HPP: HIGH-PRESSURE PROCESSING

HOST Bill Kinross Publisher, Meatingplace MODERATOR Mike Fielding Managing Editor of Technical Content, Meatingplace

FUNDAMENTALS AND PACKAGING ASPECTS

Tatiana Koutchma, PhD. Research Scientist Agriculture and Agri-Food Canada

Poll Question

What research topics should federal government scientists focus on to assist faster implementation of HPP technology in the meat industry?

1. Microbial safety 2. Nutritional considerations 3.Chemical/Toxicological considerations 4. Raw meats functionality 5. HPP for control of emerging pathogens

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 a pre-treatment before cooking

•

Regulatory Status of HHP

•

USA

USDA has approved High Hydrostatic Pressure intervention method for Listeria contaminated pre packed ready-to-eat (RTE) meat products as an U.S Food and Drug Administration (FDA) has accepted the commercial use of pressure-assisted thermal sterilization (PATS) processes for application in the production of low acid foods (LAF) ( February 2009)  

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)

Principles of High Hydrostatic Pressure

(

Listeria

HPP systems design

Vertical vessel Horizontal vessel

Commercial HPP systems

Vessel layout – horizontal Automatic loading / unloading • • • • Wave 6000 / 55 L Wave 6000 / 135L Wave 6000 / 300T L Wave 6000 / 420 L • • Maximum pressure – 87,000 PSI Pressure Hold Time – 3 min Photo courtesy of NC Hyperbaric

Commercial HPP systems

• Wide range of HHP systems – 100 L - 600 – 215 L - 600 – 350 L - 600 – 687 L - 300 • 7 contract services facilities Photos courtesy of Avure

HIGH HYDROSTATIC PRESSURE Preservation Transformation Value Added

Sterilization Pasteurization Shelf-life extension Meat Protein Seafood PATS LAF RTE meals Fruit and Vegetable Products

pH, a w

Product and process conditions for establishment of HPP preservation

HPP pasteurization HPP sterilization

Temperature, o C Pressure, MPa Pathogenic Spoilage Storage Packaging Product parameters 3.5

Process parameters ≤ 45 ≤ 600 Target microorganisms

E. coli; Listeria; Salmonella

Lactic bacteria, yeasts, molds Refrigerated conditions Hermetically sealed flexible containers pH>4.6; a w >0.86

> 100 > 700

C. botulinum

spores

Geobacillus

spp.

Bacillus cereus

Ambient temperature Hermetically sealed flexible containers

Product Development Issues

• Product selection • Product formulation • Food safety/regulatory • Pre & post pressure processing • Packaging • Product storage temperature • Shelf-life

HPP In-Container Principles

• Product is generally treated in its final primary package • Food and its packaging are treated together • Entire package remains a “secure unit” until the consumer opens it • Packaging must withstand a change of volume up to 18% followed by return to its original size – – – Without loosing package integrity Seal integrity Barrier properties • Packaging under vacuum or modified atmosphere

Food Packaging Materials

• In general, traditional packaging materials are not intended to have any technical effect in the food, and considered as

food additives

because their components can migrate into the food that contacts the packaging • In the case of active and intelligent packaging, sometimes the package may be designed to deliver a chemical to the food for the purpose of exerting some technical effect in the food.

Definition

Available Packaging Materials

• Plastic-laminated materials – nylon/coextruded EVOH – – – nylon/PP PET/AlOx/CPP PET/PE • Aluminum foil-laminated pouches – PET/Al/CPP – nylon/Al/PP • Deposited coatings of SiOx • Blends of polymers • Nanocomposite materials

•

Physical Compression

Compression forces act on – Food – – Air Packaging materials • Decompression – Food package system undergoes a reversible return to its initial volume – Except for porous structures ln (V/V 0 ) = ln[1 - C ln(1 + p/CB 0 )] –

where V o constant and B o are the polymer volume and the bulk modulus at atmospheric pressure for each polymer, respectively, p is pressure and C is a polymer dependent

