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Adapting Novel Processing
Technologies to Meat Operations


       Tatiana Koutchma, PhD
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
Safety Risks of
                              Modern Food Production

Products                                                   New Risks

   Higher quality - Mild treatment    Incomplete microbial inactivation
   Extended product shelf-life        Possible non respect of adequate
   “Fresher” quality,                  storage conditions and expiration
   RTE pre-cooked                      dates
   Convenience                        Undercooking
   Low salt, sugar, fat               Overcooking
   Globalization of food supply       Generation of stress-resistant
                                        organisms
                                       Emerging pathogens
Food Technologies
Branch of food science and engineering which deals with the actual
production processes to make foods.

Traditional processing concepts

1. Application of thermal energy to      5. Novel or emerging
   elevate product temperatures to       technologies
   achieve long term or extended
   stability or preservation
2. Removal of thermal energy to
                                         Contemporary technical
   reduce product temperature and        innovations which represent
   extend shelf-life                     progressive developments within
3. Removal of water from products        a field for competitive advantage
   structure and thus achieving of
   extended shelf-life
4. Packaging or the step required to
   maintain product properties
   achieved during processing
Future Processing Trends

     Traditional
                              vs     Novel Technologies
    Technologies
Improvements in Designs and
     Control. Redesign                  Novel Processes



Improved Manufacturing                  Transformation &
     Performance                          Preservation



Improved Product Quality           Improved Quality and Safety

Traditional Foods                      Novel Foods
The Novel Foods

• Non-traditional foods with   • Definitions available
  no history of safe use and
  manufactured, prepared,
                               in 6 countries
  preserved or packaged by
  a process that has not
  been previously applied to
  that food
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
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!
High Pressure

  Hydrostatic      Pre-Packed Foods   2000
    (HHP)                             MPa

 Hydrodynamic         Raw Meats       100
    (HDP)                             MPa
  Hydrodynamic        Beverages       300
 Homogenization                       MPa
     (HDH)
Pressure and CO2        Juices        100
                                      MPa
Pressure Cycling       Extraction     300
     (HPC)                            MPa
   Hyperbaric        Fresh Produce     900
                                       kPa
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
UV Technology
Technology Assessment

          and




   Fundamental Physical Methods
   Technology Performance
   Technology Readiness
   Risk Assessment
   Regulatory Status
   Life Time Cycle
   Cost Efficacy
NASA Assessment

              9 - Ready for full-scale commercialization

              8 - Economic feasibility and regulatory issues
   Emerged    addressed




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

              6 – Systems available commercially

  Emerging    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
      Under   2 - Technology concept and/or application
              formulated
development   1 - Basic principles observed and reported
Thermal Processing Technologies




   Traditional             Emerging
                                                      Under
Retorting             Pressure + Heat (8)          Development
                      Microwave dielectric (8)
Aseptic               High frequency or RF (5-6)
Pasteurization        Infrared (6-7)                 Conductive
     Hot, Cold-Fill   Ohmic (6-7)                     Heating
Sous vide
Non-thermal
                      Processing Technologies




  Emerged                Emerging                      Under
  Irradiation (9)                                   Development
                    Pulsed Electric Fields (6-7)
High Hydrostatic                                    Cold Plasma (3-4)
 Pressure (8-9)            UV light (6)
                                                   Electrolyzed water (5)
  Filtration (9)      Pressure and CO2 (6)
                                                       Sonication (5)
  Ozone (8-9)                                      Low dose e-beams (5)
Technology Knowledge

          Traditional/Thermal                                        Novel
      Established organism of public       Target organisms of concerns and
                        health concern       surrogates has to be determined
            Understood destruction         Detailed knowledge of microbial
                 kinetics/mathematics        dose-response behavior
   Knowledge of products heating in        Complete representation of
            given processing systems         distribution of the lethal agent
         Relationships between the         Process uniformity
    organism of public health concern       Process monitoring &verification
                          and spoilage      Process Equivalency (FSO)
       Equivalent safety of different      Chemical safety
       processing systems express in
                     “Lethality” terms      Risk assessment
What Understanding is Needed when
          Establishing a Novel Process?


