Collecting data for modeling: Product heat penetration, equipment temperatures, and residence time

Transcription

1 Collecting data for modeling: Product heat penetration, equipment temperatures, and residence time Presentation to the GMA Science Forum April 4, 2012 V1 David Anderson Food Safety Manager Del Monte Foods Company Pittsburgh PA

2 Discussion points A. Introduction B. Methods to validate processes C. Validation tasks D. Further information E. References

3 A. Introduction: Examples of processes Milk, Eggs: Pasteurize (wet) Dry Almonds: Water blanch Hot, humid air Steam Dry Roast Oil Roast Kibbles: PreCondition Extrude Dry Cool Treats: Extrude Cool Bones: Bake Dry Cool Jerky: Steam Dry Cool Dry Cool

4 B. Methods to validate processes

5 Methods to validate processes Codex (CAC/GL ) and Scott (2005): Use scientifically valid data Conduct experiments (microbiological tests, and measures of the system & product) Use mathematical modeling Σ [( (T Tref)/z 10 )Δt]/D

6 Experiments Tests of the system Temperature mapping; Heat transfer distribution Retention time Other required process conditions (e.g. rel. humidity) Tests of the product Heat penetration studies Analyses (e.g., moisture/aw, preservative level) Microbiological tests Thermal death time studies Count-reduction tests in lab or in process End-point lethality (presence/absence) tests

7 Temperature mapping Continuous baking oven: Entry Exit Datalogger spans the width of the belt

8 Temperature mapping To confirm minimum temperatures; adjust the process Continuous baking oven (from top, looking down):

9 Heat Transfer Distribution To confirm uniform heat transfer & adjust the process Moist heat (retorts) Material Lexan blocks Reference (Campbell and Ramaswamy, 1992) Aluminum or steel bricks (Tung and others, 1984) Silicone food simulants (Smout and others, 1998) Lowmoisture Product-filled containers (IFTPS, 2008) 5% Bentonite-filled containers, or other material of known heating Aluminum almond (FDA, 2011c) ABC, 2007d (Photo from Harris, 2009)

10 Product heat penetration To understand heating rates & model the process Example, pet treats: Temperature probes and location in product: Product entry into the oven:

11 Heat penetration

12 Wireless datalogger examples DataTrace MPIII TM and MadgeTech Temperature dataloggers, with protective insulation for high temperatures. Scorpion Data Logging System for ovens (Temperature, air velocity, heat flux, humidity).

13 Examples of equipment suppliers Manufacturer Web address DataTrace MPIII TM (Mesa Labs) Dickson Ecklund Harrison Ellab Tracksense Pro MadgeTech, Inc. Omega Engineering Scorpion Systems Super M.O.L.E. TechniCAL, Inc. ThermoLog TM TMI (Not an endorsement of any supplier. Exclusions are unintended.)

14 Retention time studies To demonstrate retention, prepare for lab simulations; model the process Options: - Mark product or belt, use a stopwatch - Analytes (e.g. salt in product, in preconditioner or extruder) - Note that some particles may travel faster than the mass average in dryers with a tumble

15 C. Validation tasks

16 1. The source document describes a scheduled thermal process Example 1: Guidelines for Validation of Blanching Processes (ABC, 2007c) Guidelines for Validation of Oil Roasting Processes (ABC, 2007e) (ABC commissioned the TDT tests.) Measure uniformity of heating medium temperature (e.g., a temperature distribution test). Measure residence time in equipment. ABC requires three validation runs. Control incoming, cold almond temperature and other critical factors in production.

17 1. The source document describes a scheduled thermal process Example 2: Guidelines for Validation of Dry Roasting Processes (ABC, 2007d) ABC commissioned TDT tests. Identify the coldest spot or path for each roasting line (e.g., a temperature distribution test). Use an aluminum almond, or similar device (e.g., a heat transfer distribution test). Measure residence time and temperatures achieved during worst case conditions. ABC requires three validation runs. Control, monitor, verify CCPs in process.

18 1. The source document describes a scheduled thermal process Example 3: Appendix A, Compliance Guidelines for Certain Meat And Poultry Products (FSIS, 1999) Temperature must be maintained in all parts of each piece of meat for the required time (e.g., a heat penetration test) 90% relative humidity is maintained during processing. Control, monitor, verify CCPs in process.

