A complete course in canning and related processes, volume 2 microbiology, packaging, HACCP and ingredients

11 A Complete Course in Canning consists of Three Books This is Book 11 The books are designed to be used together However, the contents are separated in a manner so that they can be used separately If Book I or I11 is desired, contact the publisher The Contents of Book I include the following Chapters: Creating A Business Plan Plant Location And Construction Food Laws, Regulations And Standards Kosher And Halal Food Regulations A Food Labeling Guide; Water Energy Requirements And Supply Food Processing Residuals Treatment And Disposal Canning Operations; Equipment And Sanitary Design Process Room Operations Sterilization Systems; Cleaning And Sanitizing Warehousing Of Canned Foods Appendix, Glossary of Terms Figures, Charts, Tables The Contents of Book III include: Canning of Vegetables Canning of Fruits Canning of Juices and Fruit Drinks & Water Canning of Dry Pack Products Canning of Marine Products Canning of Meat and Poultry Products Canning of Soups Preserves (Jams),Jellies and Related Products Pickles Mayonnaise and Salad Dressing Products Manufacture of Canned Baby Foods Tomato Products Evaporated Milk Canned Meat and Vegetable Salads Appendix, Glossary of Terms Figures, Charts, Tables 111 BOOK 11 MICROBIOLOGY, PACKAGING, HACCP 8c INGREDIENTS A technical reference book and textbook for studentsof food technology,food plant managers, product research and development specialists, food brokers, technical salesmen, food equipment manufacturers, and food industry suppliers Revised and Enlarged by DONALD L DOWNING, PH.D Professor of Food Processing New York State Agricultural Experiment Station Cornell University Geneva, New York A PUBLICATION OF CTI PUBLZCATIONS, INC Baltimore, Maryland 212184547 USA 410-467-3338 FAX 410-467-7434 iv A COMPLETE COURSE IN CANNING While the recommendations in this publication are based on scientific studies and industry experience, references to basic principles, operating procedures and methods, or types of instruments and equipment, and food formulas are not to be construed as a guarantee that they are sufficient to prevent damage, spoilage, loss, accidents or injuries, resultingfim use of this information Furthermore, the study and use of this Publication by any person or company is not to be considered as assurance that that person or company is proficient in the operations and procedures discussed in this publication The use of the statements, recommendations, or suggestions contained, herein, is not to be considered as creating any responsibilityfor damage, spoiluge, loss, accident or injury, resulting from such use COPYRIGHT 01996 BY CTI PUBLICATIONS, INC all rights reserved No part of this book may be reproduced in any form or by any means-graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval system, without written permission from the publishers ISBN Numbers are as follows: 0930027-256 0-930027-26-4 0930027-27-2 l%930027-2&0 - A COMPLETE COURSE IN CANNING, (3 Volume set), 13th Edition, 1996 Hardbound A COMPLETE COURSE IN CANNING, Volume I, 13th Edition, 1996, Hardbound A COMPLETE COURSE IN CANNING, Volume 11, 13th Edition, 1996, Hardbound A COMPLETE COURSE IN CANNING, Volume III.13th Edition 1996, Hardbound Library of Congress Catalog-In-Publication Data A Complete Course In Canning and Related Processes - 13th Edition Revised and Enlarged by Donald L Downing P cm Includes bibliographical references and indexes Contents: Book I Fundamental Information On Canning; Book I1 Microbiology, Packaging, HACCP 8c Ingredients Book 111 Processing Procedures for Canned Food Products ISBN 0-930027-25-6 (Set); ISBN 0-930027-26-4 (BK I); ISBN 0-930027-27-2 (BK 11); ISBN 0-930027-28-0 (BK 111) Canning and preserving I Downing, Donald L., 1931 TP371.3.C66 1996 664'.0282 dc20 96-8381 CIP V PREFACE This book is being presented in three parts: Book I, I1 and 111 Book I includes updated information on canning operations spanning from Business Plan, Plant Location and Construction Through Warehousing, and including, among other subjects, "Food Laws, Regulations and Standards," "Labeling," "Preparing Kosher Foods," "Processing Room Operations," and "Sterilization Systems"; Book I1 presents the subjects of "Microbiology of Canned Foods,""Packaging," "Quality Control," "HACCP," "Computer Aided Manufacturing," and "Ingredients," as they apply to food processing, and particularly to canning Book I11 contains specific procedures for over 210 canned food products, and for salad dressing and pickle products This 13th edition