    A                                       B        B
                Process
Ingredients                              Product




                                            B
                z ard is                Regulatory
    Process   Ha alys                   Acceptance
    Design     An      V   alid
                                ation

A
Challenges of Novel Processing

                Safety Equivalence
                                                    O
                                                        O
                                               O
Traditional Foods Vs Novel Foods
                                                 OH
• Nutritional, Allergenicity, Toxicological, Chemical

                &             =
Traditional Process Vs Novel Process
• Performance Objective, Food Safety Objective
• Validation, Verification, Monitoring
Safety of Novel Processes
Technology         Microbial Risks   Chemical Risks        Other
HPP                Incomplete        Chemical reactions    Spore inactivation
                   microbial                               at elevated
                   inactivation,                           temperature
                   recovery
PEF                No spore          Electrochemical       Non homogeneity
                   inactivation      reactions             arcing
                                     Metal transfer from
                                     electrodes
UV light and pulsed Repair           Photo oxidation       Non-homogeneity
light                                reactions

Ohmic heating      Survivors         Metal transfer from   under/over heating
                                     electrodes
Microwaves         Survivors         Chemical reactions    Non-homogeneity
                                                           Possible reduction
                                                           of power
Risk Assessment of Novel Foods
• Details of novel process

• Dietary Exposure
                                          O

• History of organism                         O
                                 O

• Nutritional considerations
   – Dietary intakes                 OH


• Toxicology considerations

• Allergenicity considerations

• Chemical considerations
Microbiological Assessment

             Product                      Food Chain
• Raw ingredients                  • Production
   – Contamination                    – Local/Imported

• Semi-finished/
                                   • Food Processing
   – pH, Aw, composition, ToC


• Finished                         • Transportation
   – Packaging/Storage
                                   • Storage & Distribution
• Predictive modelling of             – Food Services/Retail
  growth/death/survival
                                         • RTE
   – Indigenous flora
   – Shelf-life
   – Safety in terms of target
                                   • Consumption
     pathogens of concern             – Preparation
Chemical Hazards
 Product                                 Process
• Natural - Endogenous                  • Formed during food
  toxicants                               processing
     •   Trypsin
     •   Mycotoxins                        Migration
                                           from packaging
• Synthetic                                      Biphenols
      Produced, through                       Acrylamide
      contamination of food                   Furans
      material or processing
      environment                             Lipid oxidation products
                                              Maillard reaction
     •   Pesticide residues in fruits
         and vegetables
     •   Heavy metals, nitrites
     •   Drug residues in foods of
         animal origin
     •   Allergens
Global Regulations
Novel Foods               No Definition

   European Union               USA
   United Kingdom               Japan
   New Zealand                  India
   Australia
   Canada
   China
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.
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
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 )
                                                        26
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
HIGH HYDROSTATIC PRESSURE

                    Preservation                 Transformation   Value Added

                                    Shelf-life       Meat
Sterilization   Pasteurization                                     Seafood
                                    extension        Protein


            PATS            RTE            RTE meats
             LAF            meals          Raw meats
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
Other parameters affecting HHP
Product                            Packaging
• pH, water activity               • Type of packaging: vacuum or
• Composition:                       MAP
   •   Fat                         • Packaging and material
   •   Salt content                  influence the log reduction data
                                   • Design and geometry




• Physiological state of
  bacterial cells
• From exponential or stationary
  growth phase
Raw Meat Processing
                 Ambient Temperature at Pressure < 350 MPa

    Harvest Processing                       Fresh Meats
   Hair/feather removal                        Shelf-life Extension
           Loosens hair/feather follicles         Stops post-mortem glycolysis
           Eliminates scald tank                  Improves meat quality




                                                     Stabilizes pH >6.0
                                                     Improves color
   Toenail removal                                  Increases water-holding capacity
         Loosens toenails from hoof                 Decreases shear force
   Reduces fecal contamination                      Increases tenderness
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
HPP Preservation of RTE meals
   Shelf Life Extension                  Sterilization
     Pasteurization
 Marinated Meats                 Pre-packed
 RTE meats and poultry (ESL)     Low Acid Foods (LAF) MREs
    Pre-treatment                Pressure Assisted Thermal
    Post-Lethality                Sterilization (PATS)




   Ambient & Mild Temperatures    Elevated Temperature (>100oC)
         400 – 600 MPa                       700 MPA
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         Hermetically sealed
                         flexible containers         flexible containers
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.
HHP for Low Sodium Products

