UHT Theory LTH

Tetra Pak
UHT technology Seminar LTH
PSD.TPD&B.BP.1.01, AA10
Presented by
Andrzej Holanowski, PhD
Senior Dairy Technologist Tetra Pak Dairy & Beverage Systems AB Lund, Sweden
Aseptic processing
on ta in er C
Aseptic environment
Sterilisation
Pr u od ct
Sterilisation
Filling & sealing
Aseptically packaged product

UHT definitions
Sterilisation
A process applied to a product with the object of destroying all microorganisms (by heat treatment at a temperature exceeding 100C)
Sterile
Condition in which living cells are absent or killed
Steriliser
Equipment used for sterilisation: autoclave, hydrostatic steriliser or aseptic processing plant
Commercial sterility
Product which is free from micro-organisms that can grow and contribute to its deterioration (Not absolutely sterile)
Aseptic
Conditions to prevent bacteriological contamination
Long-life products
Low-acid pH >4.5
milk products, tea, coffee, liquid food products containing vegetables
High-acid pH <4.5
juices, fermented milk products, fruit products
UHT what do we need to achieve ?

In low acid foods (specifically milk):
Required bacteriological effect expressed as:
- Reduction of Clostridium botulinum spores to the level of 10-12 or 1 of initial 1012 survives - public health requirement (12D reduction or Fo= 3 process) - Reduction of thermophilic spores by minimum 9D (B*>1) guarantying commercially sterile product
Minimised chemical changes expressed as:

- Decomposition of thamin (vit. B1) less than 3% (C*<1) - Lactulose value <600 mg/l - undenaturated -Lactoglobulin >50 mg/l
UHT what do we need to achieve ?

In low acid foods (specifically milk):
Biochemical stability expressed as:
- Maximal reduction of enzymatic activities in the heat treated product
Physical and chemical stability:

- No phase separation (fat, proteins, serum) - No sedimentation
Raw milk quality

for processability: pH 6.65-6.80 alcohol stability >75% total Count of bacteria for sterility level: limit of heat resistant spores
Classification of bacteria by temperature preference

Thermophilic
45 C
Mesophilic
20 C
Psychrophilic
7 C
Psychrotrophic
Bacterial formation of spores

1
1 Viable bacterium 2 Nuclear content gathered (at bad growing conditions)
3 A thick wall is formed around the nucleus (the spore) 4 The cell decomposes and the spore is liberated
5 The spore is free
6 At favourable conditions the membrane of the spore bursts and a new cell will be formed
No. TP70:68, 9311BM
Commercial sterility
The commercially sterile product must:
Keep without deterioration, stable and good commercial value during storage Free from micro-organisms and toxins harmful to the health of consumers Free from any micro-organisms liable to proliferate during storage
Legislation and suggestions for heat treated milk products

UHT
Heat treatment >135C and >1 s
(Council directive 92/46/EEC)
Sterile
Lactulose* >600 mg/l or -Lactoglobulin* <50 mg/l
(*IDF and ECC suggestions)
--------------------
Lactulose* <600 mg/l -Lactoglobulin* >50 mg/l

(*IDF and ECC suggestions)
Heat treatments definitions

Pretreatment
Thermisation Pasteurisation 6365C/15 sec 63C/30 min Preliminary heating Pasteur's method rare today (batch pasteurisation)
Heat treatment Chilled distributed products

HTST pasteurisation HTST pasteurisation HTST pasteurisation Ultra pasteurisation UHT Conventional sterilisation 7275C/15 sec 8590C/25 sec 90120C/25 sec 125138C/24 sec 135150C/415 sec approx. 116C/20 min Milk Cream Fermented products Cold storage Ambient storage Ambient storage
Ambient distributed products
HTST = high temperature short time, UHT = ultra high temperature
Definition of D-value
D-value (decimal reduction time) is the time at a specific temperature necessary to reduce the number of micro-organisms to 1/10 of the original value
N
Number of micro-organisms 105 104 103 102 101 100 10-1 10-2
Micro-organisms D121 C B. cereus Cl. botulinum. B. stearothermophilus 2.3 sec. 12.25 sec. 408 sec.
e = nt ta ns co r tu
m te ra pe
D time, t
Rate of thermal death of micro-organisms at high temperatures depends on:

