Aseptic Processing of Foods / Edition 1

by Helmut Reuter

Overview

Aseptic food processing has become important as a safe and effective method for the preparing and packaging of a variety of foods. This recent book, prepared by a team of European specialists, provides a detailed guide and reference to aseptic food processing technology. All aspects are presented systematically: principles, practice, equipment, applications, packages and packaging, quality control, and safety. All applicable food and beverage categories are examined. More than 130 photographs, diagrams, and other schematics illustrate equipment and their function and a variety of procedures. Tables and graphs provide important quantitative data in convenient form.

Product Details

ISBN-13:	9781138426603
Publisher:	Taylor & Francis
Publication date:	07/27/2017
Pages:	313
Product dimensions:	6.00(w) x 9.00(h) x (d)

Table of Contents

Preface — Authors and Editor — Pre-sterilization of products — 1 Basic principles — 1.1 Fundamentals of UHT and HTST sterilization of foodstuffs /H. Reuter — 1.1.1 Introduction — 1.1.2 Deduction of optimal sterilizing conditions from reaction kinetics — 1.1.3 Improvement of sterilization conditions by pre-sterilization — 1.1.4 Calculation of thermal effect in sterilization — 1.1.5 Advantages and disadvantages of aseptic processing — 1.1.6 References — 1.2 Ohmic heating of particulate food products /W. Reitler — 1.2.1 Introduction — 1.2.2 Indirect heating of particulate food products — 1.2.3 Ohmic heating of particulate food products — 1.2.4 Computer simulation of the heating behavior of heterogeneous foodstuff suspensions — 1.2.5 References — 1.3 Dielectric heating of foodstuffs and temperature distribution in the product /H. Reuter — 1.3.1 Introduction — 1.3.2 Effect of the electromagnetic alternating field — 1.3.3 Energy conversion — 1.3.4 Temperature distribution in the product — 1.3.4.1 Penetration depth — 1.3.4.2 Temperature change in the product — 1.3.4.3 Influence on shape, edge or corner effect — 1.3.4.4 Dielectric unhomogeneity of foodstuffs — 1.3.4.5 Engineering reasons for nonuniform temperature distribution — 1.3.4.6 More uniform temperature distribution — 1.3.5 Industrial applications — 1.3.6 References — 2 Process and equipment for UHT and HTST pre-sterilization — 2.1 Tubular heat exchangers systems for liquid foods with solid particles and criteria for structural behavior /N. Nicolaus — 2.1.1 Comparing views: The product - expectations and requirements — 2.1.2 Application of tubular heat exchangers - system concept — 2.1.3 Tubular heat exchangers - test stand and test run — 2.1.4 Findings from test results and presentation of a nomogram for getting the degree of damage — 2.2 Thermal stabilization of soups and sauces containing particles by double flow processing /E. Plett — 2.2.1 Characteristics of aseptic processing technology — 2.2.2 Areas of application — 2.2.3 Heat-transfer systems for aseptic technology — 2.2.3.1 Criteria for construction — 2.2.3.2 Possible uses of indirect heat-exchangers — 2.2.3.3 Possible uses of direct heat exchangers — 2.2.4 System family for aseptic processing technology — 2.2.5 Possibilities for combining different heat exchangers — 2.2.6 Alternative processes for continuous flow-sterilization of foodstuffs with particles — 2.2.7 Outlook — 2.3 Single-Flow Fraction Specific Thermal Processing ("Single-Flow FSTP'1) of liquid foods containing particulates /W.F. Hermans — 2.3.1 Introduction — 2.3.2 Single-Flow Fraction Specific Thermal Processing (Single-Flow FSTP) — 2.3.3 Selective Holding Sections (SHS) — 2.3.4 Time-temperature profiles and processing values — 2.3.5 Stork STERI PART System — 2.3.6 Stork STERIPART Pilotplant — 2.4 New system for the sterilization of particulate food products by ohmic heating /P. J. Skudder — 2.4.1 Introduction — 2.4.2 Principle of ohmic heating — 2.4.2.1 Design of the ohmic heater — 2.4.2.2 Measurement of electrical conductivity of particulate food products — 2.4.2.3 Temperature control of the ohmic heater — 2.4.2.4 Aseptic processing using the ohmic heater — 2.4.3 Product quality — 2.4.4 Conclusions — 2.4.5 Acknowledgements — 2.4.6 Reference — 2.5 Pasteurization and sterilization of unpackaged liquid food containing solid parts in a continuous process by means of microwaves /K. Koch — 2.5.1 Introduction — 2.5.2 Heat treatment by means of microwaves — 2.5.3 Constructional requirements for an even temperature distribution inside the product — 2.5.4 Sterilization