of A Complete Course in Canning contains chapters not included in previous editions These are "Creating a Business Plan," "Kosher Food Manufacturing," "Labeling," "HACCP," and "Computer Aided Manufacturing." Further, the 13th edition contains several significantly expanded chapters These are "Plant Location and Construction," "Food Laws," Regulations and Standards," "Microbiology of Canned Foods," "Metal Containers," "Glass and Plastic Containers," and "Ingredients." The Glossary of Terms has been enlarged to include many technical terms that have come into common usage in the food processing industry These terms are found in federal and state regulatory literature, and quality control procedures, container specifications, descriptions of new technological methods, and in other food processing publications All the material included in this edition has been reviewed and updated This work could not have been done without the cooperation of many individuals and firms and the U.S.Food and Drug Administration National Food Processors Association deserves special recognition, because information from several of its excellent publications was used, and because helpful advice on several topics was received from several of its scientists, as well as many others It is hoped that this 13th edition of A Complete Course in Canning will be useful to food processors, to other persons associated with the food industry, and to students of food science and technology The updating of this 13th Edition would not have been possible without the earlier work of Anthony Lopez, Ph.D., Professor Emeritus, VPI & State University who developed the 9th through 12th Editions For this earlier work we are extremely grateful Thank you Dr Lopez Lastly, I would like to thank my wife, Rochelle, Olga Padilla Zakour, and Julia Chia-Day Fu for their help during the preparation of the manuscript Donald L Downing Geneva, New York May 1996 This Book Belongs To: TABLE OF CONTENTS CHAPTER 1.MICROBIOLOGY OF CANNED FOODS INTRODUCTION 11 Basic Considerations on pH Value 11 Influence Of pH On Food Microbiology and Spoilage 12 Effect of Temperature on Growth Of Microorgansims 14 pH And Growth of Closridium Botulinum 14 Acidity Classificationof canned Foods 14 Botulism 15 Methods of Commercial Control of Botulism 16 Botulism Outbreaks 17 Spoilage of Canned Foods 20 Low-Acid Canned Foods 20 Acid Foods 20 Types of Spoilage of Canned Foods 23 Swells : 23 Pinholing 24 Flat Sours 24 Stack Burning 25 Food Discoloration 25 Black Stains 26 Glass-Like Deposits in Canned Foods 26 Off Flavors 26 Spoilage By Recontamination 27 Precautions For Handling Filled and Sealed Containers 27 General Sources and Control Of Spoilage Due To Contamination 28 Specific Sources of Spoilage Due To Contamination 31 Corn 31 Peas, Beans, etc 31 Pumpkin 32 Spinach 32 Sources of Contamination Of Vegetables In General 34 Microbiological Standards For Ingredients 35 Standards for Sugars and Syrups 36 VIII MICROBIOLOGY PACKAGING HACCP 8c INGREDIENTS CHAPTER HEAT PENETRATION DETERMINATIONS AND THERMAL PROCESS CALCULATIONS pH Classification of Canned Foods High-Temperature Short-Time Processing Thermal Death Time Heat Penetration Determinations Equipment Procedure for Making a Heat Penetration (HP) Test Equipment Check Making the Heat Penetration Test Plotting Heat Penetration Curve Process Calculations Methods of Analyzing Data Standards The Graphical or General Method The Formula Method Simple Heating Curve Broken Heating Curve Summary HTST Process Calculation Symbols Used Computerized Data Acquisition and Evaluation of Thermally Processed Foods 40 40 42 45 51 51 56 56 57 59 62 62 62 63 71 71 93 93 97 98 98 105 CHAPTER METAL CONTAINERS FOR CANNED FOODS Tin Plate Cans Three-Piece Cans Types of Steel Plate Soldered side seam Cemented side seam Welded side seam Two-Piece Cans Draw and redraw Drawn and ironed Tin Free Steel (TFS) Recommended Can Sizes Truck Trailer Shipping of Empty Cans Carload Shipping of Empty Cans Can Corrosion Fundamental Electrochemical Basis of Can Corrosion Internal Corrosion 105 105 106 106 108 108 110 110 111 112 112 114 123 124 125 126 TABLE OF CONTENTS METAL CONTAINERS FOR CANNED FOODS Continued Factors Influencing Internal Corrosion External Corrosion Corrosion Attributable To Canning Practices Fill and Vacuum Thermal Exhausting Code Marking Faulty Closures Washing the Sealed Can Open Water Bath Operation Steam Retort Operation Contact with Rusty Iron Contact with Alkaline Water Improper Cooling Corrosive Water Supplies Scratches and Abrasions Corrison Attributable To Storage Conditions High Storage Temperature