Pre-treatment                    Post-lethality
• HHP may have beneficial        • HHP is effective intervention
  effects on meat product          methods against Listeria and
  quality                          other pathogenic bacteria
   – Improves water holding
      capacity and decreased
      water losses
                                 • Pressures: 500 up to 600 MPa
   – Induce changes in protein
                                 • Temperature: ambient
• Pressures: 50 up to 300 MPa
                                   Refrigerated or Ambient
• Temperature: Refrigerated or
                                 • Time: up to 3min
  Ambient
• Time: up to 5 min
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
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
Lab scale HP units
 • Avure




Laboratory Scale Pressure Test     The QFP-2L-700 high pressure unit
System Model PT-100
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
Vessel Technologies

 Wire winding                              Autofrettage




                                           Vessel is subjected to over-pressure
                                           which locks plastic strain in an
                                           internal core
                                                Autofrettage pressure is selected
http://www.avure.com/company/quintus.asp        according to plastic behaviour od
                                                steel used (15-15PH)

                                           http://www.freshertechusa.com/index.html
FresherTech
• Mono - Single Chamber
  Systems

• Duo - Dual Chamber
  Systems

• Quattro - Four Chamber
  Systems
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
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
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
Why UV?
 Effective against microbial and chemical hazards

 Physical non-thermal method

 Chemicals free

 Cost effective

 Energy efficient
                                                                     38        39

 Approved by Regulatory Agencies                               33        33

                                                                                    25
                                                           23
    EPA                                    16   17
                                       14
    US FDA (2001)                                    12

    Health Canada (2003)
                                      2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
Ultraviolet UV light




Energy per photon:


     UV-V                UV-C             UV-B             UV-A
 6.20 – 12.4 eV      4.43 – 12.4 eV   3.94 – 4.43 eV   3.10 – 3.94 eV
Effectiveness of UV light
                            Against Food microflora
- Eschierichia coli O157:H7
- Listeria monocytogenes                          - Hepatitis A virus
- Salmonella enteredius                           - Norovirus
- Staphylococcus
  aureus
                         Bacteria
                         Spores       Viruses



                         Spoilage     Parasites
                         microflora
- aerobic microflora                              - Cryptosporidium
- yeasts                                            parvum
- molds                                           - Giardia lamblia
- Lactic acid bacteria
Development and Applications of UV sources
                                        Food           Regulatory      Environment
 UV source        Applications        Industry          Approval         impact
                                                     Implementation
 Low Pressure        Air Water         Surfaces             YES          Mercury
Mercury (LPM)        Surfaces           Water          US FDA (2000)      Glass
Amalgam (LPA)                           Juices         Health Canada
                    Since 1930                             (2003)



Medium Pressure        Water            Water              NO            Mercury
 Mercury (MPM)                                                            Glass
    Eximer        Medical – Packed     Surfaces                           Glass
                   Blood Plasma          Cost              NO
                       Curing
  Pulsed (PL)          Curing           Produce                           Glass
                                       RTE Food            YES
                                     Surfaces, Dry
                                      ingredients
 Light Emitting      Lightings
 Diodes (LED)           Air              NO                NO              NO
Why LEDs will replace UV lamps?
 UV Lamps: Wavelength are not    UV Lamps: short life time,
  optimized for applications       mercury, glass




 • LEDs: Emit single peak         LEDs: Energy efficient, NO
   Tunable                         mercury, long time, COST




        LEDs are Building Blocks for Future UV systems
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
Air, water
                        Non-food contact         Pathogens
           Safety           surfaces
                                                inactivation
                          Food contact
                            surfaces


                                               Liquid foods and
                                                  beverages
                          Pasteurization
        Preservation
                        Shelf-life extension
 UV                                            Whole and fresh
LIGHT                                           cut produce

                                                  Vitamins

        Functionality                           Antioxidants
                          Enhancement
                                                  Microbial
                                                  resistance

                              Toxins
         Chemicals                                 Patulin
                             Allergens
        destruction                               Aflotoxins
                             Pesticides
UV on Food Plant

