Retort Processing Research Articles

Application of Soft Bone Milkfish Processing Technology for Processed Fish SMEs in The City of Semarang

Processed fish in the form of soft bone milkfish is a superior product of the city of Semarang that needs attention because it involves many business actors and has an influence on regional economic growth. However, there are still many obstacles related to production and marketing aspects. This paper is limited to handling production aspects in two fish processing SMEs in Semarang City, namely CV New Citra and UD Putri Laut. The problem faced by the two SME partners is that the production equipment for pressure cooking milkfish has a small capacity so that productivity is less than optimal. Another problem is that the shelf life of existing products is not long enough. To overcome this problem, the implementation team carries out community service using several methods, including socialization, training and mentoring. After the two tools were successfully created, the implementation team provided training and assistance on how to operate the two tools until the partners mastered and were skilled. Currently these two tools have been used in the pressure cooker milkfish production process, and have been proven to be able to increase production capacity and quality. Based on field observations, pressure cookers are able to increase production capacity by up to 300 percent, saving fuel costs by 66.66 percent. The retort tool succeeded in increasing product shelf life by up to 1 year, and saved retort costs of IDR 600,000, per retort process.

Pulsed Light and Retort Processing of Coconut Inflorescence Sap (neera): Process Optimization and Storage Stability

Pulsed Light and Retort Processing of Coconut Inflorescence Sap (neera): Process Optimization and Storage Stability

Organoleptic Qualities of Retort Processed Commercial Paneer Butter Masala Vs in-House prepared Paneer Butter Masala

Organoleptic Qualities of Retort Processed Commercial Paneer Butter Masala Vs in-House prepared Paneer Butter Masala

Computer-based monitoring system of retort processes for energy efficiency and carbon emission reduction

Retort sterilization is critical in the food industry. However, retorts are not smart enough to fully monitor and calculate their energy usage to reduce their carbon emissions. In this project, sensors and network equipment were installed in a retort, and a PC-based system was used to process the collected data. To monitor the sterilization status and energy consumption, we added flow sensors and electricity meters and built a visual identification system. Carbon emissions were calculated, and energy conservation and carbon emission reduction strategies were explored. According to the monitoring data, the electricity consumption of the air compressor, boiler, and natural gas combustion accounted for 80 % of the total carbon emissions. If the equipment cannot be changed, the cooling water system can be stopped in noncooling stages to conserve energy. This strategy reduced the energy consumption of the cooling system by 70 % and was the most effective strategy for this project.

Effects of different types of starches on heat penetration and physicochemical characteristics in alfredo sauce

Corn starch is frequently used as a thickening agent in food products because of its stability under thermal processing conditions. However, with fluctuating raw material costs due to weather conditions, disruptions in supply chains, and geopolitical challenges, there is an increasing need to explore alternative sources of starch. This study examines the effect of retort processing on the heat penetration and physicochemical aspects of modified corn, tapioca, and potato starches in Alfredo sauce. Modified corn starch, commonly used in commercial sauces, was compared with tapioca and potato starches to evaluate their effects on viscosity, color, and processing times required to achieve a F0 = 6 for Clostridium botulinum. Using the reference starch concentration of 1.90%, modified corn starch showed a significant increase in viscosity from 3,328 cP to 13,296 cP with a processing time of 31.33 min. Modified tapioca starch, at the same concentration, increased from 3440 cP to 8176 cP over 38.38 min, indicating superior thermal stability being the longest cooking time evaluated between all samples. For modified potato starch, using the reference concentration, viscosity increased from 1,200 cP to 4,656 cP, with a processing time of 31.93 min. Adjusting the starch concentration to 3% for modified tapioca starch and 2.38% for modified potato starch increased viscosity to 14,400 cP and 16,336 cP, respectively. These adjustments resulted in a darker Alfredo sauce, with the L value decreasing from 92.27 to 83.67 due to the longer cooking time. Heat penetration findings suggest that modified potato starch can replace modified corn starch safely using the reference concentration (1.90%) without altering the process holding time but requiring further adjustments to match commercial viscosity standards, while modified tapioca starch, although requiring higher concentrations and longer processing times, was tested for retention time at 3.00% and to be a feasible alternative. This study offers valuable insights to the food industry in selecting appropriate starches to maintain the quality and safety of thermally processed Alfredo sauce.