Compression of Packaging Materials

• 5% of the vessel is full of packaging material • Polypropylene (PP) and polyethylene (PE) undergo compression heating (CH) • CH was greater than water under – HP-LT (10ºC and 50ºC) – HP-HT (90ºC) conditions up to 750 Mpa • CH was non-linear • “Warmer” layer may be formed surrounding the food

Temperature elevation due to

140

pressurization

Water 140 120 120 140 100 100 120 80 80 100 60 60 80 40 40 60 20 20 40 data16 0 0 0 0 100 100 200 200 300 400 400 20 Pressure / MPa 500 500 0 0 100 600 600 200 700 700 300 400 500 600 700

Ardia et al., 2004 Knoerzer and Versteeg, 2009

•

Requirements for HPP Packaging Materials

Flexibility • Visual integrity • Gas barrier • Material and seal strength • Head space • Aging and printability

Integrity requirement 1 (maximum expected pressure/temperature)

Visual integrity Oxygen permeability (maximum deviation 12%) Water permeability (maximum deviation 12%) Seal strength properties (maximum deviation 25%)

HP-LT (600 MPa/80ºC)

no delamination or blistering product dependent product dependent material dependent

HP-HT (800 MPa/133ºC) Retort 2 (0.2 MPa/ 133ºC)

no delamination or blistering 0.06 for US military or 0.5 1.0 g/m²/day for some commercial products 0.01 g/m²/day or product dependent material dependent no delamination or blistering 0.06 for US military or 0.5-1.0 g/m²/day for some commercial products 0.01 g/m²/day or product dependent seal strength, 2-3.5 kg/100 mm; bond strength 150 150-500 g/10 ml; burst test 7.5 kg/15 mm seal Physical strength (tensile, elongation, elasticity modulus; maximum deviation 25%) Global migration of packaging components to food simulants Maximum headspace 3,4 High thermal conductivity 4 material dependent < 10 mg/dm up to 30% 2 not required (with exceptions) material dependent < 10 mg/dm 2 up to 30% required material dependent < 10 mg/dm 2 up to 30% required

Polymer Ethylene vinyl alcohol (EVOH) Poly(vinylidene chloride) (PVDC) Poly(vinyl alcohol) (PVAL) Polyamide (PA) or nylon Oxygen permeability at 23C 50% or 0% RH (ml/m 2 /day) 0.001-0.01 (dry) 0.01-0.3

0.02 (dry) 0.1-1 (dry) 0.5

Poly(ethylene naphthalate) (PEN) Poly(ethylene terephthatlate) (PEF) Poly(vinyl chloride) (PVC) Polypropylene (PP) Polyethylene (PE) Polystyrene (PS) 1-5 2-8 50-100 50-200 100-500 Water vapour permeability at 23C 85% RH (g/m 2 /day) 1-3 0.1

30 0.5-10 0.7

0.5-2 1-2 0.2-0.4

0.5-2 1-4

Residual Headspace

• Residual headspace in certain packages has been shown to influence package integrity by causing delamination • Headspace must be minimized not only to maximize vessel use capacity but also to maintain integrity • Further work must be done in order to establish a minimum headspace value acceptable to maintain package integrity at both HP-LT and HP-HT conditions

•

Summary

Integrity criteria has to be met by a packaging material after HPP processing at mild and high temperature – visual integrity, gas permeability, seal and physical strength properties, and global migration of packaging components into the food • Reported EVOH-based materials showed no deviations after HP LT in terms of visual integrity, permeability, and physical properties. • Information gaps for certain properties, including global migration, must be provided for a complete assessment of the suitability of some reported materials

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Future Trends

Further research is required in screening new materials that are finding applications in thermal processing (hot fill or retort) for their potential use in HPP processes • Transparent materials are desirable due to higher consumer preference – Thin vacuum deposited coatings of SiOx on PET, PP or PA which are transparent, water resistant, retortable microwaveable options – New barrier polymers currently used as discrete layers with an oxygen permeability value 50-100 times lower than PET. • Biodegradable polymers are being developed with oxygen barrier properties resembling those of EVOH, with heat sealability and resistance to grease.