under atmospheric conditions — 2.5.5 Sterilization of unpackaged cubed food by means of microwaves — 2.5.6 Measuring techniques — 2.5.7 Hygienic operating conditions for microwave lines for the sterilization of unpackaged food containing solid (cubed) parts — 2.5.8 Safety aspects — 2.5.9 Performance data — 2.5.10 Conclusion — 3 Sterile conveyance of liquids /Ph. Berdelle-Hilge — 4 Products — 4.1 Soups and sauces UHT processed and aseptically packed /F. Wilhelmi — 4.1.1 Introduction — 4.1.1.1 Importance of heat sterilized soups and sauces — 4.1.1.2 Classification of heat sterilized soups and sauces — 4.1.2 Heat processing of soups and sauces — 4.1.2.1 Conventional sterilization — 4.1.2.2 UHT heating — 4.1.3 Aseptic packing systems — 4.1.3.1 Combibloc — 4.1.3.2 Tetra -Pak, Pure-Pak — 4.1.3.3 New systems under development — 4.1.4 Product quality and quality assurance — 4.1.4.1 Ingredients suitable for UHT processing — 4.1.4.2 Recipes, working instructions and product descriptions — 4.1.4.3 Minimum shelf-life-date of "best before" — 4.1.4.4 Sensory evaluation of products and corresponding standard methods — 4.1.5 Varieties for UHT processed and aseptically filled soups and sauces — 4.1.5.1 Soups — 4.1.5.2 Sauces — 4.1.6 References — Annex 1 — Annex 2 - Functional properties of starches Suitability test - check list — Annex 3 - Functional properties of hydrocolloids (except starches) Suitability test - check list — Annex 4 - Raw material and ingredients specification — Annex 5 - Quality assessment heat sterilized soups — Annex 6 - Quality assessment heat sterilized soups-conventional sterilization — 4.2 Flavorings for UHT-treated and aseptically packed soups and sauces /A. van Eijk — 4.2.1 Flavor and flavorings — 4.2.2 Physico-chemical interactions — 4.2.3 Flavoring of UHT-treated soups and sauces — 4.2.4 Summary — Aseptic packaging — 5 Processes for packaging materials sterilization and system requirements /H. Reuter — 5.1 Introduction — 5.2 Sterilization of the packaging material — 5.2.1 Time-law — 5.2.2 Commercially applied sterilization processes — 5.2.3 Required germ reduction of sterilization process — 5.2.4 Non-sterility rate in packaging material sterilization — 5.3 Aseptic packaging machines — 5.3.1 Consideration of faults of pre-sterilized and aseptically packed products — 5.3.2 Acceptable rate of total error — 5.4 Commercially applied aseptic packaging systems — 5.5 Packaging materials — 5.6 Pros and cons of aseptic packaging — 5.7 Reference — 6 Aseptic filling and packaging — 6.1 Roll-fed carton packaging /E. Schoefert — 6.1.1 Introduction — 6.1.2 Why carton packages from the roll? — 6.1.3 Packaging material — 6.1.4 Aseptic filling process — 6.1.4.1 Sterilization of the filling machine — 6.1.4.2 Sterilization of the packaging material — 6.1.4.3 Forming, filling, sealing, and separating the packages — 6.1.4.4 Filling with head space — 6.1.4.5 Final folding of the separated packages — 6.1.5 The Tetra Brik Aseptic TBA /8 filling machine — 6.1.5.1 Filling machine functions — 6.1.5.2 Safety and hygiene — 6.1.5.3 Available package volumes and sizes — 6.1.6 Summary — 6.2 Carton packaging from sleeves /A. E. Ostermann — 6.2.1 Introduction — 6.2.2 Pre-made sleeve — 6.2.3 Combibloc aseptic FFS machine — 6.2.3.1 Container base forming — 6.2.3.2 Machine sterilization — 6.2.3.3 Container sterilization — 6.2.3.4 Filling system — 6.2.3.5 Container top closure — 6.2.4 Combibloc system flexibility — 6.2.5 Field of application — 6.2.6 Future options — 6.2.7 References — 6.3 Vertical form-fill-seal machines for bags /S. Linder — 6.3.1 Bag sizes and secondary packaging — 6.3.2 Machines and operating principle — 6.3.3 Product range and filling systems — 6.3.4 Packaging materials — 6.3.5 Summary — 6.4 Thermoform filling and sealing machines for plastic cups /S. Linder — 6.4.1 Introduction — 6.4.2 Package related machine design — 6.4.3 Operating principle — 6.4.4 Filling systems — 6.4.5 Packaging materials — 6.5 Thermoform filling and sealing machines for plastic cups with steam sterilization /K. Waiter — 6.5.1 Introduction — 6.5.2 Possible sterilization methods — 6.5.3 Selection of the method — 6.5.4 Description and operating sequence — 6.5.4.1 Base material degerming — 6.5.4.2 Lidding material degerming — 6.5.4.3 Economy — 6.5.5 Results — 6.5.6 Metering method — 6.5.7 Concluding remarks — 6.6 Aseptic handling of particulate products /J. Perigo — 6.6.1 Introduction — 6.6.2 Problems — 6.6.3 Solutions — 6.6.3.1 Process solids in viscous