FOOD PRESERVATION

UNIT 3 – PRESERVATION BY HIGH

TEMPERATURE TREATMENT
 OBJECTIVES
The main objective (microbiological) of heating food is to destroy vegetative cells and spores of microorganisms
that include molds, yeasts, bacteria, and viruses (including bacteriophages), specifically destroy pathogens and
spoilage causing microbes

Heating of foods also helps destroy undesirable enzymes (microbial and food) that would otherwise adversely
affect the acceptance quality of food. Some microorganisms also produce heat- stable proteinases and lipases in
food. Heating a food to a desired temperature for a specific time can help destroy or reduce the activity of these
enzymes.
Some microorganisms can release toxins in food; also, some foods can have natural toxins. If a toxin is heat
sensitive, sufficient heating will destroy it, and consumption of such a food will not cause health hazards. It is also
important to recognize that microbial (and natural) heat-stable toxins are not completely destroyed even after
high heat treatment.

Heating (warming) of ready-to-eat foods before serving is also usually used to prevent growth of pathogenic and
spoilage microorganisms. A temperature above 50°C (122°F), preferably 60°C (140°F), is important to control
growth of many microorganisms in such foods during storage before serving.

Finally, heating of raw materials, such as milk, is done before adding starter culture bacteria for fermentation to kill
undesired microorganisms (including bacteriophages) and to allow growth of the starter cultures without
competition.
 MECHANISM OF THERMAL INACTIVATION
❑ Depending on the temperature and time of heating, microbial cells and spores can be heat shocked, sublethally injured, or
dead.
❑ Heat-shocked cells acquire some resistance to subsequent heating, and sublethally injured cells and spores retain the
ability to repair and multiply.
❑ Results of different studies have shown that following heat injury, bacterial cells show a loss of permeability and
increased sensitivity to some compounds to which they are normally resistant. Sublethally injured cells seem to suffer
injury in the cell membrane, cell wall, DNA (strand break), ribosomal RNA (degradation), and some important enzymes
(denaturation). Death occurs from damages in some vital functional and structural components. Bacterial spores,
following heating, were found to lose structural components from the spore coat, suffer damage to the structures that are
destined to become membrane and wall, and develop an inability to use water for hydration during germination.
❑ Exposure of microbial cells to approximately 45°C–50°C (104°F–122°F) for a short time, which can occur while heating a
large volume of a food, such as a large rare roast, may induce production of heat-shock proteins (stress proteins) by the
cells.
PASTEURIZATION
 1. PASTEURIZATION

I Pasteurization – Heating each and every particle of a liquid food at a specified temperature for a specified
period followed by rapid cooling to about 40C.
These temperatures are equivalent and are suffcient to destroy the most heat sensitive of the non-spore-
forming pathogenic organisms. Milk pasteurization temperatures are also sufficient to destroy all yeasts,
molds, gram negative bacteria and many gram positive. The two groups of micro-organisms that survive
pasteurisation temperatures used in milk are: Thermodurics and Thermophilics. Also spores
▪ Milk (HTST - 720C/15sec: LTLT - 630C/30min)
▪ Wine (82-850C/1 min in bulk)
▪ Carbonated juices (65.60C/30 min)
▪ Vinegar (65.60C/30 min in bulk/bottled -65.60 to 71.10C flash)
▪ Beer (600C/30 min)
▪ Apple juice (85 to 87.80C/30-60 min in bulk)
▪ Bottled grape juice (76.70C/30 min)
PURPOSE OF PASTEURIZATION