Sweating Other Causes of Rusting Can Enamals (Linings, Coatings) Types of Enamels Application of Enamels Desired Qualities of Enamels Trends Evaluation of Enamels Can Seam Inspection Visual Examination of Double Seams Tear-Down Examination of Can Seams Essential and Optional Seam Measurements Tearing Down The Double Seam For Inspection Adequacy of Double Seams and Recognition of Defects Micsellaneous Information On Cans The Half-Size Steam Table Tray Thermal Processing Vacuum Determination Double Seam Evaluation Aluminum Cans Plant Handling of Aluminum Cans Corrosion Resistance Liquid Nitrogen Injector System Ix 127 127 127 127 128 128 128 129 129 130 131 131 131 132 132 133 133 133 134 134 135 136 136 136 137 138 141 144 144 145 155 158 161 162 164 164 165 166 168 169 X MICROBIOLOGY PACKAGING HACCP 8c INGREDIENTS METAL CONTAINERS FOR CANNED FOODS Continued Fruit and Vegetable Canning Meats and Seafoods Carbonated Beverages and Beer Non-Carbonated Beverages Collapsible Tubes Flexible Packages and Semi-Rigid Containers Shipping Cases Casing 169 170 170 170 170 172 172 172 CHAPTER GLASS AND PLASTIC CONTAINERS 173 Glass Containers 173 Vacuum Closures-General Characteristics 174 Factors Affecting Vacuum Formation 174 175 Method of Cold Water Vacuum Check Vacuum Closure Application for Glass Containers 175 Auxiliary Equipment 175 Headspacer 175 Cocked-Cap Detector and Ejectors 175 Dud Detectors 176 Closures for Glass Containers-Applications 176 176 Vacuum Sealing Shipping Containers and Casing 187 Commercial Packaging Of Food Products In Plastic Containers 187 Consumer Acceptance 188 Container Design/Structure 189 Shelf Life Requirements/Product Compatibility 190 192 Decorating Technique 193 Filling Line Requirements Sealing Techniques/Tamper Indication 196 Warehousing and Transportation 198 Plastic Package Recycle Potential 199 CHAPTER RETORTABLE FLEXIBLE CONTAINERS Introduction Products Packed in Retortable Flexible Containers Structure Of Flexible Containers Retort Pouch Forming, Filling and Sealing Semi-Rigid Containers-Filling and Sealing Formed Pouches Forming, Filling and Sealing 201 201 204 204 208 212 212 SUBJECT INDEX Acesulfame-K, 18 Acidification, 15 Acidified foods, 15 Acidity classification of canned foods, 14 Acidity, total, 278 Acidulants, 412 Additives, color, 397 Additives, food, 337 functions, 338 incidental, 337 intentional, 337 safety, 340 Adipic acid, 414 Aerobic sporeformers, bacteria, 20 Agar, 379 Agitating cookers, 42,45 Alginates, 387 Aluminum cans, 165 beverages, 170 corrosion resistance, 168 fruit and vegetable, 169 liquid nitrogen injector system, 169 meats and seafoods, 170 plant handling, 166 Aluminum, collapsible tubes, 170 flexible packages, 171 semi-rigid containers, 171 Aluminum sulfate salts, 416 Anthocyanins, 127 Antibiotics, 406 Antimicrobial agents, 404 Antioxidants, 406 Ascorbic acid, 406 Aseptic bulk storage, 255 Aseptic anring, fiuing and sealtng, 244 products, 245 systems, 240 Aseptic drum fillers, 247 automated filling, 250 quadraseptic system, 247 Aseptic filling, 244 Aseptic packaging, 225 classification of packages, 225 low-acid foods, 239 packaging materials, 226 regulations, 259 reprocessing, 246 sterilization of equipment, 238 storage, 258 systems, 230 testing and start-up, 238 Aseptic sealing, 244 Aseptic transportation, 255 Aspartame, 418 Autosterilization, 21 Bacillus cereus, 367 Bacteria aerobic mesophilic spore-formers, 20 flat sour producing, 20 non-spore-forming,20 putrefactive anaerobic, 20 sulfide spoilage, thermophilic, 20 thermophilic anaerobic, 20 B,, 74, 75, 95 Benzoic acid, 404 Bleaching, starch, 360 Botulism, 15 commercial control, 16 outbreaks, 17 Brik-Pak, 231 476 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS Brine, 342 AOAC measurement, 344 dispensing, 342 regulations, 343 Bulk storage, aseptic, 255 Bulking agents, 417 Butylated hydroxyanisole (BHA), 406 Butylated hydroxytoluene (BHT), 406 Byssochlamysfulva, 41 “C” enamel, 135 Calcium salts, 416 Can seams cemented, 108 inspection, 138 measurements, 144 recognition of defects, 155 soldered, 106 tear-down examinations, 144 visual examination, 141 welded, 108 Canned foods high-acid, 41 low-acid, 41 pH classification, 40 Canned foods acidity classification, 14 high-acid, 15 low-acid, 14 microbiology of, 11 Cans draw and redraw, 110 drawn and ironed, I11 enamels, I34 three-piece, I05 tin plate, 105 two-piece, 110, 165 washing, 129 Cans, aluminum, 165 beverages, 170 corrosion resistance, 168 fruit and vegetable, 169 liquid nitrogen injector system, 169 meats and seafoods, 170 plant handling, 166 Cans, corrosion, 124 control of canning