Characteristics of Indonesian traditional food “Ayam Taliwang” and “Sate Rembiga” packed by retort process: F0 - value, metal contamination and microbial analysis

Abstract “Ayam Taliwang” and “Sate Rembiga” are traditional foods from Mataram, West Nusa Tenggara, Indonesia with meat-based ingredients and have a short shelf life. In this study, the packaging of ready-to-eat food products with a retort process to increase shelf life was explored. The main objective of this study was to identify the packaging results of Indonesian traditional food “Ayam Taliwang” and “Sate Rembiga” by retort process, including parameters of Lethality value (F0 -value), metal contamination and microbial analysis. The procedure of this study was that the food samples were packed in aluminum foil, then vacuum sealed and processed in a retort. The retort processing temperature and time used were 121°C and 20 minutes. The results showed that the F0-value for “Ayam Taliwang” was 19.62 minutes, while the F0-value for “Sate Rembiga” was 30.32 minutes. Metal contamination test results for “Ayam Taliwang” showed that Plumbum (Pb) was 0.531 ppm, Cadmium (Cd) 0.0047 ppm and Arsenic (As) 0.0317 ppm, while Mercury (Hg) and Lead (Sn) were not detected. The metal contamination test for “Sate Rembiga” was Cd 0.0013 ppm, As 0.0104 ppm and Sn 1.1621 ppm, while Pb and Hg were not detected. Microbial contamination test results for “Ayam Taliwang” showed that Staphylococcus aureus and Clostridium perfringens were 10 colonies/gr, Enterobateriaceae were 10 colonies/gr, while Salmonella and Lysteria monocytegens were negative. “Sate Rembiga”, Staphylococcus aureus and Clostridium perfringens were found at 102 colonies/gr, while Enterobateriaceae, Salmonella and Lysteria monocytegens were negative. Therefore, ready-to-eat “Ayam Taliwang” and “Sate Rembiga” meet the requirements for distribution using the retort process.

Effect of Retort Processing on the Microbiological, Sensory Evaluation and Physicochemical properties of the Ready-To-Eat Grilled Beef

Retort processing is a method of preserving food by heating it in hermetically sealed containers like cans, glass jars and retortable pouches. Objective: The objective of this paper is to look at the effect of retort processing on grilled beef in retort pouches for microbiological, physicochemical, and sensory quality. Materials and Methods: Ready-to-eat (RTE) grilled beef was thermally processed at different Fo values (sterilization unit) of 8, 10 and 12 at the temperature of 121 °C. Before the thermal process, beef was marinated and grilled at 200 °C, for 20 min. The filled and sealed pouches were then subjected to retort processing for optimizing the Fo value at process temperature. Grilled beef without a retort process is subjected to a control sample. The effect of different Fo values on the microbiological (total plate count, yeast& mould, Ecoli, coliform. Salmonella and staph aureus) sensory evaluation and physicochemical properties were evaluated. Results: Results on the microbial analysis showed that there is no growth of bacteria for all Fo values tested. The sensory evaluation scored the highest for the product processed at 121 °C, Fo 12 for overall acceptance attributes. For moisture analysis, as the Fo value increases the moisture content decreases. Retort processed grilled beef had significantly lower L*, a* and b* values as the Fo value increases. Conclusion: It is concluded that grilled beef product retorted to Fo 12, 121 °C, had acceptable microbiological limits, highest score of organoleptic evaluation and acceptable physicochemical characteristics.

