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WHY PROCESS FOODS?

PENGOLAHAN PANGAN
DENGAN APLIKASI THERMAL 1. EXTEND SHELF LIFE
2. MAINTAIN SENSORY PROPERTIES
3. MAINTAIN OR IMPROVE NUTRITIVE PROPERTIES
4. ENSURE SAFETY
5. MAKE MORE CONVENIENT
6. BOTTOM LINE: IDR (ECONOMIC VALUE)

RYN

HEAT PROCESSING: Use of high temperatures to destroy

enzymes and microorganisms that could reduce quality and/or
safety of food 2. PASTEURIZATION - A mild heat treatment used primarily to
destroy pathogenic organisms but it also destroys enzymes
and reduces microbial load. Requires an addition preservation
1. BLANCHING - A mild heat treatment that primarily destroys method to extend shelf life (example: refrigeration, drying).
enzymes and reduces microbial load (does not necessarily kill
pathogens), further preservation methods needed to extend
shelf life.
Example: Vegetables, frozen, canned

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METHODS OF HEAT TRANSFER

3. COMMERCIAL STERILIZATION –
A severe heat treatment that destroys pathogenic and many
microorganisms that could spoil food. Extends shelf life, room
temperature stable. (canned foods) 1. CONDUCTION: Heating of solids; Slow heating; Heating of
fixed molecules in a row.
4. STERILIZATION - A very severe heat treatment that destroys • Examples: spoon in sauce pan; Solid pack pumpkin in a
all microorganisms. can.

METHODS OF HEAT TRANSFER METHODS OF HEAT TRANSFER

2. CONVECTION: Faster heating of liquids and gas; Hot liquids
and gasses raise, cooler portions sink, creating a flow or current.
3. RADIATION: Electromagnetic waves. Two general
• Examples: forced air heating in houses; Canned juices. Air vs. types:
liquid heating - liquid faster.
a. Heat radiation from a heat source.
• Flames: campfire and marshmallows,
hot dogs, hamburgers, BBQ. Infrared.
b. No heat radiation that causes the food to heat up
• Microwaves
• Irradiation that does not transfer heat: Gamma
rays, x-rays, electrons (E-beam), Ultraviolet).

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FACTORS INFLUENCING CHOICE OF HEAT TREATMENTS TYPE OF FOOD (cont.)

º This is insured by:

i. Margin of safety process

1. Type of food
• microbial population reduced significantly
º a. pH
• Low acid: 5.0 - 6.8. Meat, dairy, vegetables ii. Use of more heat resistant organism to base study
• Medium acid: 4.6 - 5.0. Soups, vegetables
• Acid: 3.7 - 4.5. Fruits iii. Process is regulated by government.
• High acid: 2.3 - 3.6.Citrus fruits, berries • Aw (more information in dried food section)
º In medium & low acid (>4.5 pH) Foods, the canning process is • Composition
designed to kill C. Botulinum.

FACTORS INFLUENCING CHOICE OF HEAT TREATMENTS

(cont.) BLANCHING OF FRUITS AND VEGETABLES

2. Level of contamination OBJECTIVES:

3. Presence of oxygen 1. Inactivate enzymes**
4. Heat resistance of organisms or enzymes A. Metabolic
5. Heat penetration
B. Maintain color
º characteristics of the food
C. Texture
6. Packaging material
7. Size of container D. Flavor
8. Sensory qualities desired E. Nutritive value