practices, 127 external, 127 fundamental electrochemical basis, 125 internal, 126 storage conditions, 133 water cooling, 131 water supplies, 132 Cans, empty carload shipping, 123 truck trailer shipping, 114 warehousing, 160 Caps, glass containers, 180 Carbohydrates in canning and preserving, 346, 347 corn syrup, 351 dextrose, 348 fructose, 350 high fructose corn syrup, 354 invert sugar, 351 levulose, 350 maltodextrins, 356 mannitol, 364 modified starches, 363 sorbitol, 364 starch, 356 sucrose, 350 Carrageenan, 388 Cases, shipping, 171 Casing, 172 CCP decision tree, 289 SUBJECT INDEX Cemented side seam, 108 Chelating agents, 408 Citric acid, 408,415 Clostridium botulinum, 20,44,367 botulism, 15 pH value, 14 thermal death time curve, 50 Closures, can corrosion, 128 Code marking, can corrosion, 128 Collapsible tubes, 170 Color additives, 397 certified, 399 classification, 400 use in processed foods, 402 Combibloc system, 234 Complaints, 309 recording, 310 responding, 310 Computerized maintenance management systems (CMMS),331 Computer-integrated management, 331 Computer-integrated manufacturing, 329 HACCP, 334 nutritional labeling, 334 product development, 334 production control, 332 use in food industry, 331 Containers, glass, 173 metal, 103 plastic, 187 retortable flexible, 201 semi-rigid, 201,225 Continuous thread (CT) caps, 180 Control point, 289 Cooling, can corrosion, 131 Cookers, agitating, 45 hydrostatic, 42 477 open flame, 42 Corn syrup, high fructose, 354 Corn syrup, 351 Corrosion, cans, 124 Corrosive water supplies, 132 Critical control point (CCP), 289 Critical defect, 289 Critical limit, 289 Crossbonding, starch, 361 Cut-Out Brix, 276 “D”value (decimal reduction value), 47 Danish agar, 382 Detinning, can corrosion, 126 Dextrose, 348 Discoloration of food, 25 Discoloration, can corrosion, 126 Dole aseptic canning system, 245 Dole aspetic packaging system, 237 Double seams, visual examination, 141 Drained weight, 274 Drawn and ironed cans, 11 Drawn-redrawn cans, 110 Dud detector, 176 Efficientconsumer mponse (ECR), 332 Emulsifiers, 395 Enamels, can, 134 application, 136 “C” enamel, 135 Enamel Rater, 137 epoxy and epoxy-phenolic, 135 evaluation, 137 lifting, 126 oleo-resinous, 135 phenolic, 135 powdered, 135 qualities, 136 “R” enamel, 136 - 478 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS Enamels - Continued trends, 136 vinyl, 136 waterbase, 135 Enamel Rater, 137 Epoxy enamels, 135 Erythorbic acid, 406 Essential oils, 367 Ethylene diamine tetraacetic acid (EDTA), 408 applications, 410 regulatory status, 410 EVOH (Ethyl vinyl alcohol), 205 Expert systems, 330 Extractives, soluble, 368 spray-dried, 368 Fat replacers, 419 "fJUn value, 74, 75 "Finvalue, 74 Fill weight, 274 Firming agents, 416 Flat sour, 24 producing bacteria, 20 Flexible containers, retortable, 201 Flexible packages, 171 Flipper, 23 F, value, 48 "Fonvalue, 74 Food additives, 337 color additives, 397 functions, 338 safety, 340 Formula method, heat penetration, 62, 71 Fructose, 350 Fumaric acid, 414 Furcellaran, 382 Fuzzy logic, 330 Gasti system, 236 Gel strength, 392 Gelatin, 389 desserts, 393 for clarification, 395 gel strength, 392 jellied meats, 394 General method, heat penetration, 62, 63 Generally recognized as safe (GRAS), 338,396 Geotrichum candidum, 35 Glass containers, 173 dud detector, 176 headspace, 174 vacuum check, 175 vacuum closures, 174, 175 vacuum sealing, 176 Glucose, 348 Graphical method, heat penetration, 62, 63 Guar gum, 383 Gums, water soluble, 375 agar, 379 alginates, 387 Carrageenan, 388 characteristics, 376 classification, 378 Fucellaran, 382 gelatin, 389 Guar gum, 383 gum Arabic, 379 gum ghatti, 381 gum Karaya, 381 gum tragacanth, 385 locust bean gum, 384 Xantham gum, 386 Gum Guaiac, 406 HACCP Plan, 289 Half-size steam table tray, 161 Hardware, 329 SUBJECT INDEX Hazard Analysis and Critical Control Point (HACCP),285 assemble the HACCP team, 292 CCP decision tree, 289 critical control point, 289 critical defect, 289 HACCP plan, 289 identify the CCPs, 294 purpose and principles, 290 records, 301 Headspace, 174,272 Heat penetration curve, 52,72 curve, plotting, 59 data, 58, 62 determinaitons, mechanism, 39 tests, 56 Heating curve, broken, 61,93 simple, 60,71 High fructose corn syrup, 354 High-acid foods, 15 High-Temperature Short-Time processing (HTST), 42 calculation, 97 Honey, microbiological standards, 37 Hydrocolloids, 375 Hydrogen peroxide (H202),229 Hydrostatic cookers, 42 Hydrostatic sterilizer, 214 Incidental additives, 337 Indian gum, 381 Ingredients, food, 337 Initial temperature (IT), 45,73 Intelligent systems, 330 Intentional additives, 337 