 Pasteurization is a relatively mild heat treatment in which food is heated to <100°C. It is widely used throughout
the food industry and is frequently employed as a CCP in various HACCP plans. As a unit operation in food
processing it can be used to destroy enzymes and relatively heat sensitive micro-organisms (e.g. non spore
forming bacteria, yeast and moulds). In this regard is it used to extend shelf life by several days e.g. milk or months
e.g. bottled fruit.
 The severity of treatment and resulting extension of shelf life is determined mostly by pH of the food. In low acid
foods (pH<4.5), the main purpose is destruction of pathogenic bacteria, while below pH 4.5 the destruction of
spoilage microorganisms or enzyme deactivation is usually more important. The extent of heat treatment required
is determined by the D value (Decimal reduction time or time to reduce numbers by a factor of 10 or 90% of the
initial load) of most heat resistant enzyme or micro-organism which may be present. In terms of
checking the effectiveness of the process, Alkaline Phosphatase (ALP) naturally occurring enzyme in raw milk
with a similar D value to heat-resistant pathogens and so is routinely used as an indicator of adequate
pasteurisation. If phosphatase activity is found, it is assumed that pasteurisation is inadequate.
 Pasteurization is normally used for the destruction of all disease causing organisms (e.g. pasteurization of milk) or
the destruction or reduction in the number of spoilage organisms in certain foods e.g. vinegar.
 Two groups of MO are known to survive Pasteurization process: Thermodurics and Thermophilies
METHODS OF PASTEURIZATION

 This is done most commonly in two methods i.e.

1) Low Temperature and Longer Time / Batch process

2) High Temperature Short Time / Continuous process

The former method is used in most of the Batch processes and involves a multipurpose vat.

The latter method is used with Plate type of heat exchanger.

BATCH PROCESS

 The Batch processes are suitable for small capacity.

 Batch process involves heating to 63°C and holding at that temperature for 30 minutes.
 For this process, multipurpose vat is most suitable.
 The Multipurpose vat used for Batch pasteurization is a jacketed and insulated tank.
 It is a cylindrical vessel with double jacket.
 The tank is heated by circulating hot water or steam in the inner jacked. Slow speed agitation provides uniform
heating through the wall.
 The milk is slowly heated and after reaching the required temperature, is held at that temperature for 30 minutes.
 Then it is cooled to below 4°C.The bringing up time and cooling time are not accounted for the pasteurization
time.
HTST/CONTINUOUS PROCESS

 The Plate heat exchanger for HTST pasteurizer is made up of groups of plates that are used for heating the milk
to the high temperature required, holding at that temperature for the required period and cooling it.
 It consists of heat exchange plates, frame for hanging the same.
 End plates along with tightening bolts are provided to keep these plates pressed together, with gaskets in
between.
 The groups of plates are provided in between with connecting plates which make it possible to introduce or exit
milk after each of the processes, like Regeneration, heating, holding, and chilling.
 The plates are made of die-pressed sheet of stainless steel with a corrugated surface, to give turbulence to the
flow and thereby achieve maximum heat transmission, even with very low temperature gradient between the heat
exchange fluids.
 CONTINUOUS PROCESS
1. Balance tank
1. The float-controlled inlet valve regulates the flow of milk and maintains a constant level in the balance tank. If the supply of milk is
interrupted, the level will begin to drop. The pasteurizer must be full at all times during operation in order to prevent the product from
burning on to the plates. The balance tank is therefore often fitted with a low-Ievel electrode which transmits a signal as soon as the level
reaches the minimum point. This signal actuates the flow diversion valve which recirculates the product to the balance tank. The milk is
replaced by water and the pasteurizer shuts down when circulation has continued for a certain time.
2. Feed pump
1. The milk is pumped from the balance tank, which provides a constant head, through the pasteurizer by the feed pump.
3. Flow controller
1. The flow controller maintains the flow through the pasteurizer at the correct value. This guarantees stable temperature control and a
constant length of the holding time for the required pasteurization effect.
4. Regenerative preheating
1. The pasteurization process requires both heating of the incoming milk and cooling of the treated milk. These two stages in the process
can therefore be combined. The milk, which is already pasteurized, is used as a heating medium for the incoming cold milk. This technique
is called regenerative heat exchange and saves much energy.
2. The untreated milk continues from the flow controller to the first section in the pasteurizer, the preheating section. Here it is
regeneratively heated with pasteurized milk, which is cooled at the same time.
3. The incoming Raw milk is Heated by the outgoing Pasteurized milk and the Outgoing Pasteurized milk is cooled by the
incoming Raw milk
4. Pasteurization
1. Final heating to pasteurization temperature with hot water or vacuum steam takes place in the
heating section of the pasteurizer. The hot milk continues to the holding section (or to an external
holding section). After the holding time, the temperature of the milk is checked by a sensor in the
line. It transmits a continuous signal to the temperature controller in the control panel. The same
signal is also transmitted to a recording instrument which records the pasteurization temperature.
5. Flow diversion
1. A sensor after the holding section transmits a signal to the temperature monitor. As soon as this
signal drops below a preset value, corresponding to a specified minimum temperature, the monitor
switches the flow diversion valve to diversion flow. In many plants the position of the flow diversion
valve is recorded together with the pasteurization temperature.
6. Cooling
1. After the holding section the milk is returned to the regenerative section(s) for cooling. Here the
pasteurized milk transfers the heat to the cold, incoming milk. The outgoing pasteurized milk is then
chilled, first with cold water and then with ice-water, a glycol solution or some other refrigerant,
depending on the required temperature. The temperature of the chilled milk is normally recorded
together with the pasteurization temperature and the position of the flow diversion valve. The
graph consequently shows three curves.
 ULTRA HIGH TEMPERATURE (UHT) PASTEURIZATION