19 2. The source document describes D- and z-values (TDT tests were conducted by the source.) Justify substantial similarity of the product and process to the source data. Obtain temperature distribution and/or heat transfer distribution data from the process. Collect heat penetration data for the product Model the process for cumulative log reduction. General method models, Weibull model Consult your friendly neighborhood statistician! Control, monitor, verify CCPs in process.

20 D. Further Information E. References

21 Validation guidance Guideline for the Validation of Food Safety Control Measures (CAC/GL ) (Codex) ICMSF Microorganisms in Foods 8: Use of Data for Assessing Process Control and Product Acceptance (ICMSF, 2011) Validating the Reduction of Salmonella and Other Pathogens in Heat Processed Low-Moisture Foods. (Anderson and Lucore, April 2012)

22 References ABC (Almond Board of California), 2007a. Considerations for Proprietary Processes for Almond Pasteurization and Treatment, v1.0, April 13, Almond Board of California, Modesto, CA. ABC, 2007b. Guidelines for Process Validation Using Enterococcus faecium NRRL B-2354, v1.2, October Almond Board of California, Modesto, CA. ABC, 2007c. Guidelines for Validation of Blanching Processes, v1.0, April 13, Almond Board of California, Modesto, CA. ABC, 2007d. Guidelines for Validation of Dry Roasting Processes, October Almond Board of California, Modesto, CA. ABC, 2007e. Guidelines for Validation of Oil Roasting Processes, v1.0, April 13, Almond Board of California, Modesto, CA. ABC, 2007f. Guidelines for Validation of Propylene Oxide Pasteurization, v3.0, October 1, Almond Board of California, Modesto, CA. ABC, 2007g. Guidelines for Validation of Propylene Oxide Treatment for In-shell Almonds, v2.0, October 1, Almond Board of California, Modesto, CA.

23 References ABC, 2007h. Pasteurization Treatments. December Almond Board of California, Modesto, CA. Anderson, D. G. and L. A. Lucore Validating the Reduction of Salmonella and Other Pathogens in Heat Processed Low-Moisture Foods. Alliance for Innovation & Operational Excellence, Alexandria, VA. Published online at ASTA (American Spice Trade Association), Clean, Safe SPICES: Guidance from the American Spice Trade Association., 2025 M Street, NW, Suite 800, Washingt5on, DC Campbell, S. and H.S. Ramaswamy Distribution of heat transfer rate and lethality in a single basket water cascade retort. J. Food Process Engineering. 15: Center for Meat Process Validation, Accessed February 6, Codex (Codex Alimentarius Commission), Guideline for the Validation of Food Safety Control Measures (CAC/GL ). Joint FAO/WHO Food Standards Program, FAO, Rome, Italy.

24 References FDA (Food and Drug Administration) Processing in Steam-Air Retorts (Retort Survey). FDA Inspection Form FDA 3511h (1/11). FSIS (U.S. Department of Agriculture - Food Safety Inspection Service), Appendix A. Compliance guidelines for meeting lethality performance standards for certain meat and poultry products. Available at Accessed October 26, 2011 Harris, L. J., Process Validation for Low-Water Activity Foods. Presentation for IAFP: Salmonella in Peanut Products. Found at ICMSF (International Commission on Microbiological Specifications for Foods), 2011a. Microorganisms in Foods 8: Use of Data for Assessing Process Control and Product Acceptance. Katherine M. J. Swanson, ed. chair. New York: Springer Science+Business Media, LLC. IFTPS, Temperature and Heat Transfer Distribution Guidelines for Processing in Batch Agitating Retorts. From accessed February 13, 2012.

25 References NACMCF (National Advisory Committee on Microbiological Criteria for Foods), Requisite Scientific Parameters for Establishing the Equivalence of Alternative Methods of Pasteurization. J. Food Prot. 69: NACMCF Parameters for Determining Inoculated Pack/Challenge Study Protocols. J. Food Prot. 73: Scott, V. N How does industry validate elements of HACCP plans? Food Control. 16: Smout, C., A. Van Loey, M. Hendrickx Heat Distribution in Industrial-scale Water Cascading (Rotary) Retort. J. Food Sci. 63: Tung, M. A., H. S. Ramaswamy, T. Smith and R. Stark Surface heat transfer coefficients for steam/air mixtures in two pilot scale retorts. J. Food Sci. 49:

26 Thank You David Anderson Food Safety Manager Del Monte Foods Company Pittsburgh PA