 Air and water treatments     OFFERS UV-PROTECTION
 Non-food contact surfaces
    Walls, ceilings, floors                    • Airborne
                                     – Molds Spores, human
 Food contact surfaces                            pathogens
    Conveyor belts                          • Waterborne
    Packaging materials              – Viruses and Bacteria
    Equipment surfaces                                spores
                                              • Foodborne
 Food surfaces                           – Bacteria, spores
    RTE meats                                  • Spoilage
    Fresh produce                 – Yeast, molds, lactobacilli
Microbial Resistance to UV

 Air          Water           Food
                              Fluids
Viruses    Cryptosporidium     Parasites

Bacteria      Bacteria         Bacteria
               Yeasts           Yeasts
Spores         Spores           Spores
               Viruses          Viruses
            (Adenovirus)
                             Molds spores
RH, T,oC      Turbidity         pH, Aw
                              composition
Commercial UV unit
   to Treat Odors
UV resistance of Listeria on Surfaces
• Agar:                        • Products
   – D10= 0.5 mJ/cm2              – Frankfurters
                                    D10 = 300 mJ/cm2
• Surfaces of packaging
  materials, conveyor belts       – Cut Pear
   – D10 = 2.55 – 3.2 mJ/cm2
                                   D10~ 2000 mJ/cm2
UV for Poultry, Fish and
                                RTE products

Raw                                  RTE
                                     Continuous UV
• Poultry reduction of
  Salmonella without affecting       • Effective against Listeria on the
  color or increasing rancidity of     surface of frankfurters
  the meat                           • Up to 2-log reduction at 4 J/cm2
• Chicken Breast Fillet - L.         • No changes in colour
  monocytogenes without
  negatively affecting meat color    Pulsed UV
• Raw Salmon Fillets - PL            • Effective against Listeria on the
  caused visual color and quality       surfaces of steel coupons
  changes due to T increase
                                     • Up to 4 log reduction at 6 J/cm2
Challenges of UV surface
             inactivation
       Surface characteristics

       Quality parameters

       Duration of the treatment

       Continuous UV vs
        Pulsed Light
Decontamination of Surfaces
UVC Tumbling Machines by Reyco Systems

                                         •   Frozen
                                         •   Fresh
                                         •   RTES
                                         •   Products prior to bulk
                                             storage: onions, potatoes,
                                             fruits, grain




                                             Heraeus, Blue Light Module
Claranor: Packaging,
Caps, Cups
Novel UV Processes
                                                UV pasteurization /
Transformation / Added value
                                                Shelf-life Extension
                                            Fresh Juices
 Milk - Vitamin D synthesis
                                             – Apple, apple cider, carrot,
 Mushrooms - Vitamin D2 synthesis             orange
 Peanut butter, soy - reduce               Liquid sweeteners
  allergenicity                              – Sucrose, fructose, glucose
 Fruits – increased nutrients content      Ice teas, soft drinks
 Carrots - increased AO capacity           Liquid egg products
 Fresh Cut Fruits/ Juices -                Milk, cheese milk and calf milk
   enzyme Inactivation                      Whey protein concentrates
                                            Brewery & winery
                                            Emulsions, brines, marinades
Challenge


      High UV
                                         ~ 2 log reduction    UV overdosing
   absorbance        Low microbial
                                         at UV fluence of       can lead to
of liquid foods at     reduction
                                            190 mJ/cm2       sensory changes
     253.7 nm




                                      Solutions
                                      Improve designs of UV systems

                                     Efficient mixing: Turbulent flow
                                     Dean, Taylor-Coutte Flows

                                      Match UV source for the
                                      application

                                      Optimized UV dose
Commercial Applications
Processing                         Finished product
    CIP water                        Bottled water
    Packaging and product rinse      Fruit juice and fruit
     water                             concentrates
                                      Isotonic and fortified drinks
Raw material application              Iced tea
                                      Wine
      Dilution water                 Tetra-hopped beer
      Sugar syrup                    Dairy
      Brines
      Liquid egg
UV units for Low UVT Liquids
   Annular reactor “UltraDynamics”     Thin film reactor “CiderSure”




                          L-NN                                           L-N


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


                                                          UV lamp

                               NL-                       Teflon tube
                                                                         NL-
                               NN                        wound in
                                                         helix pattern   NN
                                                           Inlet
UV units: Turbulent flow




SurePure turbulator   Salcor 3G UV   CiderSure
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
UV treatment of Liquid Eggs
                                and Brines