❑ UHT pasteurization process involves heating the milk at a temperature of 88°C for 3 sec.
❑ The equipment is much the same as the HTST units and the controls are also similar, but the
operating temperature is higher.
❑ The holder is much smaller for smaller pasteurizing time. Advantages
• Better texture of milk due to short holding time
• Greater bacterial destruction is possible.
• When UHT treatment is needed for greater bacterial destruction or its beneficial effect on
the body and texture of ice cream, then the treatment may be given following regular
pasteurization.
BLANCHING
 BLANCHING - MEANING

Blanching as a preliminary treatment in the canning process and freezing process.

The objective of blanching as a pretreatment of vegetables for canning is the removal of tissue gases; the
shrinking of the material so that adequate fills can be contained in the can; and the heating of the material
prior to filling so that a vacuum will be obtained after heat processing and boiling.

Blanching is necessary as a part of the preparation for freezing preservation to inactivate the enzymes in the
tissues and to shrink the material so as to conserve space in packing.

The inactivation of the enzymes is very important in this process because no final cook or sterilization is
used previous to freezing, and freezing storage, at least at the temperatures commonly employed, does not
prevent undesirable deterioration in flavor, odor, and color on the part of the enzymes in the tissues.

Many studies have been conducted to determine the effects of steam and water blanching on the vegetables
so processed. The relative merits of water-blanching versus steam-blanching have been studied. It seems that
steam-blanching is the more effective of the two for the conservation of soluble nutrients.
 PURPOSE OF BLANCHING

The primary purpose of blanching is to

• Destroy/Inactivate enzyme activity in fruit and vegetables.

It is not intended as a sole method of preservation, but as a

pre- treatment prior to freezing, drying and canning.

Other functions of blanching include:

• Reducing surface microbial contamination
• Softening vegetable tissues to facilitate filling into containers
• Removing air from intercellular spaces prior to canning
 ENZYME INACTIVATION

❑ Freezing and dehydration are insuffcient to inactivate enzymes and therefore

blanching can be employed.
❑ Canning conditions may allow suffcient time for enzyme activity. Enzymes are
proteins which are denatured at high temperatures and lose their activity.
❑ Enzymes which cause loss of quality include
❖ Lipoxygenase
❖ Polyphenoloxidase
❖ Polygaacturonase
❖ Chlorophyllase.
❖ Heat resistant enzymes include Catalase and Peroxidase
 METHODS OF BLANCHING

1. Blanching is carried out at up to 100°C using HOT WATER OR STEAM at or

near atmospheric pressure.

2. Some use OF FLUIDIZED BED BLANCHERS, utilizing a mixture of air and

steam, has been reported.
1. Advantages include faster, more uniform heating, good mixing of the product,
reduction in effluent, shorter processing time and hence reduced loss of
soluble and heat sensitive components.