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Blanching
• Blanching is a mild heat treatment, but is not a method of
preservation
• It is a pretreatment usually performed between preparation and
subsequent processing.
• Blanching consists of heating the food rapidly to a predetermined
temperature, holding for a specified time, then either cooling
rapidly or passing immediately to the next processing stage
• The major purpose of blanching is frequently to inactivate
enzymes, which would otherwise lead to quality reduction in the
processed product
• Blanching causes the removal of gases from plant tissues,
especially intercellular gas.
• Shrinking and softening of the tissue is a further consequence of
blanching
• A further benefit is that blanching acts as a final cleaning and
decontamination process.
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Mechanisms and Purposes of Blanching
• Blanching causes cell death and physical and metabolic chaos within
the cells.
• The heating effect leads to enzyme destruction as well as damage to
the cytoplasmic and other membranes, which become permeable to
water and solutes.
• An immediate effect is the loss of turgor pressure.
• Water and solutes may pass into and out of the cells, a major
consequence being nutrient loss from the tissue.
• Also cell constituents, which had previously been compartmentalised in
subcellular organelles, become free to move and interact within the
cell.
BLANCHING OF FRUITS AND VEGETABLES
OBJECTIVES (cont.):
2. Lower microbial load (combination of rinsing action and heat)
3. Aids in packaging – wilts vegetables and removes respiratory
gases
4. Removes dirt, leaves, etc.
5. Aids in peeling
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WATER: Typically 190-210° F
• 1.5 (peas) to 12 minutes (corn on the cob); Some exceptions:
green beans.
STEAM: 212 ° F ATM Pressure
CHEMICAL: Ascorbic acid (color only), Bisulfite salts (color,
preservative
Water Blanching
• Water blanching is performed in hot water at temperatures
ranging typically from 70 to 100 oC.
• However, low temperature long-time (LTLT) blanching and
combinations of LTLT with high-temperature short-time (HTST)
blanching have also been studied
• Water blanching usually results in a more uniform treatment,
allowing processing at lower temperatures.
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Processing Conditions
It is essential to control the processing conditions accurately to avoid loss
of texture, weight, colour and nutrients.
• fruit or vegetable properties, especially thermal conductivity, which will
be determined by type, cultivar, degree of maturity etc.;
• overall blanching effect required for the processed product, which could
be expressed in many ways including: achieving a specified central
temperature, achieving a specified level of peroxidase inactivation,
retaining a specified proportion of vitamin C;
• size and shape of food pieces;
• method of heating and temperature of blanching medium.
• Use a blancher which has a blanching basket and cover, or fit a wire
basket into a large pot with a lid.
• Use one gallon water per pound of prepared vegetables.
• Put the vegetable in a blanching basket and lower into vigorously
boiling water.
• Place a lid on the blancher. The water should return to boiling within 1
minute, or you are using too much vegetable for the amount of boiling
water.
• Start counting blanching time as soon as the water returns to a boil.
• Keep heat high for the time given in the directions for the vegetable.
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Steam Blanching
• Heating in steam is recommended for a few vegetables. For
broccoli, pumpkin, sweet potatoes and winter squash, both
steaming and boiling are satisfactory methods. Steam blanching
takes about 1 1/2 times longer than water blanching.
• To steam, use a pot with a tight lid and a basket that holds the
food at least three inches above the bottom of the pot. Put an inch
or two of water in the pot and bring the water to a boil.
• Put the vegetables in the basket in a single layer so that steam
reaches all parts quickly. Cover the pot and keep heat high. Start
counting steaming time as soon as the lid is on.

GREEN BEANS: Become mushy upon high heat treatment.
Therefore, one way to keep them firmer is to activate Pectin
Methyl Esterase (PME). The resulting negative charge on the
pectin attracts divalent cations (calcium) allowing cross-linking of
the pectin molecules, which makes them more resistant to heat
induced softening. Can you have too much of a good thing??
Turn to your neighbor and discuss.
DRY BEANS: Must be partly rehydrated before blanching can
take place. Multiple blanchers or long water blanchers are used.
Where does the rest of the water come from to finish the
thermal process (example: canned chili). How long do you cook
the canned dried beans?

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ADEQUACY OF BLANCHING: PASTEURIZATION

Enzyme tests: • Pasteurization is a thermal process used to eliminate specific
pathogenic microorganisms from food.
• Peroxidase
• Is a process of heating a food, usually liquid, to a specific
• Catalase temperature (below boiling point) for a definite length of time, and
then cooling it immediately. This process slows microbial growth
• Lipoxygenase in food
• Unlike sterilization, pasteurization is not intended to kill all micro-
Physical: organisms in the food. Instead pasteurization aims to reduce the
• Wilting number of viable pathogens so they are unlikely to cause disease
(assuming the pasteurized product is stored as indicated and
• Color consumed before its expiration date).

PASTEURIZATION
• Used for milk, liquid eggs, fruit juices and beer. MILK PASTEURIZATION: Based upon T.B. Microorganism; Test for
adequacy using phosphatase (blue color test).
• Destroy pathogens
• Vat: 145° F (62.8° C) for 30 minutes
• Reduce microbial load (numbers)
• HTSH: 161° F (71.7° C) for 15 seconds
• Inactivate enzymes
191° F (88.3° C) for 1 second
• Extend shelf life
194° F (90° C) for 0.5 second
• UHT: 275-284° F (135 to 140° C) for a few seconds

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The continuous high temperature- short-time (HTST) pasteurization system has

Example of Pasteurization system several basic components, including the following:

• Heat exchangers for product heating/cooling. Most often: plate heat

exchangers. The heating medium: hot water or steam, Cold water is the
cooling medium in a separate section of the heat exchanger.
• Holding tube. The holding tube is an important component of the
pasteurization system. Although lethality accumulates in the heating, holding,
and cooling sections, the Food and Drug Administration (FDA) will consider
only the lethality accumulating in the holding section ( Dignan et al., 1989 ). It
follows that the design of the holding tube is crucial to achieve a uniform and
sufficient thermal process.