• Blends of barrier polymers and standard polymers have been developed, including EVOH in PP, PE or PA; PA in PP or PET, and LCP in PET and PE • Nanocomposite materials, or polymers filled with small (100-1000 nm) inorganic particles, may improve barrier properties by a factor of 50 or higher.

GFRC PILOT PLANT: CL-02 Certified Facility

2009

PHAC certification

2011 2010

26

McCormick Place, Chicago, IL Wednesday, November 2 2:30-3:30 PM The Promises and Challenges of Applying High Pressure Pasteurization (HPP) for RTE Food Products Presented by Dr. Tobias Richter Dr.-Ing., Dipl.-Kfm., M.Sc.

MULTIVAC Sepp Haggenmueller GmbH & Co. KG, Germany

NEXT-GENERATION HPP: BEYOND SHELF-LIFE EXTENSION

Dr. Phil Minerich Vice President of Research and Development Hormel Foods

• • Applications – Natural Meats – Produce – – Fresh Meats Harvest Processing Conclusion

Agenda

Poll Question

What product features are achieved by using High-Pressure Processing?

1. Minimally processed 2. Extended shelf-life 3. Post-package pasteurization 4. All of the above

Application: Natural Meats

• • U.S. Department of Agriculture definition – A product containing: • No artificial or synthetic ingredient • • • No chemical preservative No coloring ingredient Only minimally processed

Hormel ®

–

Natural Choice ®

products HPP benefits • Post-package pasteurization – Inactivates harmful microbes in foods • Extends shelf-life Sourse: http://www.fsis.usda.gov/factsheets/meat_&_poultry_labeling_terms/index.asp

Application: Produce

• • • • Food safety assurance Stabilizes enzyme activity Preserves and enhances: – Natural flavor – – Color Texture – Other quality attributes Extends shelf-life

Application: Fresh Meats

• • Raw beef patties Stops post-mortem glycolysis – Improves meat quality for consumers • Stabilizes pH >6.0

– – Improves color Increases water-holding capacity – Decreases shear force – Increases tenderness eating experience – Increases overall liking

Application: Harvest Processing

• • • Hair/feather removal – Loosens hair/feather follicles from skin – Eliminates scald tank Toenail removal – Loosens toenails from hoof Reduces fecal contamination

Conclusion

• • HPP fits a variety of applications: – Allows ready-to-eat meats to meet the USDA natural definition – Enhances quality attributes for produce products – – Enhances quality for fresh meats Improves harvest processing Future outlook – ???

HOW TO ENTER THE MARKET WITH AN ADVANTAGE

Justin Segel – President Greg Zaja – Vice President American Pasteurization Company

Poll Question

Besides food safety, what is driving your interest in high-pressure processing?

• Clean labels • Longer shelf life • Risk management (raw materials/finished product) • Regulatory compliance

Basic Concept of Toll vs. In-house

 Capital costs • Hidden costs  Operations  Coordinating volume stream

First Steps

 Initial product testing • Product evaluation • Identify quality & food safety measures • Validation • Inoculation studies • Shelf studies • Packaging

Process Implementation

 Integration between establishments • USDA approval for transferring product • Product specification overview • HACCP plan

Typical Tolling Process

 Documentation of all records • Receiving • Processing • Certification of HPP • Pre-shipment reviews

What to Expect from a Toll Processor

 Final product inspection  Final packaging solutions  Storage and distribution needs  Supply chain integration  Redundancy of equipment

QUESTIONS & ANSWERS

FOR MORE INFORMATION

Dr. Tatiana Koutchma: [email protected]

Phillip L. Minerich: [email protected]

Justin Segel: [email protected]

Greg Zaja: [email protected]

Jerry Hirsh: j [email protected]

Bill Kinross: [email protected]

Mike Fielding: [email protected]

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