3. There is also some use of MICROWAVES for blanching.

1. Advantages include rapid heating and less loss of water soluble components.
2. Disadvantages include high capital costs and potential diffculties in
uniformity of heating.
 STEAM BLANCHERS
This is the preferred method for foods with large cut surface areas as lower
leaching losses.
❑ Normally food material carried on a mesh belt or rotatory cylinder
through a steam atmosphere, residence time controlled by speed of the
conveyor or rotation.
Often poor uniformity of heating in the multiple layers of food, so attaining
the required time temperature at the centre results in overheating of
outside layers.

❑ Individual Quick Blanching (IQB)

Involves a first stage in which a single layer of the food is heated to
suffcient temperature to inactivate enzymes and a second stage in
which a deep bed of the product is held for suffcient time to allow the
temperature at the centre of each piece to increase to that needed for
inactivation. Allows heating at the centre of each piece.
The reduced heating time (e.g. for 10 mm diced carrot, 25 s heating and
50 s holding compared with 3 minutes conventional blanching) results
in higher energy effcienciess
For small products (Ex: peas, sliced or diced carrots), mass of produce
blanched per kg steam increases from 0.5kg for conventional steam
blanchers to 6-7kg for IQB.
 HOT WATER BLANCHERS

Includes various designs which hold the food in hot water (70 to 100°C) for a specified time,
then moves it to a dewatering/cooling section.
❑ In blanchers of this type the food enters a slowly Rotating Drum, partially submerged in
the hot water
It is carried along by internal flights, residence time being controlled by the speed of
rotation.
❑ Pipe blanchers consist of insulated tubes through which hot water is circulated.
Food is metered into the stream, residence time being controlled by the length of the pipe and
velocity of the water.
❑ The Blancher-cooker has three sections,
• Preheating stage
• Blanching stage
• Cooling stage
As the food remains on a single belt throughout the process, it is less likely to be physically
damaged. With the heat recovery incorporated in the system, 16 to 20 kg of product can be
blanched for every kg of steam, compared with 0.25 to 0.5kg per kg stream in the
conventional hot water blanchers.
 EFFECTIVENESS OF OF BLANCHING

❑ Over blanching causes quality loss due to overheating while under blanching causes
quality loss due to increased enzyme activity because enzymes activated and substrates
released by heat.

❑ The Peroxidase test in vegetables is used to detect enzyme inactivation.

❑ This enzyme is not in itself implicated in degradation, but is relatively heat resistant and
easily detected.
❑ It consists of adding guaiacol solution and hydrogen peroxide solution and observing the
development of a brown colour indicating peroxidase activity.
❑ Complete inactivation is not always essential – green beans, peas and carrots with some
residual peroxidase activity have shown adequate storage quality at -20°C through with
other vegetable (e.g. Brussels sprouts) zero peroxidase activity is essential.
THERMIZATION
 2. THERMIZATION

Thermization – below pasteurization temperature time – to inhibit growth of psychrotrophs in milk &
increase shelf life of milk and not safe for consumption
 630C-680C/15sec & 50C
 Opt 660C-700C/15sec
 Reduce growth of psychrotrophic bacteria. Sub pasteurisation process
 Keeping quality of food - At 80C for 3 days
TYNDALLIZATION
 TYNDALLIZATION

I. 1000C for 3min – 3 consecutive days

II. Tyndallization, also called fractional sterilization and discontinuous heating, is a form of
sterilization. The term sterilization means the removal of all living microorganisms, including spores, from
a food product. Given by John Tyndall.

III. The idea behind this is that any microorganisms that don't get killed by the first day's boiling session will
germinate from the warmth and get released from their spore coatings, and then get killed in the next
day's boiling session, or, if they survive that one, then on the third day's boiling session.

IV. Very occasionally used in industries.

 STERILIZATION

Sterile
• Free from viable micro-organisms
Sterilization

• Any physical or chemical process which destroys all life forms, with special regard to microorganisms (including
bacteria and sporogenous forms), and inactivates viruses.