Brine Water: 235 J/L
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
UV for Meat Applications
• Control of Listeria
                                • To reduce aging of beef
  monocytogenes in recycled
                                  carcases
  chill brines

                                • Extension of retail
• Decontamination of poultry,
                                  display of fresh beef
  associated packaging and
                                  packages in modified
  contact surfaces
                                  atmosphere

• Decontamination of poultry
  carcasses
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
Energy use
                 in processing of apple juice
                                  E. coli    Capacity   Specific Energy
       Processing conditions
                                  strain       (L/s)        (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     ATCC        0.670          137.2
                μs*               11775
UV     1.56 kW x 25 °C x 89 s      K-12        1.1            5.2
UF      0.02 μm, 1.474 kPa, 5    Pseudomo      1.0           0.028
               L/m2.s               nas
                                  diminuta
Energy for Processing
Fluid product by Novel Technologies

                UF


               UV
  Technology




               PEF


           HTST


               HPP


                     0   100     200     300     400      500
                               Energy consumption (J/g)
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
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
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
Thank You !
Dr. Tatiana Koutchma
Contact info:
tnk08@live.com
AAFC
Guelph Food Research Center
93 Stone Road West
Guelph, ON, Canada

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Adapting Novel Processing Technologies to Meat Operations

  • 1. Adapting Novel Processing Technologies to Meat Operations Tatiana Koutchma, PhD
  • 2. 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
  • 3. Safety Risks of Modern Food Production Products New Risks  Higher quality - Mild treatment  Incomplete microbial inactivation  Extended product shelf-life  Possible non respect of adequate  “Fresher” quality, storage conditions and expiration  RTE pre-cooked dates  Convenience  Undercooking  Low salt, sugar, fat  Overcooking  Globalization of food supply  Generation of stress-resistant organisms  Emerging pathogens
  • 4. Food Technologies Branch of food science and engineering which deals with the actual production processes to make foods. Traditional processing concepts 1. Application of thermal energy to 5. Novel or emerging elevate product temperatures to technologies achieve long term or extended stability or preservation 2. Removal of thermal energy to Contemporary technical reduce product temperature and innovations which represent extend shelf-life progressive developments within 3. Removal of water from products a field for competitive advantage structure and thus achieving of extended shelf-life 4. Packaging or the step required to maintain product properties achieved during processing
  • 5. Future Processing Trends Traditional vs Novel Technologies Technologies Improvements in Designs and Control. Redesign Novel Processes Improved Manufacturing Transformation & Performance Preservation Improved Product Quality Improved Quality and Safety Traditional Foods Novel Foods
  • 6. The Novel Foods • Non-traditional foods with • Definitions available no history of safe use and manufactured, prepared, in 6 countries preserved or packaged by a process that has not been previously applied to that food
  • 7. 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
  • 8. 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!
  • 9. High Pressure Hydrostatic Pre-Packed Foods 2000 (HHP) MPa Hydrodynamic Raw Meats 100 (HDP) MPa Hydrodynamic Beverages 300 Homogenization MPa (HDH) Pressure and CO2 Juices 100 MPa Pressure Cycling Extraction 300 (HPC) MPa Hyperbaric Fresh Produce 900 kPa
  • 10. 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
  • 12. Technology Assessment and  Fundamental Physical Methods  Technology Performance  Technology Readiness  Risk Assessment  Regulatory Status  Life Time Cycle  Cost Efficacy
