Extended Shelf life Chilled Foods and Sous-Vide · PDF fileExtended Shelf life Chilled Foods...
Transcript of Extended Shelf life Chilled Foods and Sous-Vide · PDF fileExtended Shelf life Chilled Foods...
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Extended Shelf life Chilled Foods and Sous-Vide
Processing
Phil MinerichVP Research & Development
Hormel Foods Corp.
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Can it be done?
YES !!!!
However…..
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Pasteurized Food Processes
Pasteurize > Cool > Package (Normal Kitchen)• Normal spoilage process
Pasteurize > Package > Cool (Refrigerated Soups)• Hot pack, spore growth concerns
Package > Pasteurize > Cool (Sous vide)• Vac-pack, spore growth concerns
Pasteurize to eliminate vegetative spoilage organisms, cool and maintain temperature control throughout shelf life
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Understand the Science (risks)
Not talking about;• Retorted, shelf stable foods• High-acid, shelf stable foods• Cured, refrigerated foods
Talking about ‘extended’ shelf life, refrigerated, non-cured foods; either cooked, then packaged, or vacuum-packaged, then cooked (sous-vide)
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Spore former
facultative anaerobe107.629.77.010.04.20.94Yesinia enterocolitica
facultative anaerobe109.446.45.010.05.00.96Vibrio vulnificus
facultative anaerobe111.041.010.011.04.80.94Vibrio parahaemolyticus
facultative anaerobe109.450.06.010.05.00.97Vibrio cholerae
facultative anaerobe118.050.010.09.84.00.85Staphylococcus aureus - toxin
facultative anaerobe122.044.625.010.04.00.83Staphylococcus aureus - growth
facultative anaerobe116.843.05.29.34.80.96Shigella spp.
facultative anaerobe115.241.48.09.53.70.94Salmonella spp.
facultative anaerobe113.031.310.09.44.40.92Listeria monocytogenes
facultative anaerobe120.944.66.59.04.00.95Escherichia coli (pathogenic strains)
anaerobe125.650.07.09.05.00.93Clostridium perfringens
anaerobe113.036.05.09.05.00.97Clostridium botulinum, non-proteolytic E, B, F
anaerobe118.450.010.09.04.60.93Clostridium botulinum, proteolytic A, B, F
micro-aerophilic113.086.01.59.54.90.99Campylobacter jejuni
aerobe131.039.218.09.34.30.92Bacillus cereus
facultative anaerobe107.631.84.010.04.00.94Aeromonas hydrophila
Oxygen Requirement
max. temp., °F
min. temp., °F
max. % Salt
max. pH
min. pH
min. aWPathogen
Limiting Conditions for Targeted Pathogens
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C. botulinum Characteristics
Canned Foods ESL & Sous-Vide
<0.1-min @ 212 F>15-min @ 212 FSpore heat resistance
0.96
10%
4.6
98 F (37 C)
50 F (10 C)
Proteolytic A,B,F
Minimum aw for growth
NaCl conc. to prevent growth
Minimum growth pH
Optimum growth temp
Minimum growth temp
5%
5.5
0.97
77 F (25 C)
36 F (2.5 C)
Non-Proteolytic B,E,F
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Time to Toxin vs. TemperatureNon-Proteolytic C. botulinum
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C. botulinum Characteristics
Canned Foods Sous-Vide
0.1-min @ 212 F25-min @ 212 FSpore heat resistance
0.96
10%
4.6
98 F (37 C)
50 F (10 C)
Proteolytic A,B,F
Minimum aw for growth
NaCl conc. to prevent growth
Minimum growth pH
Optimum growth temp
Minimum growth temp
5%
5.5
0.97
77 F (25 C)
36 F (2.5 C)
Non-Proteolytic B,E,F
Target 6-log reduction
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Audits International/FDA1999 U.S. Food Temperature Survey
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Spore-forming Pathogens
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Safety of Extended Shelf life Chilled Foods non-proteolytic C. botulinum
Temp/Time Cool Store Shelf life• 194°F 10 min. <50°F ≤ 37°F Not Stated
≤ 41°F ≤ 10 days≤ 50°F ≤ 5 days
≤ 50°F and pH <5.0 NaCl >3.5%aW <0.97
• Other combination of factors to give a 6-log reduction of non-proteolytic C. botulinum
UK Advisory Committee on the Microbiological Safety of Foods (ACMSF)
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Sous Vide & Minimally Processed Chilled Foods
Temp/Time Cool Store Shelf life
French Regulations• 158°F 40 min. <50°F in 120 min. <=37°F 6 day • 158°F 100 min. 21 day• 158°F 1000 min. 42 day
Dutch Belgian Guidelines• 194°F 10 min. <=41°F 10-42 day
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FDA Derived Safe Storage Time
°F °C
55 12.850 10.045* 7.241* 5.040 4.435 1.730 -1.1
* FDA Food Code recommended holding time and temperature
Days
1.72.44.07.07.5
19.5123.8
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What’s Gone Right?
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Hurdle Concept
Water activitypH
Water activitypHTemperaturePressurePlus meat-only, no root crops (onion, carrot, potato, mushroom, etc)
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New Players Push the Limits
Stews, Chilis, Soupsand Sauces
With Veggies
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Still No Wreck?
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Multiple, Multiple Hurdles
Pre-washesPeeling to remove outer contaminantsVision sorting technologiesChemical / acid washes
In addition to traditional hurdlesAND, food science in product formulation
wash peel sort wash
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Natural Antimicrobials
Live cultures• Lactobacillus vavaricus, Carnobacterium piscicola
Fermentates• Organic acids, peptides
Bacteriocins• Nisin, Natamycin, Pediocin
Enzymes• Lysozyme
Natural antioxidants• Rosemary extract
Natural extracts
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Acids/Salts
AcetateLactatePropionateBenzoateOctanoic acidMonolaurinSorbateAscorbateCitrateGDL (Glucono delta Lactone)Phosphates (trisodium phosphates)Salt (NaCl or KCl)
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Chemicals
Nitrite/NitrateSulfite or SO2
Smoking/PhenolsSodium metasilicatesAcidified sodium chloriteAcidified sodium nitriteBHA, BHT, TBHQ
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Process Options
Traditional Thermal Processes• Retort, Steam, Hot Water
UHT plus aseptic fillingRadio FrequencyOhmicHigh Pressure ProcessingIrradiation
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Concerns with Current Strategy
Sept, 2006 Bolthouse Farms Carrot Juice bot incidentFlorida, Georgia, CanadaFDA response: shelf stable processGMA response: form a committeeIndustry response: spoils to the survivorsRisk, category lost to consumers
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Proposed FSO’s
VEGETATIVE FOOD BORNE PATHOGENS1 – 160° F hot fill – kills vegetative pathogens
NON-PROTEOLYTIC CLOSTRIDIUM BOTULINUM1 – Processing steps to target minimum 6-log spore reduction2 – Antimicrobials – prevent outgrowth of C. Bot.
PROTEOLYTIC CLOSTRIDIUM BOTULINUM1 – Significant intervention to reduce spore loads2 – Antimicrobials – prevent outgrowth of C. Bot.3 – Validation of raw material spore loads <3 MPN/g 4 – Distribution temperature control <50° F does not grow5 – TTI to validate temperature control <50° F