – raw meat treatment

• Process Temperature

• Final product temperature after pressurization

• Process hold time

• Time recorded between end of

• compression and start of decompression

Page 30: Adaptando novas tecnologias para o processamento da carne

Other parameters affecting HHP

Product

• pH, water activity

• Composition:

• Fat

• Salt content

• Physiological state of

bacterial cells

• From exponential or stationary

growth phase

Packaging

• Type of packaging: vacuum or

MAP

• Packaging and material

influence the log reduction data

• Design and geometry

Page 31: Adaptando novas tecnologias para o processamento da carne

Raw Meat Processing

Harvest Processing Fresh Meats

Shelf-life Extension

Stops post-mortem glycolysis

Improves meat quality

Stabilizes pH >6.0

Improves color

Increases water-holding capacity

Decreases shear force

Increases tenderness

Hair/feather removal

Loosens hair/feather follicles

Eliminates scald tank

Toenail removal

Loosens toenails from hoof

Reduces fecal contamination

Ambient Temperature at Pressure < 350 MPa

Page 32: Adaptando novas tecnologias para o processamento da carne

Fundamental Mechanisms

• The modifications of meat structure are strongly dependent on the time post-mortem

• Pre- or post-rigor when HPP is applied

• Pressurisation of pre-rigor meat usually results in a

– rapid pH decrease

– intense contraction

– phenomena depend on treatment time, meat temperature and muscle type.

• Pressurization of post-rigor meat

– no contraction was induced,

– Extensive modifications in sarcomere structure

– Cheftel, Meat Science, 1997

– Sun and Holley, JFS, 2009

Page 33: Adaptando novas tecnologias para o processamento da carne

HPP Preservation of RTE meals

Shelf Life Extension

Pasteurization

Marinated Meats

RTE meats and poultry (ESL)

Pre-treatment

Post-Lethality

Ambient & Mild Temperatures

400 – 600 MPa

Sterilization

Pre-packed

Low Acid Foods (LAF) MREs

Pressure Assisted Thermal

Sterilization (PATS)

Elevated Temperature (>100oC)

700 MPA

Page 34: Adaptando novas tecnologias para o processamento da carne

Product and Process conditions for

Establishment of HHP preservation

HPP pasteurization HPP sterilization

Product parameters

pH, aw 3.5 <pH<4.6; pH<3.5 pH>4.6; aw >0.86

Process parameters

Temperature, oC ≤ 45 > 100

Pressure, MPa ≤ 600 > 700

Target microorganisms

Pathogenic E. coli; Listeria; Salmonella C. botulinum spores

Bacillus cereus

Spoilage Lactic bacteria, yeasts, molds Geobacillus spp.

Storage Refrigerated conditions Ambient temperature

Packaging Hermetically sealed

flexible containers

Hermetically sealed

flexible containers

Page 35: Adaptando novas tecnologias para o processamento da carne

Microbial Safety and Functionality in

Reduced Sodium Chloride Foods

High sodium intake is a risk factor for hypertension, cardio vascular and other diseases

The WHO has set a target for daily intake of 5g or less of salt (<2g sodium)

Sodium intake commercially processed foods (CPF) (77 %)

naturally occurring (12%),

addition at the table (6%) and added during cooking (5%)

NaCl is an important ingredient added to meats formulations increases gelation, water holding capacity and fat retention.

decreases Aw

retards growth of spoilage and pathogenic microbes, Listeria monocytogenes.

Page 36: Adaptando novas tecnologias para o processamento da carne

HHP for Low Sodium Products

Pre-treatment • HHP may have beneficial

effects on meat product

quality

– Improves water holding

capacity and decreased

water losses

– Induce changes in protein

• Pressures: 50 up to 300 MPa

• Temperature: Refrigerated or

Ambient

• Time: up to 5 min

Post-lethality

• HHP is effective intervention

methods against Listeria and

other pathogenic bacteria

• Pressures: 500 up to 600 MPa

• Temperature: ambient

Refrigerated or Ambient

• Time: up to 3min

Page 37: Adaptando novas tecnologias para o processamento da carne

Commercial HHP systems

Vessel layout – horizontal

Automatic loading / unloading

• Wave 6000 / 55 L

• Wave 6000 / 135L

• Wave 6000 / 300T L

• Wave 6000 / 420 L

• Maximum pressure – 600 MPa

• Pressure Hold Time – 3 min

Page 38: Adaptando novas tecnologias para o processamento da carne

Commercial HHP systems

• Wide range of HHP

systems

– 100 L - 600

– 215 L - 600

– 350 L - 600

– 687 L - 300

• 7 contract services

facilities in US

Page 39: Adaptando novas tecnologias para o processamento da carne

Lab scale HP units

• Avure

Laboratory Scale Pressure Test

System Model PT-100

The QFP-2L-700 high pressure unit

Page 40: Adaptando novas tecnologias para o processamento da carne

BaoTou HHP Technology

Lab size equipment

3-5L 600 Mpa

Commercial equipment

30-50 L 600 MPa

2 x 300L 600 MPa

4x 600 L 600 MPa

Page 41: Adaptando novas tecnologias para o processamento da carne

Vessel Technologies

Wire winding Autofrettage

http://www.avure.com/company/quintus.asp

Vessel is subjected to over-pressure which locks plastic strain in an internal core