International Paper system, 235 Invert sugar, 351 I S 9000 series, 281 479 "j" value, 73 L plate, 106 Lethal rates, table, 64 Lethal ratio, 63 Levulose, 350 Liqui-Pak system, 236 Liquid nitrogen injector system, aluminum cans, 169 Locust bean gum, 384 "log g" value, 74 Low-acid foods, 14 aspectic packaging, 239 Lug caps, 182 Malic acid, 414 Maltodextrins, 356 Mannitol, 364 Manufacturing, computer-integrated, 329 Market withdrawal, product recalls, 314 MC plate, 106 Mesophiles, 14 Metal Box "FreshFill" system, 236 Microbiology of canned foods, 11 Molasses, 37 Molds, canned foods spoilage, 20 Modified starch, 360 use of, 363 Monosodium glutamate (MSG), 339,372 acceptable daily intake, 374 regulations, 373 standards of identity, 374,375 MR plate, 106 Net weight, 278 Networks, 329 Nitrites, 406 480 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS Oleo-resinous enamels, 135 Oleoresins, 367 Open flame cookers, 42 Open water bath operation, can corrosion, 129 Oxidation, 407 Packages for aseptic packaging, 225 Packaging systems, aseptic, 230 Parabens, 404 Perforations, can corrosion, 126 pH value, basic considerations, 11 classification of canned foods, 40 growth of Chtridium botulinum, 14 influence on food microbiology, 12 measurement, 278 of selected foods, 13 Phenolic coatings, 135 Phosphoric acid, 408,416 Pinholing, can, 24 Plant inspection, daily, 267 Plastic containers, 187 consumer acceptance, 188 design/structure, 189 filling line requirements, 193 recycle potential, 199 shelf life requirements, 190 transportation, 198 warehousing, 198 Plate, type L, 106 type MC, 106 type MR, 106 Polyester, 204 Polyethylene, 205 Polypropylene, 204 Post consumer resin (PCR), 199 Potassium chloride, 344 Potentiometers, 55 Pouch, retort, 201 advantages and disadvantages,221 critical defects, 221 critical factors in sterilization, 216 forming, filling, sealing, 208 quality control tests, 218 structure, 204 thermal sterilization, 213 Powdered coatings, 135 Preservatives, 403 mechanisms, 403 Propyl gallate (PG), 406 Psychrotrophs, 14 Putrefactive anaerobes, bacteria, 20 PVDC (polyvinyledenechloride),205 Quality control canned foods, 271 flavor, 278 headspace, 272 in-plant, 261 IS0 9000 series, 281 laboratory facilities, 263 line samples, 269 net weight, 278 organization, 261 personnel requirements, 263 pH measurement, 278 plant inspection, 267 purchasing raw products, 278 sanitation survey, 266 total acidity, 278 vacuum, 271 water, 270 Quality control tests, retortable flexible containers, 218 "R" enamel, 136 Raw products, purchasing, 278 Recall team, product recall, 315 Recalls, 309 FDA, 313 information required, 316 SUBJECT INDEX 48I Recalls - Continued quality control tests, 218 market withdrawal, 314 aseptic packages, 225 procedure, 319 Sequestering agents, 407 product, 312 Shipping cases, 171 recall team, 315 Side seam, welded, 108 stock recoveries, 314 cemented, 108 strategy elements, 318 soldered, 106 USDA, 313 Slowest Heating Zone (SHZ), 99 Records Sodium sulfite, 406 complaints, 310 Software, 337 HACCP, 301 Soldered side seam, 106 laboratory facilities, 263 Sorbates, 405 plant inspection, 267 Sorbitol, 364 Regulations, aseptic processing, 259 Spices, 365 monosodium glutamate (MSG), 373 microbiology of, 366 Reprocessing, aseptic packaging, 246 quality evaluation, 366 aspetic storage, 258 storage, 368 Rusting, 129,134 Spoilage, acid foods, 20 can corrosion, 126 beans, 31 Retort rusting, 130 corn, 31 Retortable flexible containers, 201 low-acid canned foods, 20 advantages and disadvantages,221 peas, 31 critical defects, 221 pumpkin, 32 critical factors in sterilization, 216 recontamination, 27 products, 204 spinach, 32 structure, 204 vegetables, 34 thermal sterilization, 213 Springer, 23 Springers, can corrosion, 126 Saccharin, 417 Stack burning, 25 Safety, food additives, 340 Staining, can corrosion, 126 Salmonella, 367 Starch, 356 Salt, 341 bleaching, 360 AOAC measurement, 344 modifications, 360 bulk dispensing, 345 viscosity reduction, 360 purity, 341 Steam retort operation, tablet depositors, 344 can corrosion, 130 tablets, 344 Steel plate, 106 Sanitation survey, daily, 266 Stock recovery, product recalls, 314 Scholle Aseptic filling system, 254 Succinic acid, 415 Semi-rigid containers, 201 Sucrose, liquid, 37,350 filling and sealing, 212 microbiological standards, 37 482 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS Sugar, microbiological standards, 36 Sulfur dioxide, 406 Surfactants, 395 Sweating, can corrosion, 133 Sweetners, 347 Acesulfame-K, 418 Aspartame, 418 corn syrup, 351 dextrose, 348 fructose, 350 glucose, 348 high fructose corn syrup, 354 