Objective of sterilization

The sterilization is the process of heating to a high enough temperature (usually more than
100°C) for specific time to kill almost all bacteria. The sterilized milk can be stored at room
temperature for a long period of time.
The sterilization of milk has the following characteristics.
• Temperature more than 100°C is used in the process.
• No chilling is required for storage.
• Excellent storage life at room temperature.
• High operating pressure is employed to prevent milk from boiling at the processing
temperature.
 STERILISATION PROCESS AND EQUIPMENT

The sterilization process in the canned product can be subdivided into three phases.

Phase 1 = Heating phase

• By means of a heating medium (water or steam) the product temperature
is increased from ambient to the required sterilization temperature.
Phase 2 = Holding phase
• This temperature is maintained for a defined time .

Phase 3 = Cooling phase

• The temperature in the can is decreased by introduction of cold water
into the autoclave.
 METHODS OF STERILIZATION
Conventional method or Canning or Appertization:
• Packaging is done before heat treatment. The processing is usually carried out at 105-110°C for 30-45 min. It is
also known as In-bottle sterilization.
UHT or aseptic method:
• Packaging is done after heat treatment. The ultra high temperature short time (UHTST) and very high
temperature short time (VHTST) processes come under this category. The processing is at 135-150°C for 1-20
seconds. Then the commodity is packed aseptically.
 1. CONVENTIONAL CANNING/ IN-BOTTLE STERILIZATION
The in-bottle sterilization method can be further categorized as batch or continuous types. The basic flow
chart to explain the in-bottle sterilization is given
CANNING PROCESS
 BATCH STERILIZATION

The equipment which is used for the sterilization process is called a retort and the processing is often called
Retorting. The batch retorts can be either horizontal type or vertical type. The retort has a lid or door with good
fastening. It has necessary controls for temperature, pressure and safety devices. They can also be of circular or
rectangular cross section.

Different Equipments used in Batch

Process

Water Spray
Vertical Horizontal Rotary Batch Hydrostatic
or Cascading
Retort Retort Retort Retort
Water Retort
 BATCH PROCESS

The batch retorting process can be explained as follows.

• The bottles are loaded onto crates and then the crates are travelled into sterilizer with the help of a
trolley/truck.
• After the commodity is packed, the door is closed, the vessel is supplied with steam at required pressure.
• The processing time and pressure are properly maintained by controls.
• After desired processing time, steam is vented to atmosphere.
• After this the crates (bottles/cans) are immediately cooled by air (fans) to avoid further cooking of the
product.
 1.1 SIMPLE SMALL AUTOCLAVES/VERTICAL RETORT

❑ These are usually vertical autoclaves with the lid on top.

❑ Through the opened lid the goods to be sterilized are loaded into the
autoclave.
❑ The cans are normally placed in metal baskets.
❑ The baskets are placed in the autoclave, either singly or several stapled
on top of each other. Before starting the sterilization, the lid must be
firmly locked ontothe body of the autoclave.
❑ The autoclave and lid are designed to withstand pressures up to 5.0 bar.
❑ These types of autoclaves are best suited for smaller operations as they
do not require complicated supply lines and should be available at
affordable prices.
 1.2 LARGER AUTOCLAVES/HORIZONTAL RETORT

❑ These are usually horizontal and loaded through a front lid.

❑ Horizontal autoclaves can be built as single or double
vessel system.
❑ The double vessel systems have the advantage that the
water is heated up in the upper vessel to the sterilization
temperature and released into the lower (processing)
vessel, when it is loaded and hermetically closed.
❑ Using the two–vessel system, the heat treatment can begin
immediately without lengthy heating up of the processing
vessel and the hot water can be recycled afterwards for
immediate use in the following sterilization cycle.
❑ If steam is used instead of water as the sterilization
medium, the injection of steam into a single vessel
autoclave will instantly build up the autoclave temperature
desired for the process.
 1.3 WATER SPRAY OR CASCADING WATER RETORT

