Công nghệ sản xuất nước giải khát hot fill Hot fill process

Basics on Hot Fill Process


What Is the Hot-Fill Process ?

A beverage processing method that
achieves microbiological stability by
heat sterilizing a high acid product
and filling while hot to sterilize the
container, headspace, and closure.


Hot Fill Basics
General Biological & Microbiological Requirements
for packaged products (long term shelf life
outside of the “cold chain”)
Free from live microorganism (CFU) to secure
shelf live and avoid quality deterioration due to
microbiological activities within the closed
package
Free from harmful ( toxic, pathogen )
metabolism and by-products
Free from active bio catalysts (enzymes)
avoiding changes & deterioration by autolysis
Avoid visual {color, consistency}, chemical
{composition }, physical { density, gas
generation, viscosity } and organoleptic {smell,
taste, sensory} deterioration by either live
activities or decomposition effects of killed
3
microorganism {autolysis}

Hot Fill Basics
Product classification
(according to pH)
Low acid teas
Milk
Tea+milk
Coffee+milk
Flavoured milk
Ice Tea
Sport drinks
Apple juice
Orange juice
CSD

0
High acid product
Low acid product

1

2

3

4
pH

5

6

7

8


Range of pH values for various juices
pH 4.6 is critical: pathogens
cannot grow < pH 4.6


Hot Fill Basics
Growth Factor of Microorganism
(according to pH)
Bacillus spec
Escherichia Coli
Pseudomonas spec
Staphylococcus
Lactobacillus spec
Lactococcus lactis
Yeast
Mould

4.5 – 8.5
4.4 – 9.0
5.0 – 8.5
4.5 – 8.5
3.0 – 7.2

4.0 – 4.5
1.5 – 8.5
1.5 – 11.0

Recommended Sterilizing
Temperature approx 90 ºC

1

2

3

High acid products

4

Recommended Sterilizing
Temperature min 120 ºC

5

6

7

Low acid products

8

9


Hot Fill Basics
Temperature Classification of Microorganism

Extreme Thermophilic

Thermophilic
Mesophilic
Psychrotrophic
Psychrophilic

0

10

20

30

40

Optimal Breeding Temperature
Psychrophilic:

4 – 10 ºC

Psychrotrophic:

10 - 20 ºC

Mesophilic:

20 - 30 ºC

Thermophilic:

50 - 60 ºC

Extreme Thermophilic:

75 - 85 ºC

50

60

70

80

90

100
T [ºC]


Hot Fill Basics
Glass Bottles

Cold (Ambient)
Filling with
Preservatives

PET Bottles
Cold (Ambient)
Filling with
Preservatives

Cold (Ambient)
Filling with
Pasteurizer

Hot Filling

Aseptic Filling

Cans
Cold (Ambient)
Filling with
Preservatives
Cold (Ambient) Filling
with
Pasteurizer/Autoclave

Hot Filling

Hot Filling

Aseptic Filling

8


Heat treatment parameters


D Value : Thermal death time / decimal reduction time



Time required to kill 90% of microbes
D65°C :
E. coli
D121°C : (= Dr)
 C. botulinum
 B. stearothermophilus






0.1-0.2 min
4-5 min

z Value : Thermal resistance constant





0.1 min in apple juice

Increase in temperature required to drop D 10 fold
z is generally 5-10°C (9-18°F)

Fo Value : Time at 121°C to destroy an organism


C. botulinum

12 log reduction (12-D)


Thermal treatment




The destruction of a population of
microorganisms is a function of time
and temperature
Both, temperature and time, are critical
parameters :






The effect of time on microbial destruction
is linear
The effect of temperature on microbial
destruction is exponential

It is more effective to increase the
temperature than the time


How do we calculate the time and
temperature needed to destroy microbes ?
The rate of destruction with
temperature is a constant for any
particular food environment
 We can calculate equivalent times
and temperatures


For example: With z = 5.5,
95°C for 22 seconds = 90°C for 3
minutes



Yeast Kills at Various Temperatures
LogCFU/mL

8
7

60°C
D=5.4 min

65°C
D=2.1 min

70°C
75°C
D=0.93 min D=0.39 min

6
5
4
3
2
1
0

0 5 10 15 20 25 30

0 5 10 15 20 25 30

0 5 10 15 20 25 30

Minutes

0 5 10 15 20 25 30


Effect of Temperature on Yeast Kill Rates

Minutes for 10-Fold Reduction
100
30
10

Z-Value = 13°C

3
1
0.3
0.1
0.03
0.01
50

60

70
80
Temperature(°C)

90

100


Equivalent Time-at-Temperature
Combinations
Log Reductions (Z-value = 13°C)
Minutes at Temperature

100

LogReduction

30

24
12

10

6
3

3
2

1

1

0.3
0.1
0.03
0.01

50

60

70

80
90
Temperature(°C)