  • 13. NASA Assessment 9 - Ready for full-scale commercialization 8 - Economic feasibility and regulatory issues Emerged addressed Technology Development 7 - Economic feasibility demonstrated or regulatory issues addressed (but not both) 6 – Systems available commercially Emerging 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 Under 2 - Technology concept and/or application formulated development 1 - Basic principles observed and reported
  • 14. Thermal Processing Technologies Traditional Emerging Under Retorting Pressure + Heat (8) Development Microwave dielectric (8) Aseptic High frequency or RF (5-6) Pasteurization Infrared (6-7) Conductive Hot, Cold-Fill Ohmic (6-7) Heating Sous vide
  • 15. Non-thermal Processing Technologies Emerged Emerging Under Irradiation (9) Development Pulsed Electric Fields (6-7) High Hydrostatic Cold Plasma (3-4) Pressure (8-9) UV light (6) Electrolyzed water (5) Filtration (9) Pressure and CO2 (6) Sonication (5) Ozone (8-9) Low dose e-beams (5)
  • 16. Technology Knowledge Traditional/Thermal Novel  Established organism of public  Target organisms of concerns and health concern surrogates has to be determined  Understood destruction  Detailed knowledge of microbial kinetics/mathematics dose-response behavior  Knowledge of products heating in  Complete representation of given processing systems distribution of the lethal agent  Relationships between the  Process uniformity organism of public health concern  Process monitoring &verification and spoilage  Process Equivalency (FSO)  Equivalent safety of different  Chemical safety processing systems express in “Lethality” terms  Risk assessment
  • 17. What Understanding is Needed when Establishing a Novel Process? A B B Process Ingredients Product B z ard is Regulatory Process Ha alys Acceptance Design An V alid ation A
  • 18. Challenges of Novel Processing Safety Equivalence O O O Traditional Foods Vs Novel Foods OH • Nutritional, Allergenicity, Toxicological, Chemical & = Traditional Process Vs Novel Process • Performance Objective, Food Safety Objective • Validation, Verification, Monitoring
  • 19. Safety of Novel Processes Technology Microbial Risks Chemical Risks Other HPP Incomplete Chemical reactions Spore inactivation microbial at elevated inactivation, temperature recovery PEF No spore Electrochemical Non homogeneity inactivation reactions arcing Metal transfer from electrodes UV light and pulsed Repair Photo oxidation Non-homogeneity light reactions Ohmic heating Survivors Metal transfer from under/over heating electrodes Microwaves Survivors Chemical reactions Non-homogeneity Possible reduction of power
  • 20. Risk Assessment of Novel Foods • Details of novel process • Dietary Exposure O • History of organism O O • Nutritional considerations – Dietary intakes OH • Toxicology considerations • Allergenicity considerations • Chemical considerations
  • 21. Microbiological Assessment Product Food Chain • Raw ingredients • Production – Contamination – Local/Imported • Semi-finished/ • Food Processing – pH, Aw, composition, ToC • Finished • Transportation – Packaging/Storage • Storage & Distribution • Predictive modelling of – Food Services/Retail growth/death/survival • RTE – Indigenous flora – Shelf-life – Safety in terms of target • Consumption pathogens of concern – Preparation
  • 22. Chemical Hazards Product Process • Natural - Endogenous • Formed during food toxicants processing • Trypsin • Mycotoxins  Migration  from packaging • Synthetic  Biphenols Produced, through  Acrylamide contamination of food  Furans material or processing environment  Lipid oxidation products  Maillard reaction • Pesticide residues in fruits and vegetables • Heavy metals, nitrites • Drug residues in foods of animal origin • Allergens
  • 23. Global Regulations Novel Foods No Definition  European Union  USA  United Kingdom  Japan  New Zealand  India  Australia  Canada  China
  • 24. 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.
  • 25. 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
  • 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 ) 26
  • 27. 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
  • 28. HIGH HYDROSTATIC PRESSURE Preservation Transformation Value Added Shelf-life Meat Sterilization Pasteurization Seafood extension Protein PATS RTE RTE meats LAF meals Raw meats
  • 29. 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
  • 30. Other parameters affecting HHP Product Packaging • pH, water activity • Type of packaging: vacuum or • Composition: MAP • Fat • Packaging and material • Salt content influence the log reduction data • Design and geometry • Physiological state of bacterial cells • From exponential or stationary growth phase