Autofrettage pressure is selected according to plastic behaviour od steel used (15-15PH)

http://www.freshertechusa.com/index.html

Page 42: Adaptando novas tecnologias para o processamento da carne

FresherTech • Mono - Single Chamber

Systems

• Duo - Dual Chamber

Systems

• Quattro - Four Chamber

Systems

Page 43: Adaptando novas tecnologias para o processamento da carne

Multivac and Uhde

• Multivac for HHP

packaging lines

• Fully automated and

integrated production

lines

– Filling, loading and

unloading robots,

inspection, weighting

• Continuous production

flow

http://us.multivac.com/our-products/hpp-high-pressure-

preservation.html

Page 44: Adaptando novas tecnologias para o processamento da carne

HHP - What are PROS?

HHP is commercially available technology that solves consumers' demands for safety, healthiness, clean label and low sodium refrigerated foods

HHP solves the retailers' needs for fresh foods with long shelf life

Capital and operating costs of HHP systems are now line with the cost of chemical additives 2 to 8 cent per pound.

HHP allows processors to meet both retailer and consumer demands while potentially selling clean label products at a premium with the advantage of post package food pathogen inactivation

Page 45: Adaptando novas tecnologias para o processamento da carne

What are Cons?

CONS

Batch process for pre-packed products

Cost is still can be an issue

Most popular applications – post-lethality treatment of RTE meats, seafood

Process uniformities needs to be monitored

Application of HHP is limited :

to fresh meat and sea products due to resulting discolouration

Fresh produce – texture

Page 46: Adaptando novas tecnologias para o processamento da carne

Why UV?

Effective against microbial and chemical hazards

Physical non-thermal method

Chemicals free

Cost effective

Energy efficient

Approved by Regulatory Agencies EPA US FDA (2001) Health Canada (2003)

2011201020092008200720062005200420032002

25

39

33

38

33

23

12

17 16 14

Page 47: Adaptando novas tecnologias para o processamento da carne

Ultraviolet UV light

UV-V

6.20 – 12.4 eV

UV-C

4.43 – 12.4 eV

UV-B

3.94 – 4.43 eV

UV-A

3.10 – 3.94 eV

Energy per photon:

Page 48: Adaptando novas tecnologias para o processamento da carne

Effectiveness of UV light

Against Food microflora

Bacteria

Spores Viruses

Parasites Spoilage microflora

- Hepatitis A virus

- Norovirus

- Cryptosporidium

parvum

- Giardia lamblia

- aerobic microflora

- yeasts

- molds

- Lactic acid bacteria

- Eschierichia coli O157:H7

- Listeria monocytogenes

- Salmonella enteredius

- Staphylococcus

aureus

Page 49: Adaptando novas tecnologias para o processamento da carne

Development and Applications of UV sources

UV source

Applications

Food

Industry

Regulatory

Approval

Implementation

Environment

impact

Low Pressure

Mercury (LPM)

Amalgam (LPA)

Air Water

Surfaces

Since 1930

Surfaces

Water

Juices

YES

US FDA (2000)

Health Canada

(2003)

Mercury

Glass

Medium Pressure

Mercury (MPM)

Water

Water

NO

Mercury

Glass

Eximer Medical – Packed

Blood Plasma

Curing

Surfaces

Cost

NO

Glass

Pulsed (PL) Curing Produce

RTE Food

Surfaces, Dry

ingredients

YES

Glass

Light Emitting

Diodes (LED)

Lightings

Air

NO

NO

NO

Page 50: Adaptando novas tecnologias para o processamento da carne

Why LEDs will replace UV lamps?