100

110

120


Pasteurization Conditions

(Equivalent to 75°C
for 10 minutes Z =
8.0°C)

Min = Antilog °C – Equivalent to
(°C)
Z -Value

°C
70.0
71.0
72.0
73.0
74.0
75.0

76.0
77.0
78.0
79.0
80.0
81.0
82.0
83.0
84.0
85.0
86.0
87.0
88.0
89.0
90.0

°F
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
172.4
174.2
176.0
177.8
179.6

181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0

Min
42.2
31.6
23.7
17.8
13.3
10.0
7.5
5.6
4.2
3.2
2.4
1.8
1.3
1.0
0.7
0.6
0.4
0.3
0.2
0.2

0.10

Sec
2530.
2
1897.
4
1422.
8
1067.
0
800.1
600.1
449.9
337.4
253.0
189.7
142.3
106.7
80.0
60.0
45.0
33.7
25.3
19.0
14.2
10.7
8.0

Microbial destruction




At high temperatures, microbes are destroyed faster
than quality factors such as color and nutrients are
reduced :
z (°C)

D121°C (min)

Bacteria

5-10

1-5

Enzymes

30-40

1-5

Vitamins

20-25

150-200

Pigments

40-70

15-50

For this reason, a high temperature and short time,
heat treatment is better for product quality than a
lower temperature and longer time


Hot Fill Basics
Pasteurization T < 100 ºC
Destruction of Pathogenic Microorganism
Inactivation of Enzymes
Noticeable total cfu damage & reduction
Limitations
Heat resistant Microorganism ( Thermophilic & Extreme
Thermophilic ) may be damaged only and survive
No destruction of viable spores
To overcome these limitations High Temperature Sterilization or
UHT is required


Hot-Fill Technology for High Acid Beverages


Hot Fill Manufacturing Process
Major Control Points




Understand and control initial microbial load of food
ingredients and other incoming materials
Meet processing conditions











Product sterilization
Filling temperature
Head space and closure sterilization
Final product temperature

Sanitize incoming containers
Protect the filling environment
Perform system sanitation regularly
Monitor the quality of cooling water
Maintain GMP


Hot-Fill Line Main Components

Incoming Product
Thermal Processing System
Filler
Crowns

Rinser

Culiniary Steam
Treatment

Potable Water

Crowner
Head Space Sterilizer
Cooler
Date Coder
Secondary Packaging System

Quarantine & Release
Finished Product

Washer

Containers


Hot-Fill PET Line Main Components


requirements for Hot Fill












Washer validation
Blend beverage- Magnetic Separator & Strainer.
Blend beverage-Max Hold Time < 4 hrs (< 25*C).
Blend Syrup- Max Hold; < 18 hrs (< 25*C)
< 24 hrs (< 15*C)
Pasteurization 96-98*C for 5-10 secs.
Auto Low Temperature Divert.
Max Bev recirculation/bypass flow during
normal operation to be < 15% of beverage flow.
Cool bypass beverage < 38*C.


requirements for Hot Fill




Max time at Beverage full flow recirculation is
one pass through the process. (batch size X

flow rate).
Temperature recorders







Return line from CIP circuit.
Holding Loop Exit.
Filler Bowl or entry to Filler Bowl.
Recirculation cooling loop exit.

Filling Temperature; Filler Bowl not less than
86*C.


requirements for Hot Fill


Pasteurizer Heat Exchanger Design


To minimize the potential for product cross contamination in the
pasteurizer heat exchanger due to pinhole leaks or cracked plates by:
a) Monitor and record pressure readings in all sections of the pasteurizer
b) Maintain sterile product pressure at 1-5 psi higher than non-sterile (Heating
or cooling medium) pressure by:







Installation of an operational alarm activated by a pressure differential of
less than 1-5 psi. Automatic shut down for sanitation when pressure
drops to 0.
MOC –SS 304/316, 3A sanitary design, withstands 95-100*C for 30
minutes.
Recirculation system




enable partial to full-flow re-circulation (filler by-pass) capability
provide a line to drain or flush the system
cool re-circulated product typically to 38 °C, in a cooling heat exchange,
before return to the process


requirements for Hot Fill


Pasteurizer Heat Exchanger Design







Water used as heating or cooling medium is drinking quality. Hot
process water medium is generated in a clean loop using steam.
An inline meter is installed to measure flow through the heat
exchange system.

Before filling: pre-heat glass bottles
Heat Closure before application by directing culinary steam at the
inside surface for ≥ 0.1 second.



Closure & Headspace Heat Treatment Invert
containers or otherwise ensure interior surface is ≥ 77°C for no less than
7 seconds or equivalent.



Delay cooling for 45-60 seconds after filling.