invert sugar, 35 levulose, 350 maltodextrins, 356 saccharin, 417 sucrose, 350 Swells, 23, 24 Syrup, corn, 351 fountain, 37 microbiological standards, 36 Tampering, product, 312 Tamper evident, 197 indicating, 197 proof, 196 Tartaric acid, 408 Temperature, initial, 45, 73 can corrosion, 133 Tetra Pak, 231 Textured vegetable proteins, 369 Thermal death time (TDT), 45 Thermal exhausting,can corrosion, 128 Thermocouples, 53, 58 Thermophiles, 14 Thermophilic anaerobes, bacteria, 20 Three-piece cans, 105 Tin free steel (TFS), 112 Tocopherols, 406 Total Qdity Management (TQM),280 Two-piece cans, 110, 165 Vacuum, canned foods, 271 Vegetable proteins, textured, 369 advantages, 371 PER value, 371 Vinyl enamels, 136 Viscosity, starch pastes, 371 Vision systems, 338 Warehousing, empty cans, 160 Water base coatings, 135 Water quality control, 270 Welded side seam, 108 Wooden equipment, contamination control, 29 Xanthan gum, 386 Yeasts, canned foods spoilage, 20 "z" value, 47 Figures Index FIGURE 2.1- Mechanism of Heat Penetration FIGURE 2.2 - Heat penetration curve for pea puree in 603x700 can "still retorted" at 252°F 39 43 FIGURE 2.3 - Heat penetration curve for peas in brine in 307x409 can "still retorted" at 252°F 43 Process Determination for Low-Acid Products 44 Decimal Reduction Time Curves (D = 10 min.) 46 Mini-Retort System for TOT Determination 47 Close-up View of Two of the Six Mini-Retorts in the Mini-Retort System for TDT Determination 48 FIGURE 2.8 - Retort Baskets and 208 x 006 TOT Cans Used in Mini-Retort System for TOT Determination 49 FIGURE 2.9 - Diagram of Mini-Retort System for TDT Determination 49 FIGURE 2.10- Classical Thermal Death Time Curve for Clostridium botulinum 50 FIGURE 2.11 - Heat Penetration Curve for Can at Cold Point and Retort Temperature (Drawn on semi-log graph paper) 52 FIGURE 2.12 - Non-Projecting Type Thermocouple (Ecklund) 53 FIGURE 2.13 - Plot of a Simple Heating Curve (Straight Line) 60 FIGURE 2.14 - Plot ofa Broken Heating Curve 61 FIGURE 2.15 - Lethal Rate Curve 69 FIGURE 2.16 - Equivalent Lethality Curves with Retort at 260 and 250°F Corn in No.2 Cans 70 FIGURE 2.17 - Heat Penetration Curve 72 FIGURE 3.1 - Architecture of the Enameled Sanitary Tin Can 104 FIGURE 3.2 - Steps in Soldered Can Manufacturing 107 FIGURE 3.3 - Profiles of Soldered Side Seam and of Welded Side Seam 108 FIGURE 3.4 - Tinplate Can with Welded Side Seam 109 FIGURE 3~5 - Flow Chart of Drawn Can Manufacturing 110 FIGURE 3.6 - Two-piece Draw/Redraw Sanitary Can 111 FIGURE 3.7 - Schematic Corrosion of Cell of Iron in Acid Environment 125 FIGURE 3.8 - Can Enamel Rater 138 FIGURE 3.9 - Video Seam Monitor 139 FIGURE 3.10- Schematic of Can Seam Projector 141 FIGURE 3.11 - Double Seam Terminology 145 FIGURE 2.4 FIGURE 2.5 FIGURE 2.6 FIGURE 2.7 - 484 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS FIGURE 3.12 - Use special can opener to cut out center 146 section of cover FIGURE 3.13 - Use nippers and remove remainder of center of cover 146 FIGURE 3.14 - Using nippers, cut through double seam about one inch from lap 147 FIGURE 3.15 - Double seam micrometer 147 148 FIGURE 3.16 - Measuring seam width (height, length) FIGURE 3.17 - Measuring seam thickness 148 FIGURE 3.18 - Measuring countersink depth using a special depth gage 149 149 FIGURE 3.19 - The point of the countersink depth gage pin 150 FIGURE 3.20 - Long body hooks FIGURE 3.21- Correct first operation 150 151 FIGURE 3.22 - Loose first operation FIGURE 3.23 - Normal double seam 151 FIGURE 3.24 - Wide double seam 152 FIGURE 3.25 - Measuring body hook length using double seam micrometer 152 FIGURE 3.26 - Short body hooks 153 FIGURE 3.27 - Long cover hooks 153 FIGURE 3.28 - Measuring cover hook length using double seam micrometer 154 FIGURE 3.29 - Short cover hooks 154 FIGURE 3.30 - Can seam saw 155 FIGURE 3.31 - Tightness (Wrinkle) Rating in Percentage 156 FIGURE 3.32 - An irregularity in a double seam 157 FIGURE 3.33 - A false seam 157 FIGURE 3.34 - Area of tin plate required for cans having the same capacity but different dimensions 159 FIGURE 3.35 - Area of tin plate required to contain unit volume of product decreases as the capacity of the can increases 159 FIGURE 3.36 - A vacuum seamer to automatically vacuumize and double seam the half-size, 105 f1 oz., institutional tray 161 FIGURE 3.37 - The half-size institutional tray can has a capacity of 105 ounces 162 FIGURE 3.38 - Retort baskets loaded with half-size tray cans 163 FIGURE 3.39 - Half-size steam table tray 164 FIGURE 3.40 - How All-Aluminum Beverage Cans Are Made 167 FIGURE 4.1- Plain Round Jar 177 FIGURE 4.2 - High Shoulder Jar 