Long-life products : heat-treated, aseptically packed : a guide to quality

1. UHT Processing ................................................... 3 1. General ............................................ 3 2. Indirect UHT Systems ................................ 4 3. Direct UHT Systems .................................. 5 4. Plant Sterilisation ....................................... 8 2. Aseptic Packaging ............................................... 9 1. General ............................................ 9 2. Sterilisation of the Packaging Material ...... 9 3. Sterile Environment .................................. 11 4. Production of Tight Containers ................ 12 3. Sterilising Effect ................................................ 15 1. General .......................................... 15 4. Hydrogen Peroxide as a Sterilant ................... 19 1. General .......................................... 19 2. Microbiological Aspects ........................... 19 3. Residual Hydrogen Peroxide .................... 20 4. Hydrogen Peroxide in the Environment ... 21 5. Packaging Material ........................................... 23 1. General .......................................... 23 2. Interactions between the Product and Packaging Material ................................... 24 3. Microbiological Aspects ........................... 27 6. Application of Microbiology to UHT Processing and Aseptic Packaging ....... 29 1. General .......................................... 29 2. Product Sterilisation ................................. 31 3. Packaging Material Sterilisation .............. 32 7. Installation .......................................................... 35 1. General .......................................... 35 2. Factory Surroundings ............................... 36 3. The Plant Layout ...................................... 36 4. The Equipment ......................................... 38 5. Installation of the Equipment ................... 39 C o n t e n t s 8. Cleaning and Housekeeping ............................ 41 A. Cleaning: 1. General ............................. 41 2. Manual Cleaning .............. 42 3. Cleaning in Place (CIP) .... 42 B. Housekeeping: .......................................... 47 1. External Housekeeping ..... 47 2. Internal Housekeeping ...... 48 9. Commissioning ................................................... 51 1. General .......................................... 51 2. Microbiological Performance ................... 51 10. Changes During Milk Processing ................... 57 1. General .......................................... 57 2. Acidity .......................................... 57 3. Water .......................................... 57 4. Lactose .......................................... 57 5. Milk Fat .......................................... 58 6. Milk Protein .......................................... 58 7. Minerals .......................................... 59 8. Freezing Point .......................................... 59 9. UHT-Induced Changes in Flavour ............ 60 10. Nutritional Value of Milk ......................... 61 11. Vitamins .......................................... 62 11. Product Changes During Storage ................... 65 1. General .......................................... 65 2. Water .......................................... 65 3. Lactose .......................................... 65 4. Milk Fat .......................................... 66 5. Milk Protein .......................................... 66 6. Minerals .......................................... 68 7. Freezing Point .......................................... 68 8. Sensory Characteristics ............................ 68 9. Vitamins .......................................... 69 12. Quality Control .................................................. 71 1. General .......................................... 71 2. Raw Material Control ............................... 73 3. Intermediate Product Control ................... 75 4. End-Product Control ................................ 76 5. Storage Control and Handling Complaints .......................................... 85 6. Hygiene Control ....................................... 87 9 C o n t e n t s 13. Quality Assurance (QA) and HACCP............ 89 1. General .......................................... 89 2. ISO 9000 .......................................... 91 3. Good Manufacturing Practices ................. 92 4. Hazard Analysis Critical Control Point .... 94 5. Quality System ......................................... 97 6. Comparison of a Quality Control System and a Quality System ................. 103 Example 1: QACP Chart .................... 104 Example 2: Flow Charts .................... 105 Example 3: A QACP for Long-Life Chocolate Milk ............... 117 Example 4: A Guide to the Introduction of Quality Assurance Systems in the Food Industry Based on the ISO 9000 Standard ......... 129 14. Troubleshooting ...............................................151 1. General ........................................ 151 2. The Intuitive Approach ........................... 151 3. The Systematic Approach ...................... 152 4. Examples of Troubleshooting ................ 164 15. Long-Life, Low-Acid Products ..................... 173 1. Long-Life Milk ...................................... 173 2. Goat’s Milk ........................................ 174 3. Recombined Long-Life Milk and Milk Products .................................. 175 4. Fruit-Flavoured Milk .............................. 179 5. Cream ........................................ 180 6. Whey-Based Products ............................ 183 7. Custards and Desserts ............................ 184 8. Formulations For Baby Food ................. 186 9. Vegetable Juice ....................................... 187 10. Wine ........................................ 187 11. Water ........................................ 189 12. Liquid Eggs ........................................ 191 16. Long-Life Acidified Products ........................ 193 1. General ........................................ 193 2. Yoghurt Production ................................ 194 17. Long-Life, High-Acid Products ....................197 1. General ........................................ 197 2. Microbiology of High-Acid Food .......... 198 3. Microbiology of Sugars and Syrups ....... 199 4. Water for Reconstitution ........................ 200 5. Factors Affecting Shelf Life ................... 201 6. Fruit Juices and By-Products ................. 201 7. Standards for Fruit Nectars .................... 206 18. Processing and Composition of Fruit Juice ............................209 1. General ........................................ 209 2. Citrus Juice ........................................ 209 3. Apple Juice ........................................ 215 4. Tomato Products ..................................... 217 5. Cranberry Juice ...................................... 219 6. Strawberry, Raspberry and Blackberry Juice ..................................... 219 7. Pineapple Juice ....................................... 220 8. Passion Fruit ........................................ 222 9. Mango Juice ........................................ 223 10. Guava ........................................ 224 11. Papaya ........................................ 224 12. Cashew Apple ........................................ 225 13. Litchi Juice ........................................ 226 19. Soya Bean Products ........................................227 1. General ........................................ 227 2. Processing ........................................ 227 3. Quality Improvement ............................. 230 4. Methods for Inactivating Anti-Nutritional Factors (Trypsin Inhibitors) ................................ 231 5. Soya Bean Drinks ................................... 231 6. Tofo and Sufu ........................................ 232 7. Examples ........................................ 233 20. Literature .................................................