LEDs: Energy efficient, NO

mercury, long time, COST

UV Lamps: short life time,

mercury, glass

UV Lamps: Wavelength are not

optimized for applications

• LEDs: Emit single peak

Tunable

LEDs are Building Blocks for Future UV systems

Page 51: Adaptando novas tecnologias para o processamento da carne

Guidelines For Choice of

UV source 1. Emission spectrum –

related to applications

2. Electrical and UV efficiency

3. Lifetime

4. Cost

5. Availability

6. Size

7. Shapes

Page 52: Adaptando novas tecnologias para o processamento da carne

UV

LIGHT

Safety

Air, water

Non-food contact surfaces

Food contact surfaces

Pathogens

inactivation

PreservationPasteurization

Shelf-life extension

Liquid foods and

beverages

Whole and fresh cut produce

Functionality Enhancement

Vitamins

Antioxidants

Microbial resistance

Chemicals destruction

Toxins

Allergens

Pesticides

Patulin

Aflotoxins

Page 53: Adaptando novas tecnologias para o processamento da carne

UV on Food Plant

Air and water treatments

Non-food contact surfaces

Walls, ceilings, floors

Food contact surfaces

Conveyor belts

Packaging materials

Equipment surfaces

Food surfaces

RTE meats

Fresh produce

OFFERS UV-PROTECTION

• Airborne

– Molds Spores, human

pathogens

• Waterborne

– Viruses and Bacteria

spores

• Foodborne

– Bacteria, spores

• Spoilage

– Yeast, molds, lactobacilli

Page 54: Adaptando novas tecnologias para o processamento da carne

Microbial Resistance to UV

Air Water Food

Fluids

Viruses Cryptosporidium

Parasites

Bacteria Bacteria

Yeasts

Bacteria

Yeasts

Spores Spores Spores

Viruses (Adenovirus)

Viruses

Molds spores

RH, T,oC

Turbidity pH, Aw

composition

Page 55: Adaptando novas tecnologias para o processamento da carne

Commercial UV unit

to Treat Odors

Page 56: Adaptando novas tecnologias para o processamento da carne

UV resistance of Listeria on Surfaces

• Agar:

– D10= 0.5 mJ/cm2

• Surfaces of packaging

materials, conveyor belts

– D10 = 2.55 – 3.2 mJ/cm2

• Products

– Frankfurters

D10 = 300 mJ/cm2

– Cut Pear

D10~ 2000 mJ/cm2

Page 57: Adaptando novas tecnologias para o processamento da carne

UV for Poultry, Fish and

RTE products

Raw

• Poultry reduction of

Salmonella without affecting

color or increasing rancidity of

the meat

• Chicken Breast Fillet - L.

monocytogenes without

negatively affecting meat color

• Raw Salmon Fillets - PL

caused visual color and quality

changes due to T increase

RTE

Continuous UV

• Effective against Listeria on the

surface of frankfurters

• Up to 2-log reduction at 4 J/cm2

• No changes in colour

Pulsed UV

• Effective against Listeria on the

surfaces of steel coupons

• Up to 4 log reduction at 6 J/cm2

Page 58: Adaptando novas tecnologias para o processamento da carne

Challenges of UV surface

inactivation

Surface characteristics

Quality parameters

Duration of the treatment

Continuous UV vs

Pulsed Light

Page 59: Adaptando novas tecnologias para o processamento da carne

Decontamination of Surfaces

UVC Tumbling Machines by Reyco Systems

• Frozen • Fresh • RTES • Products prior to bulk

storage: onions, potatoes, fruits, grain

Claranor: Packaging,

Caps, Cups

Heraeus, Blue Light Module

Page 60: Adaptando novas tecnologias para o processamento da carne

Novel UV Processes UV pasteurization /

Shelf-life Extension

Fresh Juices

– Apple, apple cider, carrot,

orange

Liquid sweeteners

– Sucrose, fructose, glucose

Ice teas, soft drinks

Liquid egg products

Milk, cheese milk and calf milk

Whey protein concentrates

Brewery & winery

Emulsions, brines, marinades

Transformation / Added value

Milk - Vitamin D synthesis

Mushrooms - Vitamin D2 synthesis

Peanut butter, soy - reduce

allergenicity

Fruits – increased nutrients content

Carrots - increased AO capacity

Fresh Cut Fruits/ Juices -

enzyme Inactivation

Page 61: Adaptando novas tecnologias para o processamento da carne

Challenge

High UV absorbance

of liquid foods at 253.7 nm

Low microbial reduction

~ 2 log reduction at UV fluence of

190 mJ/cm2

UV overdosing can lead to

sensory changes

Solutions Improve designs of UV systems

Efficient mixing: Turbulent flow

Dean, Taylor-Coutte Flows

Match UV source for the

application

Optimized UV dose

Page 62: Adaptando novas tecnologias para o processamento da carne

Commercial Applications

Processing

CIP water

Packaging and product rinse

water

Raw material application

Dilution water

Sugar syrup

Brines

Liquid egg

Finished product

Bottled water

Fruit juice and fruit

concentrates

Isotonic and fortified drinks

Iced tea

Wine

Tetra-hopped beer

Dairy

Page 63: Adaptando novas tecnologias para o processamento da carne

UV units for Low UVT Liquids

Thin film reactor “CiderSure” Annular reactor “UltraDynamics”

Thin film mixers “Pure UV”/ “Iatros” Static Mixers – Dean Flow “Salcor”