Development and Process Optimization of a Steamed Fish Paste Cake Prototype for Room Temperature Distribution

Surimi-based products typically demand cold storage and a cold chain distribution system, which not only affects their physical properties and flavor but also escalates production costs. In this study, we introduced a novel high-temperature and high-pressure retort processing method to enable room temperature storage and distribution of a surimi-based product, a fish paste cake. Our optimization efforts focused on refining the processing conditions for the fish paste cake. This included incorporating transglutaminase, sugar additives, natural herbal or seaweed extracts, and optimizing retort processing conditions to enhance textural properties, minimize browning and off flavor, and extend the shelf-life of the product. Our results demonstrated that the addition of 0.3% ACTIVA TG-K, 1.0% trehalose, and 0.5% sea tangle extract during the production process significantly enhanced the gel strength, minimized browning, and improved the overall flavor of the fish paste cake prototype. Importantly, the developed prototype exhibited favorable biochemical, textual, nutritional, and sensory properties, extending the shelf-life up to 160 days without compromising physical, chemical, or sensory attributes. In addition, the developed prototype exhibited improved elasticity, compared to control groups. The innovative process not only facilitates room temperature storage and distribution of surimi-based products but also holds potential for generating additional profits.

Processing and quality evaluation of dry beans (Phaseolus vulgaris) in flexible pouches

AbstractDry beans are a nutrient‐dense food with a history of processing in metal cans to improve convenience for consumers. Flexible retort pouches have been gaining popularity as a food package to replace metal cans because they are lighter in weight and require less energy to process. While there are potential benefits of using pouches for processed bean products, a pilot‐scale pouch processing protocol for beans is needed for testing to expand to wider commercial applications. To address that need, the objectives of this study were to optimize a pouch processing method for dry beans and assess the subsequent quality of pouch‐processed beans. Black and kidney bean genotypes from different field trials and production years and harvested by different threshing methods were used in this study. Pouch processing was conducted with two types of pouches at a pilot facility, and processing quality included texture, appearance, and color. Cooking time of dry seeds was assessed to understand how variety and environmentally induced differences in cooking time influence pouch processing quality. Kidney beans that required longer dry seed cooking times had firmer texture when pouch processed (r = .72, p < .01). Both genotype and production year impacted cooking time and pouch processing quality. Threshing method had a significant impact on the appearance of processed kidney beans, while it had no significant impact on the processing quality of black beans. Pouch processing requires 42% (at 245°F/118.3°C retort temperature) or 60% (at 250°F/121°C) less retort processing time compared with canning. Both foil and non‐foil pouches can be used to differentiate varieties for processing quality, but the non‐foil pouches require much less effort to seal. This study provides a detailed methodology for pouch processing and quality evaluation of dry beans and useful information for researchers and processors in future applications of using pouches as alternative packaging for processed beans.

Donor human milk: the influence of processing technologies on its nutritional and microbial composition.

Human milk is regarded as the gold standard nutrition for newborn infants, providing all nutrients required for adequate growth and development from birth to 6 months. In addition, human milk is host to an array of bioactive factors that confer immune protection to the newborn infant. For this reason, the supply of human milk is crucial for premature, seriously ill, or low birth weight infants (<1,500 g). When a mother's own milk is unavailable, donor human milk is the recommended alternative by the World Health Organization. Prior to consumption, donor human milk undergoes pasteurization to ensure the eradication of bacterial agents and prevent the transfer of potentially pathogenic organisms. Currently, Holder Pasteurization, a heat-based treatment, is the widely adopted pasteurization technique used by milk banks. Holder pasteurization has demonstrated degradative effects on some of milk's biologically active factors, thus depleting critical bioactive agents with known functional, protective, and beneficial properties, ultimately reducing the immunoprotective value of donor human milk. As a result, alternative strategies for the processing of donor human milk have garnered much interest. These include thermal and non-thermal techniques. In the current review, we describe the effects of Holder pasteurization and alternative milk processing technologies on the nutritional and bioactive properties of milk. In addition, the capacity of each technique to ensure microbial inactivation of milk is summarized. These include the most extensively studied, high-temperature short-time and high-pressure processing, the emerging yet promising techniques, microwave heating and UV-C irradiation, and the lesser studied technologies, thermoultrasonication, retort processing, pulsed electric field, and gamma irradiation. Herein, we collate the findings of studies, to date, to allow for greater insight into the existing gaps in scientific knowledge. It is apparent that the lack of a cohesive standardized approach to human milk processing has resulted in contrasting findings, preventing a direct comparative analysis of the research. We conclude that donor human milk is a unique and valuable resource to the health sector, and although substantial research has been completed, persistent data disparities must be overcome to ensure optimal nutrition for the vulnerable newborn preterm infant group, in particular.