The characteristics of water spray or cascading water retort are

as follows.
• It uses a low volume of water.
• Water does not completely cover the containers during processing, but
instead sprays or cascades (showers) on the containers
• The system collects (draws) water from the bottom and reintroduces
through sprays from the top and mid-section of the vessel to heat or cool.
• Heating of water is done internally by steam spreaders.
• Air is the source of overpressure.
 1.4 ROTARY BATCH STERILIZER
Another technology employed is rotary autoclaves in which the basket containing the cans rotates
during sterilization. This technique is useful for cans with liquid or semi-liquid content as it achieves
a mixing effect of the liquid/semi-liquid goods resulting in accelerated heat penetration. The
sterilization process can be kept shorter and better sensory quality of the goods is ensured.
 1.5 HYDROSTATIC RETORT

The characteristics of Hydrostatic Retort are as follows.

• It operates with steam as the processing medium.
• The processing chamber (also known as steam dome) is maintained at
constant temperature.
• It has a continuous conveyor chain that transports containers at a
constant rate.
• There is minimal container agitation during processing. (However, some
use cascading water with over pressure as the processing medium and
some provide container rotation or rocking during processing.)
• Two, four, six or eight pass hydrostatic retorts are common.
• Pressure within the chamber is maintained and counterbalanced by the
weight of water in the feed and discharge gates.
• To increase the temperature, the pressure must increase and thus
height of water column must increase.
• For the processing chamber temperature as 121°C, we require 103.4
kPa pressure in the chamber, i.e. the height of water column in the feed
and discharge legs must be 11.3m above the steam-water interface.
 2. CONTINUOUS STERILIZER

In the continuous sterilizers, the cans enter and exit the sterilizer in a continuous manner.

The characteristics of continuous rotary retort are as follows.

❑ There is continuous container handling and intermittent product agitation. The retort system is
constructed of a series of cylindrical vessels called shells (typically 1.5 m diameter).
❑ Processing and cooling in separate shells connected by transfer valves.
❑ To maintain pressure in the shells, containers enter and exit through self-sealing inlet and discharge
valves.
❑ Agitation occurs when the containers roll on the bottom of a shell. Product agitation increases rate of
heat penetration, allows use of higher processing temperature (up to 138°C), and improves product
uniformity and quality.
❑ Large initial investment and additional critical factors to monitor and control.
❑ Retorts will accommodate a limited range of both length and diameter of cylindrical container sizes due
to the physical restrictions imposed by reel steps, spacing of the spiral and other factors.
 GENERAL PROBLEMS IN IN-BOTTLE STERILIZATION

There are two kinds of problems in heat treatment

1. Heat has to pass through the container first before it goes into the milk.
2. Use of glass as container material may cause some auxiliary problems. While processing milk in
bottles, a ring of white solids is found on wall of the bottle at edges of milk surface. It could be due
to excessive foam formed during bottle filling operation. It can be avoided by rotation or violent
shaking of the bottle during heating and cooling cycle.
Important accessories in retorts
The following are the important accessories in a retort.
• Air vent
• Temperature recorder/ thermometer
• Pressure gauge
They should perform accurately so that damage to the product and to the people and machines are avoided.
Steam requirement for retorting Assuming that milk bottles are loaded at 70°C and sterilised at 113°C by
steam with a heat capacity of 2320 kJ/kg, the steam requirement is about 0.1 kg steam for each litre of milk.
However, in practice, the usually steam capacity ranges between 0.2-0.6 kg of steam per litre of milk
according to the plant characteristics.
 ULTRA HIGH TEMPERATURE STERILIZATION
The main features of Ultra High Temperature (UHT) or aseptic processing are as follows.
❖ Temperature of 135-150°C is maintained for a few seconds.
❖ So the product is treated in a continuous heat exchanger.
❖ Causes much less chemical change than the conventional sterilization process.