Inlet

Outlet

UV lamp

Teflon tubewound inhelix pattern

L-N L-NN

NL-

NN

NL-

NN

Page 64: Adaptando novas tecnologias para o processamento da carne

UV units: Turbulent flow

SurePure turbulator Salcor 3G UV CiderSure

Page 65: Adaptando novas tecnologias para o processamento da carne

Commercial UV Unit

Sure Pure Turbulator

Turbulent flow of the liquid over

the lamps ensures a foul-free,

self-cleaning system

Multiple-lamp system

Dosage of UV-C depends on

Product turbidity and UV absorbance

Initial microbiological load

Flow-rate

Desired log reduction

Flow rate 4 000 L.h-1

Retention time 0.608 s

Lamp life 5000+ hours

Page 66: Adaptando novas tecnologias para o processamento da carne

UV treatment of Liquid Eggs

and Brines

Brine Water: 235 J/L

Page 67: Adaptando novas tecnologias para o processamento da carne

UV for Dairy Applications

• Raw ESL milk - up 25 day extension of shelf-life

• Applied doses up to 1.5 kJ/l were effective to reduce total viable counts, psyhrophiles and coliforms up to 2, 3 and 4-log reductions

• E.coli O157:H7, Salmonella, Yersinia, Staphylococcus, Listeria monocytogenes and Campylobacter jejuni – 5-log reduction at 1.3-1.7 kJ/l

• Microbiological efficacy is achieved without any discernible denaturing of the product`s consistency, color, flavor or aroma

Page 68: Adaptando novas tecnologias para o processamento da carne

UV for Meat Applications

• Control of Listeria

monocytogenes in recycled

chill brines

• Decontamination of poultry,

associated packaging and

contact surfaces

• Decontamination of poultry

carcasses

• To reduce aging of beef

carcases

• Extension of retail

display of fresh beef

packages in modified

atmosphere

Page 69: Adaptando novas tecnologias para o processamento da carne

Savings Opportunities

Energy savings :

Steam, hot water

non-thermal nature of the process

Water :

Drinking water

Process water

CIP rinse water

Capital cost :

Transportation

Environmental impact

Reduced waste

Page 70: Adaptando novas tecnologias para o processamento da carne

Energy use

in processing of apple juice

Processing conditions

E. coli

strain

Capacity

(L/s)

Specific Energy

(kJ/kg)

HTST 71.6 °C x 6 s O157:H7 1.0 180.4

HPP 500 MPa x 40 °C x 180 s O157:H7 1.25 283.5

PEF 25 kV/cm x ~50 °C x 50

μs*

ATCC

11775

0.670 137.2

UV 1.56 kW x 25 °C x 89 s K-12 1.1 5.2

UF 0.02 μm, 1.474 kPa, 5

L/m2.s

Pseudomo

nas

diminuta

1.0 0.028

Page 71: Adaptando novas tecnologias para o processamento da carne

Energy for Processing

Fluid product by Novel Technologies

0 100 200 300 400 500

HPP

HTST

PEF

UV

UF

Energy consumption (J/g)

Technolo

gy

Page 72: Adaptando novas tecnologias para o processamento da carne

Food Safety Working Group (CIGR)

Survey: Food Safety and Novel Technologies

• To analyze commercial applications of novel technologies and their

development level in different countries/continents

• To evaluate the role that novel food processing technologies and

innovations can play to address global food safety issues and

challenges

• To analyze knowledge level of novel technologies in different countries

and professional groups

• To analyze factors that slow down the development of novel

technologies

• 18 questions

• Completion rate: 44.33%

• 25 countries

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Summary

Advances in science and engineering, progress in regulatory approvals make Novel Processing Technologies (NPT) a viable option for commercialization in foods preservation and transformation

Preservation NPT comprise two general categories:

(1) technologies suited for pasteurizing high-acid liquid products such as HHP, PEF, US, UV and chemical processes, including gases

(2) technologies for processing shelf-stable foods, e.g., HPP combined with temperature, MW and RF heating, ohmic heating, and irradiation

More sustainable NPT will lead to the production of processed products with

safety attributes higher than those of raw products

health and quality attributes at least equal to raw products

broader environmentally friendly benefits

potential saving opportunities in energy and water

Safety Quality Sustainability

Page 74: Adaptando novas tecnologias para o processamento da carne

Conclusion

• The scope of novel foods and novel ingredients covered by the international regulations is broad and diverse

• Safety evaluation is conducted on case-by-case scenario

• Validation of novel processing technologies requires new knowledge

• Education of food manufactures and regulators

Page 75: Adaptando novas tecnologias para o processamento da carne

Thank You !

Dr. Tatiana Koutchma Contact info:

[email protected]

AAFC

Guelph Food Research Center

93 Stone Road West

Guelph, ON, Canada