Our research team started a project to look at why we are pasteurizing at 95 °C and holding the temperature for 15 seconds. Is it possible that our temperature is too high? Could we lower it and still have the same product quality with uncompromising food safety? Yes we can. Our team has proven that we can lower the energy cost by 20% by lowering the temperature. We can design our process more flexible than other beverage pasteurizers with uncompromising food safety. Want to know more? Download the whitepaper here: http://ow.ly/rQB44

1. State of the art technology
Optimized high-acid pasteurization
MS/2013-11

2. Dramatically lowered energy cost made possible
through technology research
►
Uncompromising food safety
► Lower energy cost by 20%
−
►
Improved environmental performance
World-leading in heat transfer technology
−
Research study
− Patent
MS/2013-11
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3. Progressing cutting-edge technology
80°C/15s
►
New lower recommendation
► Microbiology research study and lab test
► PDC and customer field test
to verify result – proof
► Pasteurization unit control
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4. Research study
and customer site validation
MS/2013-11

5. Microorganisms of concern
JNSD pH<4.2
95-98°C/10-30 s
►
The traditional recommended heat
treatment of JNSD is 95°C/15 s
Primary pasteurization immediately
after squeezing to deactivate enzymes
and kill microorganisms
−
►
95-98°C for 10-30 s
A second pasteurization is usually
performed prior to filling
− Recontamination
during bulk storage
95°/15s
Heat resistance
►
of NFC juice
− Contamination while juice reconstituted
from concentrate
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6. Target organism
Possibility to reduce heat treatment
►
Possibility to reduce heat
treatment of JNSD
Growth study on bacterial
spores’ possibility to grow
at pH<4.2
95°/15s
?
Yeast ascospores
72°C/15s
Heat resistance
►
Bacterial spores
Spores of heatresistant moulds
Yeast
Moulds
Acid-tolerant bacteria
Pathogenic bacteria
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7. Growth test with bacterial spores at low pH
Result: No growth at pH<4.2
►
Orange and apple juice
► Adjustment of pH to 3.5, 3.8, 4.0, 4.2
► Inoculation with spores or vegetative cells of selected bacteria
−
Spores: B. lichenformis, P. polymyxa, Cl. pasteurianum, Cl. butyricum
− Vegetative cells: B. megaterium, B. coagulans, P. macerans
►
►
5 replicates for each juice/pH/species
Incubated at room temperature for 3 weeks
Result: No growth in any of the juices at any of the pH levels
Conclusion: The tested bacterial spores are not an issue in juice with pH<4.2
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8. Results and theoretical log reductions
Calculations confirmed. Target 9 log reductions
Test results:
Theoretical log reductions based on D and z values:
Temperature / time
Sterile packages
65°C/15 s
0%
72°C/15 s
100%
80°C/15 s
Optimized highPut & de Jong 2 Tetra Pak 3
acid pasteurization
Temp 1
D63= 1.6 min
D60= 22 min
D65= 19 s
z=5.4°C
z=6.5°C
z= 5.5°C
100%
95/15
2 755
225 000
80/15
222
13.57
421
77/15
62,0
4.69
120
72/15
7.39
0,8
14.79
65/15
Conclusions: the test results confirm the
theoretical log reduction calculations
131 800
0.38
0,07
0.79
1 Apple
2
juice, pH 3.5, 2013
Buffer solution, pH 4.5, 1982
3 Orange
juice, pH 3.8, DR8671, 1997
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9. Verification of commercial sterility
Tested at Valio, Finland, June 2013
►
4000 litres orange juice
−
►
►
►
►
►
pH 4.0, 11.3°Brix, initial load: 90 CFU/ml
Processed at 78°C/22 s (=80°C/9.5 s)
Packed in Tetra Prisma® Aseptic (250 ml), 16 000 packages
Incubated at ambient temperature (20-23°C) for 3 weeks
Inspected for gas formation
1043 packages streaked (10 μl) at OSA at Tetra Pak®, Lund
Results: No gas formation in 16 000 packages;
no growth detected from 1043 streaked packages
Conclusion: Commercial sterility achieved
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10. Process recommendation
Prerequisites
►
Turbulent flow required
► Content of Alicyclobacillus – negative in 10 g / 10 ml
► Content of Byssochlamys – negative in 10 g / 10 ml
Product
Juice, second pasteurization, pH<4.2
Juice, first pasteurization, enzyme deactivation
Nectar, pH<4.2
Set point* / holding time
80°C / 15 s
95-98°C / 10-30 s
80°C / 15 s if turbulent flow
Still drinks, pH<4.2
JNSD pH 4.2-4.6
JNSD pH>4.6
Juice with pulp
80°C / 15 s
123°C / 15 s
138°C / 4 s
80°C / 15 s
JNSD with particles
Based on particle size
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11. Pasteurization
at lower temperature
MS/2013-11