178 FIGURE 4.3 - Round Food Line Bottle (Short Neck) 179 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS 485 FIGURE 4.4 - Nomenclature of Glass Containers for Foods 180 181 FIGURE 4.5 - The "Guard-Seal" Cap FIGURE 4.6 - The "Tamper-Seal" Cap 181 FIGURE 4.7 - Six-Station, Rotary Glass Container Capper 182 FIGURE 4.8 - Glass Container Steam-Vacuum Capping Machine in Operation 183 FIGURE 4.9 - Schematic of "Twist-Off Cap on Glass Container Finish 183 FIGURE 4.10 - "Twist-Off" or Lug Cap 184 FIGURE 4.11 - Press-On, Twist-Off Finish GlassJar 184 FIGURE 4.12 - Press-On, Twist-Off Cap 185 FIGURE 4.13 - Schematic of "Press-Twist" Cap on Glass Finish 185 FIGURE 4.14 - Electronic Dud Detector to Automatically Reject Low-VacuumJars 186 186 FIGURE 4.15 - Tumbler Cap-DSR FIGURE 4.16 - Glass Container Coder 187 FIGURE 5.1- Retort Pouch and Overwrap Carton 202 FIGURE 5.2 - Semi-Rigid Aluminum Containers 203 FIGURE 5.3 - Structure of the Retort Pouch 205 FIGURE 5.4 - Section View of Lid and Body of High Barrier Multi-Layer, Plastic Retortable Container 206 FIGURE 5.5 - Semi-Rigid, Retortable Containers with High Barrier 207 Lidding Materials and Lids FIGURE 5.6 - Flow Chart of Bartelt Intermittent Motion Pouch Packager209 FIGURE 5.7 - Steam Flow Pouch Filler/Sealer 210 FIGURE 5.8 - Pouch Filler/Sealer 211 FIGURE 5.9 - Conduction Heating in the Retort Pouch and in a Cylindrical Can 217 FIGURE 5.10 - Heating Characteristics of New Containers Compared to Standard Cylindrical Cans 218 FIGURE 5.11- Seal Strength of the Retort Pouch 219 FIGURE 5.12 - Retort Pouch: Heating, Opening, Serving and Disposing 222 FIGURE 6.1 - 6-ply Construction of Shelf-stable Pure-Pak Package 228 FIGURE 6.2 - Sterilization as a Function of Hydrogen Peroxide Concentration, Time and Temperature 230 FIGURE 6.3 -Tetra Pak Machine Operation 232 FIGURE 6.4 - The Tetra Brik Model AB-9 Machine 233 FIGURE 6.5 - Tetra Brik Packages 234 FIGURE 6.6 - Schematic Diagram of an Aseptic Canning Line 241 FIGURE 6.7 - Comparison of Product Heating Curves for Thermal Processes of Equivalent Lethality in an Aseptic System 242 FIGURE 6.8 - Dole Aseptic Canning System 243 486 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS FIGURE 6.9 - Aseptic Canning Line 246 FIGURE 6.10 - Spartenburg Aseptic Containers 247 FIGURE 6.11 - FranRica "Quadraseptic" Drum and Tank Filling System 248 FIGURE 6.12 - 55·gallon Sterile Pack Drum eliminated through efficient rinsing 251 FIGURE 6.13 - ABF·1200 Aseptic Bag Filler 253 FIGURE 6.14 - The Scholle Aseptic Filling System for Bag-in-Box and Drum Filling 254 FIGURE 6.15 - Tomato Storage 257 258 FIGURE 6.16 - The "Asepticar" FIGURE 7.1 - Organization and Function ofa Quality Control (QC) Department 261 264 FIGURE 7.2 - The Succulometer 271 FIGURE 7.3 - Measuring Gross Headspace FIGURE 7.4 - Bostwick Consistometer 272 FIGURE 7.5 - LabScan II Spectrocolorimeter combines a 0°/45° sensor linked to an IBM personal computer 273 FIGURE 8.1 - First Six Steps for the Development of a HACCP Plan 291 FIGURE 8.2 - Critical Control Point Decision Tree 296 FIGURE 11.1 - Salt Storage Tank with 72·Ton Capacity 342 FIGURE 11.2 - Liquid Dispensing System (Courtesy Scienco) 343 FIGURE 11.3 - Dry Bulk Dispenser for Salt 345 FIGURE 11.4 - Part A Repeating Units of Anhydroglucose 357 Parts B & C Linking of Anhydroglucose Units 357 FIGURE 11.5 - Formation of Linear Polymer 358 FIGURE 11.6 - Branched Polymeric Structure 358 361 FIGURE 11.7 - Hydrolysis of the Bond FIGURE 11.8 - The gelatin liquor is concentrated and chilled to form strands of gel which appear like spaghetti 390 FIGURE 11.9 - The strands of gelatin gel are conveyed to drier belts and taken through a drier consisting of 10 heating zones 391 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS 487 Tables Index TABLE 1.1 - The pH Scale 11 TABLE 1.2 - Mean pH Values of Selected Foods 13 TABLE 1.3 - Human Botulism Outbreaks Involving U.S Commercially 18 TABLE 1.4 - Worldwide Botulism Outbreaks, 1973-1991 19 TABLE 1.5 - Spoilage Manifestations in Low-Acid Products 21 TABLE 1.6 - Spoilage Manifestations in Acid Products 22 TABLE 1.7 - Laboratory Diagnosis of BacterialSpoilage 22 TABLE 2.1 - Lethal Rates For z = 18 64 TABLE 2.2 - Heat Penetration Data 68 TABLE 2.3 - Effect of 3°F Errors in Retort Temperature on Fo Value of Heating Phase of TypicalProcesses for 303 x 406 Cans 71 TABLE 2.4 - Correction Factors for "j" 73 TABLE 2.5- LOG G Given FH/U (m+g = 180°F, z = 18·F) 76 TABLE 2.6 - Fi Values for Various Retort Temperatures (OF) 83 TABLE 2.7 - FH/U for GivenLOG G (m + g = 180°F, z = 18·F) 84 TABLE 2.8 - rbh For GivenLOG G (In Hundreths) (m + g = 180°F, z = 18·F) 94 TABLE 2.9 - CalculatedSterilizing Values (Fo) for Some Current Commercial Processes 96 TABLE 2.10 - Definition of Terms and Symbols 100 TABLE 3.1- Percent Composition of Grade A Tin Used for Food Cans 105 TABLE 3.2 - Chemical Composition of Four Typesof BaseSteel 106 TABLE 3.3 - Recommended Can Sizes 113 TABLE 3.4 - Characteristics of Cans Used for Canned Food Products 115 TABLE 3.5 - PalletizedCans in Trailers 122 TABLE 3.6 - PalletizedCans in Trailers 123 TABLE 3.7 - Inspection Frequencies ~ 140 TABLE 3.8 - Record of VisualExternal Seam Examination 142 TABLE 3.9 - Recording Double Seam Measurements 143 TABLE 3.10 - Equivalent, in Cases of 24/300's'of the More CommonlyUsed Cans 158 TABLE 3.11 - Capacity and Conversion Factors of Cans Most CommonlyUsed in Canning Fruits and Vegetables 158 TABLE 3.12 - Tin Plate Basis Weights 160 TABLE 3.13 - Recycling of Aluminum Cans 166 TABLE 3.14 - Internal Coatings Used on Aluminum Cans and Ends 169 488 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS TABLE5.1 - Overall Heat Transfer Coefficient (u) of Various Heating Media TABLE5.2 - Critical Defects in Pouches TABLE 7.1 - Relation Between the Refractive Index at 68°F (20°C) and the Percent by Weight of Sugar (Brix) TABLE 11.1- Recommended Hardness of Can Brine for Various Vegetables TABLE 11.2 - Canned Foods That Usually Contain Added Carbohydrates TABLE 11.3 - Carbohydrate Functions TABLE 11.4 - Corn Syrup Classification TABLE 11.5 - Corn Syrup, Typical Composition (Carbohydrate Basis) TABLE 11.6 - Corn Syrup Properties vs Dextrose Equivalent TABLE 11.7 - Typical Compositionand Properties (HFCS) TABLE 11.8 - Typical Chemical Analysis of Thermoplastic Extruded Soy Products TABLE 11.9 - Standards of Identity: Monosodium Glutamate Use in Canned Foods "Code of Federal Regulations," Title 21 TABLE 11.10 - Standards of Identity: Monosodium Glutamate Use in Meats and Poultry "Code of Federal Regulations," Title TABLE 11.11 - Summary of Functions of Plant Hydrocolloids in Foods TABLE 11.12 - Summary of Characteristics of Plant Hydrocolloids TABLE 11.13 - Classification of Plant Hydrocolloids TABLE 11.14 - Chemical Groupings of Natural Plant HydrocoUoids TABLE 11.15 - Food Color Additives Exempted From Certification or Uncertified Food Color Additives TABLE 11.16 - Current List of Certified Color Additives and Their Restrictions Permanently Listed Under 1960 Color Additives Amendment to FD&C Act TABLE 11.17 - Current List of Certified Color Additives and Their Closing Dates Permanently Listed Under 1960 Color Additives Amendment to FD&C Act TABLE 11.18 - Problems with Food Color Additives and Their Probable Causes TABLE 11.19 - Typical Sorbate Use Levels TABLE 11.20 - Antioxidants for Food Use TABLE 11.21- Sequestering Agents TABLE 11.22 - Chelation is an Equilibrium Process TABLE 11.23 - Stability Constants of Metal-EDTA Complexes 214 221 277 341 347 347 352 353 353 355 370 374 375 376 377 378 378 398 400 400 401 405 406 408 408 409 MICROBIOLOGY, PACKAGING, HACCP & INGREDIENTS 489 Forms Index FORM 9.1 FORM 9.2 FORM 9.3 FORM 9.4 - Product Recall Product Coding Press Release Guideline Problem Information Report 323 324 326 327 Appendix Index APPENDIX TABLE 1- Temperature Conversion 421 APPENDIX TABLE - Conversion Factors, English to Metric 425 APPENDIX TABLE - Metric Conversion Table 429 APPENDIX TABLE4 - Decimal Equivalents, Hundreths Of A Millimeter Into Inches 430 APPENDIX TABLE - Decimal Equivalents Inches To Millimeters 431 432 APPENDIX TABLE - Metric Weights and Measures APPENDIX TABLE 7- Tin Plate Basis Weights 433 434 APPENDIX TABLE - Case Equivalents APPENDIX TABLE - Can Dimensions/Conversions u.s System to Metric 435 APPENDIX TABLE 10 - Container Dimension Conversion Chart Metric to U S System 436 438 APPENDIX TABLE 11 - Sodium Chloride Brine Tables for Brine APPENDIX TABLE 12 - Normal pH Ranges of Selected Commercially Canned Foods 440 APPENDIX TABLE 13 - Calculated Sterilizing Values (F0) for Some Current Commercial Processes 442 ... Packaging Materials for Aseptic Packaging 22 6 Materials Used in the Manufacture of Packages for Aseptic Packaging .22 7 Sterlization Of Packaging Materials And packages 22 9 Aseptic Packaging... Prinicples 26 1 26 1 26 3 26 3 26 4 26 5 26 6 26 7 26 9 27 0 27 1 27 1 27 2 27 2 27 4 27 4 27 4 27 6 27 8 27 8 27 8 27 8 27 8 27 9 28 5 28 7 28 8 29 0 29 1 29 1 TABLE OF CONTENTS XI11 HACCP Continued 4.1.Assemble... 21 8 Advantages And Disadvantages Of Retortable Flexible Containers 22 1 CHAPTER PACKAGES FOR ASEPTIC PACKAGING 22 5 22 5 Classification of Aseptic Packages Basic Characteristics of Packaging