• Pumps and flow control. A metering pump, located upstream from CREAM: 150-155° F (65.6-68.3° C) For 30 minutes
the holding tube, is used to maintain the required product flow
rate. Usually a positive displacement pump is used for this • 166-175° F(74.4-79.4° C) For 15 seconds
application. Centrifugal pumps are more sensitive to pressure
drop and should be used only for clean-in-place (CIP)
EGG PASTEURIZATION: Based upon killing and preventing
applications.
growth of salmonella (food-borne illness microorganism).
• Flow diversion valve. An important control point in any
• Liquid eggs heated to 140-144° F
pasteurization system is the flow diversion valve (FDV). This
(60-62° C) and held for 3.5-4.0 minutes. Often sugar or salts
remotely activated valve is located downstream from the holding
are added. Why?
tube. A temperature sensor located at the exit to the holding tube

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FRUIT JUICE PASTEURIZATION: New to kill E. Coli

0157:H7 And/or other food-borne illness microorganisms. It also
reduces microbial load, inactivates enzymes, and extends shelf
life.

BEER PASTEURIZATION:
1. Use of heat before or after bottling
2. Cold pasteurization - sterile filtering: better flavor than heat
pasteurization not to be confused with irradiation.

Heat Sterilization
• Sterilization is a term referring to any process that eliminates
(removes) or kills all forms of microbial life, including transmissible
agents (such as fungi, bacteria, viruses, spore forms, etc.) present
on a surface, contained in a fluid, in medication, or in a compound
such as biological culture media.
• It aims to destroy or partially/totally inhibit enzymes and
microorganisms, whose presence or proliferation could alter the
food or make it unfit for human consumption.
• The heat sterilization involves exposing food to a temperature
generally exceeding 100◦C for a period sufficient to inhibit
enzymes and all forms of microorganisms including bacteria
spore.
• Complete destruction of microorganisms
• 121ºC for 15 minutes or more
• Can be considered to be a very harsh treatment
• Used to sterilize foods in cans or containers

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Commercial sterilization
• Destroys both vegetative and spores of pathogenic organisms.
• Reduces nutritional value.
• Causes loss of organoleptic properties (taste, colour, odour and
feel).
• Pouch Processing System
• Designed food product placed in metal can
• Alternative system for product placed in a flexible pouch
requires an approach to suspend the pouch in steam
environment within retort vessel
• Aseptic Processing System
• Another approach of continuous sterilization where the product
is thermally processed prior to being placed in container
• Require independent sterilization of container, while in aseptic
environment and placement of the product into the container
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Commercial Sterilization System
• Batch system
• Also known as still retort
• Designed to expose product to temperature >100°C
• Vessel must maintain pressure up to 475 kPa or pressure need to
maintain steam temperature of 135-150°C
• Continuous Retort System (Also known as crateless retort)
• Designed to allow for automated filing and discharge of product
container
• Run in semicontinuous where vessel is 1st filled with product
container, followed by sealing of the vessel
Commercially “Sterile” food
• All pathogens and toxin-forming organisms are destroyed as well
as other organisms that could cause spoilage under normal
conditions.
• May contain a small number of heat-resistant bacterial spores, but
these will normally not multiply in the food.
• Shelf life of two years or more.
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CANNING METHODS
CANNING - COMMERCIALLY STERILE
PRODUCT A. STILL RETORTS E. PRESSURE
B. AGITATION F. SOUS-VIDE (UNDER
THEORY - USE OF HEAT AND ABSENCE OF
OXYGEN TO PREVENT THE SPOILAGE FOODS. C. ASEPTIC VACUUM)
D. OHMIC G. MICROWAVE

PACKAGING USE OF RETORT (PRESSURE COOKER)

A. Metal
º Tin/iron/tin cans • Allowed processing at higher temperature. So process time can
º Aluminum be reduced.

B. Glass NEW METHODS:

C. Plastic/metal/fiber flexible pouches • OHMIC Heating (heat generated)

• Pulsed Electrical Fields (PEF) And Oscillating Magnetic Fields
(OMF)
Minimize heating.

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NUTRITIVE AND OVERALL QUALITY OF CANNED FOOD NUTRITIVE AND OVERALL QUALITY OF CANNED FOOD

3. CARBOHYDRATES - Nonenzymatic browning increases.

1. PROTEIN - Quality of the protein can be improved or impaired.
4. VITAMINS - Some water soluble vitamins lost: Thiamin, vitamin C.
High temperature short time best.
2. FATS - Oxidative rancidity can be increased if oxygen not
properly removed from cans. º Fat soluble vitamin A and D lost at high
temperatures in presence of oxygen.

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