Quality assessment of ready to eat baked mushroom slices after retort processing

Quality assessment of ready to eat baked mushroom slices after retort processing

Understanding retort processing: A review.

Retort processing is a food preservation technique to address the challenge posed by Clostridium botulinum for commercial sterility of a food product to get microbiologically safe and stable products by heating. This review aims to explore the journey of retort processing, starting from its early use in single-batch canned foods and progressing to its contemporary applications with different types of containers and heating mediums. Additionally, it will delve into the adaptability of retort equipment, including its ability to operate in stationary and various agitation states, as well as its flexibility in processing speed for both single-batch and continuous operations.

Effect of retort processing, containers and motion types on digestibility of black beans (Phaseolus vulgaris L.) starch

SummaryWith the growing demand for convenient and shelf‐stable canned beans, understanding the changes in starch digestibility due to retort processing is crucial for optimising nutritional quality and enhancing consumer health. The present study investigated the impact of retort processing, specifically container type and agitation, on the digestibility of black bean starch. Retort pouches exhibited a more rapid heat transfer rate to the enclosed product than cans, which reduced the overall processing duration. Also, the processing time to achieve a Fo = 6 of Clostridium botulinum was almost 2.5 min (pouches) and 3.2 min (cans) faster for the oscillating than the static mode. The in vitro digestibility data revealed that the retort processing of black beans led to an increase in rapidly digestible starch (RDS) from 10.51% to 32.11%. However, slowly digestible starch (SDS) decreased from 15.67% to 7.89%, and resistant starch (RS) decreased from 47.91% to 11.86%, regardless of the container type and motion involved. Processing enhanced starch digestibility in all the combinations of container and motions; nevertheless, black beans in pouches with oscillatory motion still contain a relatively significant amount of SDS and RS than the other combinations. These findings have important implications for the food industry in optimising processing techniques and packaging strategies to preserve the nutritional value of black beans. The findings of this study can have practical implications for food producers engaged in the retort processing of foods contained in pouches and cans. The investigation will provide insights into how the process of retort sterilisation affects digestibility, including slowly digestible starch and resistant starch of different types of starch.

Heat penetration and quality attributes of superheated steam sterilization (SHS) home meal replacement (HMR) meat products stew

Retort sterilization (RTS) is essential for the production of shelf-stable home meal replacement (HMR)-type Korean foods. However, the thermal abuse caused by excessive retort processing can result in quality degradation. Short processing times can minimize quality degradation and nutritional loss during sterilization. The potential of superheated steam sterilization (SHS) for producing shelf-stable HMR was investigated. The effect of SHS at 140 °C on HMR meat products stew was compared with that of RTS. SHS allowed a rapid temperature increase in the sausages and spam. In the sterilization equivalence of sausage, SHS at 140 °C and 1 s showed the F0 value of 34.7 ± 5.9 which could sufficiently satisfy the microbial safety standard of F0 values at 7–10 min. Thermal doses of SHS treated sausage was 97 ± 9 k°C·s which has lesser values (119 ± 9 k°C·s) than that of RTS. The sausage hardness after SHS was 107.7 ± 13.3 N, which has lower thermal degradation than the 78.9 ± 7.1 N observed after RTS. This study demonstrates the potential of SHS treatment for maintaining the quality of sterilized HMR products.