Type of micro-organism
vegetative bacteria (high) viruses (medium) endospores (law)
Medium surrounding micro-organisms

pH, water activity (aw), concentration and type of food components i.e. (simple carbohydrates, fats, chemical ions, type of acid and )
Absolute sterility not possible

N Bacteria
Logarithmic destruction Time/temperature would be too drastic Not possible to prove by random testing Not possible to prove sterility (prove absence)
t Time
Definition of z-value
z-value is the increase in temperature, necessary to obtain the same lethal action or the same effect in 1/10 of time
time, t [s] 103 102 101 100 10-1
Temperature dependance z-value [C] B. stearothermophilus 10.5 Colour changes 29.0 Losses of vitamin B1 31.2 Losses of lysine 30.9
z
temperature
Definition of F-value
t Fo = 60
. 10
(T 121.1) z
t = heating time, seconds T = heating temperature, C z = the increase in temperature necessary to obtain the same effect in one tenth of the time.
Fo = 1 when heated one minute at 121.1C
Definition of B*-value
t . B* = 10 10.1
(T 135) 10.5
Assumption: Commercial sterility is achieved at B* = 1

(heat treatment at 135 C for 10.1 sec., z = 10.5)
= reduction of thermophilic spores = 109
Definition of C*-value
t . C* = 10 30.5
(T 135) 31.4
C* = 1 = heat treatment at 135C for 30.5 sec. and z = 31.4C = 3% destruction of thiamine
UHT treatment
Time-temperature combinations needed for destruction of spores
Heating time or equivalent heating time, S
Region of in-container sterilisation

90% Ps -L
2000 1000 400 200 100 40 20 10 4 2 1 110 120

3% D
ipa s
ed
tiva no d tion i sco est o t e l o ruc as e tion inac uration tiva of t tion h ia min 1% e Des truc tion o f ly s
90%
Ps-p r
e-a c
A
ine
Mesophilic spores 30oC Thermophilic spores 55oC
UHT region
B
150 Temperature oC
130
140
Heat effects
Decimal reduction time, sec 10 6 Bacteriological destruction 10 5 Enzyme inactivation 10
4
Chemical destruction
10
Temp, C 110 120 130

No. TP70:38, 9305BM
Heat effects
Temperature
C minutes (z=10C)
Fo
Time 360 45 14 5 5
seconds
seconds (z=31.4 C)
C*
121 130 135 140 141
6.0 6.0 6.0 6.0 8.3
4.23 1.02 0.46 0.24 0.25

PSD.TPD&B.PEH.6.09, AA10
UHT Ultra High Temperature processes

Continuous processes
Temp 150 Direct UHT Indirect UHT Temp F 300
Batch sterilisation in container

Temp C Temp F
Continuous processes
100 200 Pasteurisation
50 100
Time
Seconds
Time
Minutes PSD.TPD&B.BP.2.16, AA10
Shelf-life of milk
The time the product can be stored before the quality falls below an acceptable and minimum level Subjective criteria:
Taste Colour Smell Gelation Sedimentation Fat separation Viscosity
Factors influencing shelf-life

Quality of raw product (chemical and microbiological) Pretreatment process Type of aseptic processing system used Homogenisation/deaeration Post heat treatment contamination non-sterile Aseptic packaging Barrier properties of packaging material
Main factors affecting the flavour of UHT milk

Milk quality Type and severity of heat treatment Packaging material Storage temperature and time
Sensoric changes in UHT milk

Duration of storage (week)
Off flavour Sulfur Cooked Metal Stale Rancid/Bitter
10
12 14
5 C
Optimum Sulfur Cooked Metal Stale Rancid/Bitter

Source: Blanc
25 C
Optimum
No. TP70:61, 9311BM
Sensory Quality of UHT Milk Heated Flavour - four notes

Cooked, Sulfurous, Cabbagey Various sulfur compounds Rich, Heated,UHT, Keton-like Products of Maillard reaction Caramelized, Sterilized Non-enzimatic browning Scorched, Burned Burn-on heating suffaces
No. TP XX:XXX, JF06
Sensory Quality of UHT Milk Heated Flavour