  • 31. Raw Meat Processing Ambient Temperature at Pressure < 350 MPa Harvest Processing Fresh Meats  Hair/feather removal  Shelf-life Extension  Loosens hair/feather follicles  Stops post-mortem glycolysis  Eliminates scald tank  Improves meat quality  Stabilizes pH >6.0  Improves color  Toenail removal  Increases water-holding capacity  Loosens toenails from hoof  Decreases shear force  Reduces fecal contamination  Increases tenderness
  • 32. 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
  • 33. HPP Preservation of RTE meals Shelf Life Extension Sterilization Pasteurization  Marinated Meats  Pre-packed  RTE meats and poultry (ESL)  Low Acid Foods (LAF) MREs  Pre-treatment  Pressure Assisted Thermal  Post-Lethality Sterilization (PATS) Ambient & Mild Temperatures Elevated Temperature (>100oC) 400 – 600 MPa 700 MPA
  • 34. 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 Hermetically sealed flexible containers flexible containers
  • 35. 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.
  • 36. HHP for Low Sodium Products Pre-treatment Post-lethality • HHP may have beneficial • HHP is effective intervention effects on meat product methods against Listeria and quality other pathogenic bacteria – Improves water holding capacity and decreased water losses • Pressures: 500 up to 600 MPa – Induce changes in protein • Temperature: ambient • Pressures: 50 up to 300 MPa Refrigerated or Ambient • Temperature: Refrigerated or • Time: up to 3min Ambient • Time: up to 5 min
  • 37. 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
  • 38. 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
  • 39. Lab scale HP units • Avure Laboratory Scale Pressure Test The QFP-2L-700 high pressure unit System Model PT-100
  • 40. 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
  • 41. Vessel Technologies Wire winding Autofrettage Vessel is subjected to over-pressure which locks plastic strain in an internal core Autofrettage pressure is selected http://www.avure.com/company/quintus.asp according to plastic behaviour od steel used (15-15PH) http://www.freshertechusa.com/index.html
  • 42. FresherTech • Mono - Single Chamber Systems • Duo - Dual Chamber Systems • Quattro - Four Chamber Systems
  • 43. 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
  • 44. 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
  • 45. 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
  • 46. Why UV?  Effective against microbial and chemical hazards  Physical non-thermal method  Chemicals free  Cost effective  Energy efficient 38 39  Approved by Regulatory Agencies 33 33 25 23  EPA 16 17 14  US FDA (2001) 12  Health Canada (2003) 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
  • 47. Ultraviolet UV light Energy per photon: UV-V UV-C UV-B UV-A 6.20 – 12.4 eV 4.43 – 12.4 eV 3.94 – 4.43 eV 3.10 – 3.94 eV
  • 48. Effectiveness of UV light Against Food microflora - Eschierichia coli O157:H7 - Listeria monocytogenes - Hepatitis A virus - Salmonella enteredius - Norovirus - Staphylococcus aureus Bacteria Spores Viruses Spoilage Parasites microflora - aerobic microflora - Cryptosporidium - yeasts parvum - molds - Giardia lamblia - Lactic acid bacteria
  • 49. Development and Applications of UV sources Food Regulatory Environment UV source Applications Industry Approval impact Implementation Low Pressure Air Water Surfaces YES Mercury Mercury (LPM) Surfaces Water US FDA (2000) Glass Amalgam (LPA) Juices Health Canada Since 1930 (2003) Medium Pressure Water Water NO Mercury Mercury (MPM) Glass Eximer Medical – Packed Surfaces Glass Blood Plasma Cost NO Curing Pulsed (PL) Curing Produce Glass RTE Food YES Surfaces, Dry ingredients Light Emitting Lightings Diodes (LED) Air NO NO NO
  • 50. Why LEDs will replace UV lamps?  UV Lamps: Wavelength are not  UV Lamps: short life time, optimized for applications mercury, glass • LEDs: Emit single peak  LEDs: Energy efficient, NO Tunable mercury, long time, COST LEDs are Building Blocks for Future UV systems
  • 51. 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
  • 52. Air, water Non-food contact Pathogens Safety surfaces inactivation Food contact surfaces Liquid foods and beverages Pasteurization Preservation Shelf-life extension UV Whole and fresh LIGHT cut produce Vitamins Functionality Antioxidants Enhancement Microbial resistance Toxins Chemicals Patulin Allergens destruction Aflotoxins Pesticides