Physicochemical and sensory properties of retort chicken curry mousse fortified with branched-chain amino acids for the elderly

Although retort sterilization is effective in high-temperature sterilization of special nutritional products, its effect on sensorial and nutritional properties after sterilization has not been proven. The purpose of this study was to develop a BCAAs fortified chicken curry mousse (CCM) for the elderly that is easy to chew, swallow, and convenient to cook and consume at home. Additionally, it was to investigate the effect of retort processing on the sensory satisfaction and nutritional formula of the products. A viscosity thickener was added to set the thickener concentration based on the fork drip test of the International Dysphagia Diet Standardization Initiative. CCM was retort-treated at 121 °C for 30 min to evaluate its physicochemical (color, viscosity, rheology, texture, syneresis, pH, and amino acid analysis) and sensory properties. The viscosity decreased and texture changed smoothly after retorting, and the color became darker. The syneresis and pH of the retorted mousse showed fewer changes than the non-retorted during 12 days. Retorted products were increased the BCAAs, and scored high in overall acceptance in the sensory evaluation. Therefore, the BCAAs-enriched retort CCM developed in this study is expected to hedonically appeal to the elderly as well as benefitting their muscle health and nutrition.

Effect of Retort Processing on The Nutritional Content of Ready-to-eat Winged Bean Seeds (Psophocarpus tetragonolobus)

Winged bean seeds are a source of vegetable protein and other important nutrients, and have the potential to be developed into ready-to-eat food to increase the level of consumption in society. The purpose of this study was to determine the effects of different levels of sterilization (F0) on the proximate composition of canned winged bean seeds. This study used a randomized block design (RBD) method with three levels of sterilization, F0 5, 7, and 9. The results showed that different levels of sterilization (F0 5, 7, and 9) had significant effects (P&lt;0.05) on the moisture, carbohydrate, and protein content, but had no significant effect (P&gt;0.05) on the ash and fat contents of sterilized winged bean seeds. The moisture and carbohydrate content increased as the F0 value increased. In contrast, protein levels of sterilized winged bean seeds decreased as the F0 value increased. Winged bean seeds sterilized with an F0 value of 9 had the highest levels of moisture and carbohydrates among the other two sterilization levels, but had the lowest protein content. The process of canning winged bean seeds using thermal sterilization is an alternative to maintaining the nutritional value of winged bean seeds. However, it still had a minimal effect on the nutritional content of winged bean seeds.

Effects of Microwave Pasteurization on the Quality and Shelf-Life of Low-Sodium and Intermediate-Moisture Pacific Saury (Cololabis saira).

The objective of this study was to investigate the effects of microwave pasteurization on the quality and shelf-life of low-sodium and intermediate-moisture Pacific saury. Microwave pasteurization was used to process low-sodium (1.07% ± 0.06%) and intermediate-moisture saury (moisture content 30% ± 2%, water activity 0.810 ± 0.010) to produce high-quality ready-to-eat food stored at room temperature. Retort pasteurization with the same thermal processing level of F90 = 10 min was used for comparison. Results showed that microwave pasteurization had significantly (p < 0.001) shorter processing times (9.23 ± 0.19 min) compared with traditional retort pasteurization (17.43 ± 0.32 min). The cook value (C) and thiobarbituric acid (TBARS) content of microwave-pasteurized saury were significantly lower than that of retort-pasteurized saury (p < 0.05). With more microbial inactivation, microwave pasteurization brought better overall texture than retort processing. After 7 days of storage at 37 °C, the total plate count (TPC) and TBARS of microwave pasteurized saury still met the edible standard, while the TPC of retort pasteurized saury no longer did. These results showed that the combined processing of microwave pasteurization and mild drying (Aw < 0.85) could produce high-quality ready-to-eat saury products. These results indicate a new methodology for producing high-quality products stored at room temperature.