carrying medium — 6.6.3.2 Sterilize extra water separately and mix at filler — 6.6.3.3 Select a suitable feed pump for the solids fraction — 6.63.4 Select a backpressure system which handles particles without damage — 6.6.3.5 Select pipeline valves which handle particles without damage — 6.6.3.6 Design fillers to minimize particle damage — 66.3.7 Develop simplified interface between the UHT process and the aseptic packaging system — 6.6.3.8 Functions of a surge tank — 6.6.4 Conclusions — 6.7 Manufacturing, filling and sealing of plastic bottles in the blow mould /L Zimmermann — 6.7.1 General information — 6.7.2 Packagable fill products, volumes and capacities — 6.7.3 Suitable plastic materials — 6.7.4 Sterility of the plastic material — 6.7.5 Process engineering and measures to maintain sterility — 6.7.6 Forming of the containers in the blow mould — 6.7.7 Aseptic filling in the blow mould — 6.7.8 Sealing in the blow mould — 6.7.9 Machine systems — 6.8 Aseptic packaging in glass and plastic bottles /N. Buchner — 6.8.1 For which containers is aseptic filling of interest? — 6.8.2 Advantages of aseptic packaging in glass and plastic containers — 6.8.3 Aseptic plants — 6.8.4 Sterilization of containers — 6.8.5 Sterilization of closures — 6.8.6 Filling the containers — 6.8.7 Closing the containers — 6.8.8 Characteristics of the procedure and of the plant — 6.8.9 Plants in practice — 6.8.10 Pre-requisites for the containers — 6.9 Aseptic packaging line for aerosol cans /R. Nicolas — 6.9.1 Sterilization of cans — 6.9.2 Aseptic filling of cans — 6.9.3 Capping and gassing of cans — 6.9.4 Conclusion — 6.10 Bulk aseptic packaging, the bag-in-box system /E. Plett — 6.10.1 Summary — 6.10.2 Aseptic packaging — 6.10.3 The filler — 6.10.4 The bag — 6.10.5 Aseptic emptying — 6.10.6 Overall Safety — 6.11 Sterile room techniques in the food industry /H. Blumke — 6.11.1 Introduction — 6.11.2 Definition of sterile room technique — 6.11.3 Particles — 6.11.4 Sources of contamination — 6.11.5 Filter systems — 6.11.6 Air flow in sterile room technique — 6.11.7 Sterile room specifications — 6.11.8 Examples for application of sterile room technique — 6.11.9 Conclusion — 6.11.10 References — 7 Packaging materials for aseptic packaging — 7.1 Gamma sterilization of packaging /P.J.G. Neijssen — 7.1.1 Introduction — 7.1.2 Gamma radiation — 7.1.3 Gamma sterilization process — 7.1.4 Influence of gamma radiation on materials — 7.1.5 Gamma sterilization of packaging materials — 7.1.6 References — 7.2 Thermoformable barrier sheets for shelf stable container in dairy applications /B. de Groof — 7.2.1 Abstract — 7.2.2 Introduction — 7.2.3 Production of thermoformable barrier sheets and shelf stable packs — 7.2.3.1 Formable barrier sheet — 7.2.32 Production of shelf stable packs — 7.2.4 Barrier performance — 7.2.5 Applications of shelf stable packs — 7.2.5.1 Chilled chain — 7.2.5.2 Modified atmosphere packaging — 7.2.5.3 Hot fill packaging — 7.2.5.4 Aseptic packaging — 7.2.5.5 Retortable packaging — 7.2.6 Environment — 7.2.7 Conclusion — 7.3 Glass for aseptic packaging /B. Sachs — 7.3.1 Introduction — 7.3.2 Advantages of aseptic filling method — 7.3.3 Advantage of using glass for aseptic filling methods — 7.3.4 The aseptic market — 7.3.4.1 Europe — 7.3.4.2 Eastern countries — 7.3.5 Benefits for economy and environment — 7.3.6 Market share of returnable and disposable glass packaging for drinks — 7.3.7 Glaseptik - a basis for achieving market targets — 7.3.8 Responsibility in production of glass containers — 8 Quality protection — 8.1 Hazard analysis in aseptic good manufacturing practice /D. Rose — 8.1.1 Summary — 8.1.2 Introduction — 8.1.2.1 Good Manufacturing Practice (GMP) — 8.1.2.2 HACCP concept — 8.1.3 Components of HACCP analysis — 8.1.4 Analysis — 8.1.4.1 Flow diagram — 8.1.4.2 Essential product characteristics — 8.1.4.3 Process analysis — 8.1.4.4 Devising control options — 8.1.5 Stylized flow diagram — 8.1.6 Conclusion — 8.1.7 References — 8.2 Testing of aseptic machines for their efficiency of sterilization of packaging materials by means of hydrogen peroxide /G. Cerny — 8.2.1 Importance of packaging sterilization in aseptic packaging — 8.2.2 Origin of microbial problems in aseptic processing and packaging — 8.2.3 Methods for sterilization of packaging materials — 8.2.4 Reasons for establishing testing methods — 8.2.5 Test microorganism and its culture conditions — 8.2.6 Count reduction testing procedure — 8.2.7 Endpoint test procedure — 8.2.8 Concluding remarks.