Safeguarding thermal processes in the food industry

One of the KIN’s success stories is the validation of processes. This is understood as the quantification of time and temperature and the evaluation of the thermal process. Thermal processes are key processes in food production and they deserve the highest amount of attention. In order to design these processes safely and also efficiently it is important to know them in detail and to review them frequently.

 

Up to now the KIN has been performing a large number of process validations. The KIN's scope of application in food companies ranges from a single-chamber cooking device to tunnel pasteurization plants and batch and continuous retorts. Apart from the formal check, the technologists at the Food Institute will also optimize processes. This may result in enhanced plant capacities and improved product qualities. In the past not only optimization possibilities were found but also safety gaps, maintenance errors and understerilization were identified and remedied.

 

In a four-part article in KIN aktuell, the reasons for a validation shall be depicted using selected examples. It starts in this issue with the Codex Alimentarius that provides insight into the underlying food law and describes the legal requirements for a retort validation. The next issues will focus on qualitative and economical reasons and describe the requirements requested by the trade.

 

1. Legal reasons for a retort validation: the Codex Alimentarius

The Codex Alimentarius states in chapter 7.5 Thermal Process (Sterilization) that “the thermal treatment of low acid food… is a process with high risks that is associated with health hazards for the public.” It recommends to check the temperature distribution inside the vessel prior to using newly installed retorts or other sterilization devices in practice. These measurements shall also be conducted in the event that retorts have been refitted (e.g. different circulation pump) or shall be used for another purpose (e.g. for different types of packaging). These checks have to be documented.

 

What is the Codex Alimentarius?

- The Codex Alimentarius is a highly scientific collection of recommendations provided by WHO experts on subjects such as food safety, food composition, production and HACCP. Legally the Codex Alimentarius is considered to be an internationally consented expert opinion. In case of a dispute and when no other interpretation is available, any judge may base his decision on these standards.

 

The Codex also states: Necessary thermal processes should only be defined by competent individuals and must follow scientifically approved methods. Prior to defining the process to be applied, the heat treatment (the F-value to be achieved) must be defined. The aim is to achieve commercial sterility. Next, the Codex states that heat penetration tests have to be performed. The penetration of heat into the product has to be measured under worst case conditions which are presumed to occur during the production. The temperature development has to be checked at that spots inside the container that heat up the slowest.