Effects of container type and size on thermal processing characteristics and B-vitamin retention of canned cat food.

Rigid cans were the traditional container for canned cat foods, but semi-rigid trays/tubs and flexible pouches are popular options as well. Despite this, little is published on the effects of canned cat food container characteristics on thermal processing and retention of B-vitamins. Therefore, the objective was to evaluate the effects of container size and type on thermal processing and B-vitamin retention. Treatments were arranged in a factorial with two container sizes [small (85-99 g) and medium (156-198 g)] and three container types (flexible, semi-rigid, and rigid). A canned cat food formula was prepared, filled, and sealed into containers before retort processing to a heating cycle target lethality of 8 min. Internal retort and container temperatures were used to calculate accumulated lethality. Thiamin, riboflavin, niacin, pantothenic acid, pyridoxine, biotin, folic acid, cobalamin, and moisture contents were analyzed in pre- and post-retort samples by commercial laboratories. Thermal processing metrics were analyzed (SAS v. 9.4; SAS Institute, Cary, NC) with the fixed effects of container size, container type, and their interaction. Dry matter basis B-vitamin contents were analyzed with container size, container type, processing stage, and all two-way and three-way interactions as fixed effects. Means were separated using Fisher's LSD at a P-value < 0.05. Total accumulated lethality was greater (P < 0.05) for semi-rigid and flexible containers (average 14.99 min) than for rigid containers (12.86 min). The greater processing of semi-rigid and flexible containers was likely influenced by required retort settings. Thiamin and riboflavin contents decreased (P < 0.05) by 30.4 and 18.3%, respectively, due to retort processing. Niacin, biotin, and cobalamin were not affected (P > 0.05) by processing. Processing increased (P < 0.05) pantothenic acid (9.1%), pyridoxine (22.6%), and folic acid (22.6%). This was likely caused by sampling or analytical variation. No interaction involving processing stage was significant for any B-vitamin (P > 0.05). B-vitamin retention was not influenced by differences in thermal processing caused by the packaging treatments. Thiamin and riboflavin were the only B-vitamins meaningfully impacted by processing and retention was not improved by any container characteristic.

Development of ready-to-eat (RTE) liwet rice with corn analog rice substitution as an alternative food in emergency conditions

This research aims to develop ready-to-eat (RTE) rice based on local food, namely liwet rice which is substituted with corn analog rice. This RTE rice is intended for food supplies in disaster emergencies and still contributes to the food diversification program. The RTE liwet rice production carried out in this study was by using the retort process. The retort process was carried out using an autoclave at 121 0C for 15 minutes and used retort pouch packaging. The RTE liwet rice in this study made used five formulations of corn analog rice substitution, namely 0%, 20%, 30%, 40%, and 50%. The resulting liwet rice was then analyzed for its physicochemical and organoleptic characteristics. The results showed that the substitution of corn analog rice had a significant effect on the proximate content and physical properties (texture and color) of the liwet rice produced but did not significantly affect the pH and organoleptic characteristics. The best formula in this study was obtained in the 30% substitution of corn analog rice.

Optimization of Retort Processing Parameters for the Production of Ready-To-Serve Flavored Skimmed Coconut Milk

ABSTRACT Coconut skim milk is the main by-product in the virgin coconut oil industry, nutritious, but under exploited. This work aims to develop a process protocol for ready-to-serve (RTS) flavored coconut milk employing retort pouch processing. The effect of retort processing parameters such as temperature (80–100°C) and time (10–30 min) on sample quality were studied and optimized using Response Surface Methodology by considering the organoleptic and physicochemical properties. Results showed that retorting at 85°C for 30 min offered the best sensory scores for de-fatted coconut milk. The retort processing enhanced the microbial safety of the flavored-RTS during storage with a minor change in microbial loads and with minimal changes in the quality.