  • 53. UV on Food Plant  Air and water treatments OFFERS UV-PROTECTION  Non-food contact surfaces  Walls, ceilings, floors • Airborne – Molds Spores, human  Food contact surfaces pathogens  Conveyor belts • Waterborne  Packaging materials – Viruses and Bacteria  Equipment surfaces spores • Foodborne  Food surfaces – Bacteria, spores  RTE meats • Spoilage  Fresh produce – Yeast, molds, lactobacilli
  • 54. Microbial Resistance to UV Air Water Food Fluids Viruses Cryptosporidium Parasites Bacteria Bacteria Bacteria Yeasts Yeasts Spores Spores Spores Viruses Viruses (Adenovirus) Molds spores RH, T,oC Turbidity pH, Aw composition
  • 55. Commercial UV unit to Treat Odors
  • 56. UV resistance of Listeria on Surfaces • Agar: • Products – D10= 0.5 mJ/cm2 – Frankfurters D10 = 300 mJ/cm2 • Surfaces of packaging materials, conveyor belts – Cut Pear – D10 = 2.55 – 3.2 mJ/cm2 D10~ 2000 mJ/cm2
  • 57. UV for Poultry, Fish and RTE products Raw RTE Continuous UV • Poultry reduction of Salmonella without affecting • Effective against Listeria on the color or increasing rancidity of surface of frankfurters the meat • Up to 2-log reduction at 4 J/cm2 • Chicken Breast Fillet - L. • No changes in colour monocytogenes without negatively affecting meat color Pulsed UV • Raw Salmon Fillets - PL • Effective against Listeria on the caused visual color and quality surfaces of steel coupons changes due to T increase • Up to 4 log reduction at 6 J/cm2
  • 58. Challenges of UV surface inactivation  Surface characteristics  Quality parameters  Duration of the treatment  Continuous UV vs Pulsed Light
  • 59. Decontamination of Surfaces UVC Tumbling Machines by Reyco Systems • Frozen • Fresh • RTES • Products prior to bulk storage: onions, potatoes, fruits, grain Heraeus, Blue Light Module Claranor: Packaging, Caps, Cups
  • 60. Novel UV Processes UV pasteurization / Transformation / Added value Shelf-life Extension  Fresh Juices  Milk - Vitamin D synthesis – Apple, apple cider, carrot,  Mushrooms - Vitamin D2 synthesis orange  Peanut butter, soy - reduce  Liquid sweeteners allergenicity – Sucrose, fructose, glucose  Fruits – increased nutrients content  Ice teas, soft drinks  Carrots - increased AO capacity  Liquid egg products  Fresh Cut Fruits/ Juices -  Milk, cheese milk and calf milk enzyme Inactivation  Whey protein concentrates  Brewery & winery  Emulsions, brines, marinades
  • 61. Challenge High UV ~ 2 log reduction UV overdosing absorbance Low microbial at UV fluence of can lead to of liquid foods at reduction 190 mJ/cm2 sensory changes 253.7 nm Solutions Improve designs of UV systems Efficient mixing: Turbulent flow Dean, Taylor-Coutte Flows Match UV source for the application Optimized UV dose
  • 62. Commercial Applications Processing Finished product  CIP water  Bottled water  Packaging and product rinse  Fruit juice and fruit water concentrates  Isotonic and fortified drinks Raw material application  Iced tea  Wine  Dilution water  Tetra-hopped beer  Sugar syrup  Dairy  Brines  Liquid egg
  • 63. UV units for Low UVT Liquids Annular reactor “UltraDynamics” Thin film reactor “CiderSure” L-NN L-N Thin film mixers “Pure UV”/ “Iatros” Static Mixers – Dean Flow “Salcor” Outlet UV lamp NL- Teflon tube NL- NN wound in helix pattern NN Inlet
  • 64. UV units: Turbulent flow SurePure turbulator Salcor 3G UV CiderSure
  • 65. 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
  • 66. UV treatment of Liquid Eggs and Brines Brine Water: 235 J/L
  • 67. 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
  • 68. UV for Meat Applications • Control of Listeria • To reduce aging of beef monocytogenes in recycled carcases chill brines • Extension of retail • Decontamination of poultry, display of fresh beef associated packaging and packages in modified contact surfaces atmosphere • Decontamination of poultry carcasses
  • 69. 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
  • 70. Energy use in processing of apple juice E. coli Capacity Specific Energy Processing conditions strain (L/s) (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 ATCC 0.670 137.2 μs* 11775 UV 1.56 kW x 25 °C x 89 s K-12 1.1 5.2 UF 0.02 μm, 1.474 kPa, 5 Pseudomo 1.0 0.028 L/m2.s nas diminuta
  • 71. Energy for Processing Fluid product by Novel Technologies UF UV Technology PEF HTST HPP 0 100 200 300 400 500 Energy consumption (J/g)
  • 72. 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
  • 73. 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
  • 74. 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
  • 75. Thank You ! Dr. Tatiana Koutchma Contact info: tnk08@live.com AAFC Guelph Food Research Center 93 Stone Road West Guelph, ON, Canada