12. Pasteurization at lower temperature
Same quality with unique control
►
Pasteurization unit (PU) control
−
International patent pending on total heat load control
− Each product has its own PU value and
by controlling this we secure the right pasteurization
MS/2013-11 / 12

13. Pasteurization at lower temperature
Reduction of energy consumption and carbon footprint
Tetra
Therm® Aseptic
Drink
Product: Orange juice, 12°Brix
Capacity: 10 000 l/h
Production scenario: two shifts, 5 days/week, 50 weeks/year
Production: 15 hours/day
Heat treatment process
95°C/15 s* 80°C/15 s*
Difference
Heating load
kW
182
153
-16%
Cooling load
kW
70
40
-43%
Production cost per year
kEUR/year
42
34
-17%
Production cost per 1000 litre EUR/1000 litre
1.11
0.92
-0.19 EUR
/1000 litre
Carbon footprint
7.1
6,0
-16%
kg CO2/1000 litre
* Reduced from PU value similar to 95°C/15 s to 80°C/15 s
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14. Impact of process
temperature and increased dT
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15. Impact of process temperature and increased dT
Process temperature 80°C or 95°C and dT 3-25° C
►
Taste
−
►
Colour
−
►
Process temperature and increased dT
do not impact taste of orange juice made
from concentrate
Process temperature and increased dT
do not impact colour of orange juice made
from concentrate
Vitamin C
−
Process temperature and increased dT
do not impact Vitamin C degradation
of orange juice made from concentrate
MS/2013-11 / 15

16. Impact of process temperature and increased dT
Taste
►
External taste panel by IPSOS Marketing, Kristianstad, Sweden
−
6 weeks storage at ambient temperature
− 80°C/dT=3°C vs. 95°C/dT=25°C (extreme values)
− 95°C/dT=5°C vs. 95°C/dT=12°C (reference process vs. increased dT)
− 95°C/dT=5°C vs. 95°C/dT=25°C (reference process vs. further increased dT)
Result: No significant difference in taste in any of the three tested pairs
Conclusion: Process temperature (80-95°C) and increased dT
do not impact taste of orange juice made from concentrate
A
A
B
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17. Impact of process temperature and increased dT
Colour
►
Visual appearance evaluated once a month
► Photographed using DigiEye
(consistent light conditions) after 3 and 7 months
Results: The juice was overall darker
after 7 months storage than after 3 months.
At each evaluation point no difference
could be detected between the samples
Conclusion: Process temperature (80-95°C) and increased dT
do not impact colour of orange juice made from concentrate
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18. Impact of process temperature and increased dT
Vitamin C reduction
Vitamin C content was analyzed
by HPLC at Eurofins after 3.5
and 6 months storage
Results: Normal Vitamin C decrease due to
OTR and anaerobic degradation
Conclusion: Process temperature (80-95°C)
and increased dT do not impact
Vitamin C degradation of orange juice made
from concentrate
Vitamin C content (mg/l)
►
Vitamin C content of orange juice during
ambient storage
380
370 *
360
350
340
330
320
310
300
0
80°C/dT=3°C
80°C/dT=15°C
95°C/dT=5°C
95°C/dT=12°C
95°C/dT=25°C
2
4
6
8
Storage time (months)
* Initial Vitamin C content measured on frozen raw
material 3.5 months after processing
MS/2013-11 / 18

19. Conclusions
►
►
►
Second pasteurization of orange juice
with pH<4.2 can be reduced from
95°C/15 s to 80°C/15 s
dT of orange juice can be increased
from 5°C up to 25°C without impact on
taste, colour or Vitamin C content
Increased flexibility as more products
can be run with the same configuration
MS/2013-11 / 19

20. Dramatically lowered energy cost made possible
through technology research
►
Uncompromising food safety
► Lower energy cost by 20%
−
►
Improved environmental performance
World leading in heat transfer technology
−
Research study
− Patent
MS/2013-11 / 20