The classification of UHT sterilization processes as regards to different types of heating medium and methods are
The temperature is increased to 135-150°C and the holding time is less. Hence the length of holding tube is
much smaller than the HTST pasteurization methods.
 DIRECT HEATING

1. Injection type:
• Processing is through steam-into-milk arrangement.
Steam injector is the heart of this plant.
• Preheated milk at 80-90oC enters the injector nozzles
from one side.
• Steam at slightly higher pressure enters the injector from
the other side.
• As the steam mixes with milk, steam condenses and the
product is rapidly heated. Rapid condensation of steam
prevents entry of air in holding tube.
• Air in holding tubes results in improper heating.
• Backpressure is maintained on the discharge side.
• Backpressure ensures that product does not boil in
holding tube. Boiling may result in fouling and improper
heating of milk. Several designs of injector are available.
 2. INFUSION TYPE

Infusion Type
• In this system, milk is heated by milk-into-steam arrangement.
• The processing unit consists of a chamber filled with pressurized
steam.
• Milk enters the chamber from the top.
• There are two alternative arrangements for distribution of milk. In
the first type, milk flows to a hemispherical bowl with loose circular
disc closing the top.
• When the bowl is full, milk overflows and falls in droplets through
the steam environment. In an alternative arrangement, milk flows
through a series of parallel and horizontal distribution tubes.
• These tubes have slits along the bottom and milk flows like a thin
film through the chamber.
• As milk reaches the bottom of the chamber, it is heated to desired
temperature. This system is particularly suitable for thicker liquids
and for liquids suspended with smaller chunks.
 Advantages of Direct Heating System
• In expansion vessel, along with the evaporating water incondensable gases and undesirable flavour volatiles
produced during heating are also removed.
• The product therefore tastes better.
• Rate of heating is very high (takes less than 1 sec to attain sterilization temperature).
• Thick/viscous liquid can also be easily processed. Deposit formation is minimum, hence plant can be operated
for longer time without cleaning.
• Undesirable flavours are removed during flash cooling. Oxygen is removed during cooling, hence oxidized
flavour defects are delayed during storage.

Disadvantages of Direct System

• During processing in direct type heating systems condensing of steam coming into product contact results in
dilution of the product. To remove this excess of water from the product, cooling is done in an expansion
cooling vessel.
• Steam injection induces formation of casein aggregates, which give “chalky” or “astringent” mouthfeel to the
product. Aseptic homogenizer, which can safely homogenize the product after final heating section, is generally
preferred with direct heating systems to overcome such defects in the product.
• Cost of processing per unit volume of milk is high.
• Requires additional equipment (vacuum expansion chamber and aseptic homogenizer) – cost of plant is twice
that of indirect type plant.
• Heat energy requirement is very high.
• Water and electricity (25-50% more than indirect type) consumption are high.
• Requires culinary steam and hence special boiler.
• Creates greater noise during operation.
 INDIRECT TYPE HEATING SYSTEM

Plate heat exchanger:

• This resembles plate heat exchanger of HTST plants.
• Several rectangular stainless steel plates with
corrugations are arranged in sequence.
• These plates are then mechanically tightened to hold
together.
• Corrugations on the plates induce turbulence and
therefore result in high heat transfer.
• High temperature processing generates high internal
pressure.
• The gaskets are therefore made of heat resistant
materials such as medium nitrile rubber or resin
cured butyl rubber. A major advantage of this plant is
therefore simple design and comparatively less cost.
If deposit formation is more, plates can be removed
and manually cleaned.
 TUBULAR HEAT EXCHANGER
❑ There are two types of tubular heat exchangers –
a)concentric tube, (b) shell and tube type.

❑ Concentric tube type heat exchangers comprise two or three stainless steel tube
lengths put one inside another.
❑ Spacer is placed in each inner tube space to maintain them concentric. Several such
multiple tubes are bound together and placed into an outer cylindrical housing.
❑ Two tube heat exchangers are used for simple cooling and heating.
❑ In triple tube heat exchanger, available heat transfer area is doubled. Suitable for
processing of thick liquids, which generally reduces heat transfer rate.
❑ Product flows through the middle annular space. Heating or cooling medium passes
through inner tube and outer annular space.