The cooked flavour appears immediately after UHT treatment and is reduced during storage with rate dependant on availability of oxygen an temperature of storage.
No. TP XX:XXX, JF06
Sensory Quality of UHT Milk Stale and Oxidized flavour

Stale Aldehydes from autooxidation of fat Ketons, Propanal N-Pentanal N-Hexanal Brownning reactions
No. TP XX:XXX, JF06
Oxidized, Flat Bland Chalky Cardbordy
Sensory Quality of UHT Milk Stale and Oxidized flavour

Stale and oxidized flavour develops during storage while the cooked flavour is disappearing. It depends on a large number of different compounds. Aldehydes and ketons play the major role. Formation of oxidised flavour is accelerated by high storage temperature.
No. TP XX:XXX, JF06
Sensory Quality of UHT Milk Other off-flavours

Bitter flavour Proteolitic activities of plasmin and bacterial thermoresistant proteases. Lipolitic activities of native and bacterial lipases.
No. TP XX:XXX, JF06
Rancidity
Lactose and heat effects

Lactulose Acetaldehyde Formaldehyde Formic acid pH drop Acetic acid Lactic acid Tartaric acid Maillard reactions products brown colour antioxydents
No. TP70:49, 9309BM
Loss of vitamins in UHT milk

Vitamin
Ascorbic acid Folic acid B12 B6 B2 (riboflavine) Thiamine A D E
Losses by (%) UHT Ambient Sensitivity to treatment storage Light Oxygen

080 1020 030 020 <10 <10 Very low Very low Very low Up to 100 Up to 100 Up to 100 1520 10 +++ + +++ ++
Notes
Antioxidant AA-antioxidant
Pyridoxine-fortification Light-induced flavour
Higher degradation in fortified products


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Tetra Pak

UHT technology Seminar LTH

Filling & sealing

Aseptically packaged product

UHT what do we need to achieve ?

Minimised chemical changes expressed as:

UHT what do we need to achieve ?

Physical and chemical stability:

Raw milk quality

Classification of bacteria by temperature preference

Bacterial formation of spores

5 The spore is free

Legislation and suggestions for heat treated milk products

Lactulose* <600 mg/l -Lactoglobulin* >50 mg/l

Heat treatments definitions

Heat treatment Chilled distributed products

Ambient distributed products

HTST = high temperature short time, UHT = ultra high temperature

Rate of thermal death of micro-organisms at high temperatures depends on:

Medium surrounding micro-organisms

Absolute sterility not possible

Fo = 1 when heated one minute at 121.1C

Assumption: Commercial sterility is achieved at B* = 1

= reduction of thermophilic spores = 109

Region of in-container sterilisation

2000 1000 400 200 100 40 20 10 4 2 1 110 120

Mesophilic spores 30oC Thermophilic spores 55oC

Temp, C 110 120 130

121 130 135 140 141

6.0 6.0 6.0 6.0 8.3

4.23 1.02 0.46 0.24 0.25

UHT Ultra High Temperature processes

Batch sterilisation in container

100 200 Pasteurisation

Minutes PSD.TPD&B.BP.2.16, AA10

Factors influencing shelf-life

Main factors affecting the flavour of UHT milk

Sensoric changes in UHT milk

Optimum Sulfur Cooked Metal Stale Rancid/Bitter

No. TP70:61, 9311BM

Sensory Quality of UHT Milk Heated Flavour - four notes

Sensory Quality of UHT Milk Heated Flavour

No. TP XX:XXX, JF06

Sensory Quality of UHT Milk Stale and Oxidized flavour

Oxidized, Flat Bland Chalky Cardbordy

Sensory Quality of UHT Milk Stale and Oxidized flavour

Sensory Quality of UHT Milk Other off-flavours

Lactose and heat effects

Loss of vitamins in UHT milk

Losses by (%) UHT Ambient Sensitivity to treatment storage Light Oxygen

Pyridoxine-fortification Light-induced flavour

Higher degradation in fortified products

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