❑ In shell and tube type heat exchangers, 5-7 straight lengths of smaller tubes (10-15 mm internal
diameter) are assembled in an outer tube.
❑ The smaller tubes are connected to large outer tube at both ends by a manifold. Product passes
through the smaller tubes
❑ Heating or cooling medium passes through the space around them in a counter current flow.
❑ Tubular heat exchangers are mechanically very strong and can withstand even very high internal
pressure generated during homogenization (200- 300 bar).
 SCRAPED SURFACE HEAT EXCHANGER (SSHE)

❑ It is a very specialized type of heat exchanger. It consists of a jacketed cylinder.

❑ A shaft passes along the axis of the cylinder.
❑ The shaft is supported by bearings at both ends of the cylinder.
❑ The shaft also carries several scrapper blades.
❑ As shaft rotates, scrapper blades provide turbulence and physically remove the
product from the surface of the wall. T
❑ he colder product subsequently replaces the heated product and the cycle continues.
❑ SSHE is used only for heating very thick liquids.
❑ SSHE units are very expensive and have poor energy conversion efficiency. The cost
of processing is therefore very high.
ADVANTAGES AND DISADVANTAGES OF INDIRECT HEATING SYSTEM

❑ It is simple in design and requires less pumps and controls. It can regenerate 90% of
the thermal energy requirement.
❑ It does not require aseptic homogenizer, which is very costly.
❑ It does not require culinary steam and therefore special type of boiler.
❑ The indirect type plant is less noisy.
❑ It requires low initial capital and operational cost is also comparatively less.
❑ In indirect type heat exchanger, rate of heat transfer is low.
❑ More heat load results in less acceptable product quality.
❑ Deposit formation is more and therefore plant requires frequent cleaning. For removal
of dissolved oxygen from milk, additional equipment ‘deaerator’ is required.
 ASEPTIC PACKAGING

❑ Aseptic packaging can be defined as the process in which UHT processed or sterilized milk is
filled in pre-sterilized containers under aseptic/sterile environment. This ensures that there is
no post processing contamination of the milk so that the product has longer shelf life.
❑ Since aseptic packaging systems are complex, great care is needed to prevent contamination.
Before the start of product packaging, trial runs are routinely conducted with sterile water.
❑ Critical parts of the filling machine and carton forming systems are thoroughly checked.
❑ The seal integrity of the package and overall microbial quality of the packaging material are
monitored properly.
❑ Generally, for a good processing plant permissible spoilage rate is one in every 5000 sterilized,
filled and sealed package of one litre carton.
 THERMAL DESTRUCTION OF MICROORGANISMS

• The preservative effect of high temperature treatment depends on the extent of destruction of microorganisms.
Certain basic concepts are associated with the thermal destruction of microorganisms. These include;
Thermal death time (TDT)
• D- value
• Z- value
• F- value
• 12D concept
Thermal death time (TDT)
TDT is the time required to kill a given number of organisms at a specified temperature. Here, temperature is
kept constant and the time necessary to kill all cells is determined.
Whereas, Thermal death point is the temperature necessary to kill given number of organisms in a fixed time,
usually 10 min. But it is of less importance.
TDT is determined by placing a known number of bacterial cells/spores in sealed containers, heating in a oil bath
for required time and cooling quickly. The number of survivors from each test period is determined by plating on
a suitable growth media. Death is defined as the inability of organism to form viable colonies after incubation.
 Z – Value
Z-value refers to degrees of Fahrneit required for the thermal destruction curve to drop by one log cycle. Or to
reduce D value by 90%. Z value gives information on the relative resistance of an organism for different
destruction temperature. It helps to determine equivalent thermal process at different temperature.
 F – Value
F- value is the better way of expressing TDT. F- is the time in minutes required to kill all spores/vegetative cells at
250oF (1210oC). It is the capacity of heat process to reduce the number of spores or vegetarian cells of an
organism.
 12D concept
12D concept is used mainly in low acid canned foods (pH >4.6) where C. botulinum is a serious concern. 12D
concept refers to thermal processing requirements designed to reduce the probability of survival of the most
heat resistant C. botulinum spores to 10-12.
This helps to determine the time required at process temperature of 121oC to reduce spores of C. botulinum to 1
spore in only 1of 1 billion containers (with an assumption that each container of food containing only 1 spore
of C. botulinum).