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Technical and Economic Feasibility of High-Pressure Processing on Charcuterie Foods

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Technical and Economic Feasibility of High-Pressure Processing on Charcuterie Foods Les Cahiers de l’IFIP Revue R&D de la filière porcine française Vol 3 - N° 1 - 2016 Technical and economic feasibility of high-pressure processing on charcuterie foods Jean-Luc MARTIN IFIP‐Institut du Porc, 7 avenue du Général de Gaulle, 94 704 Maisons-Alfort Cedex, France [email protected] High-pressure processing (HPP) decreases food spoilage and pathogenic flora and extends shelf life without losing sensory quality. Several national food health and safety agencies—including the French Anses—have issued approval statements conclu- ding that cold-process high-pressure treatments are safe and effective on foods and food packaging. HPP can be applied in industry in several countries across Europe without special prior expertise, permitting or red tape. In 2010, the Anses formally recognized that a HPP treatment does not form harmful substances up to a process pressure of 600 MPa for 2 to 5 minutes. Food business operators do not have to compile, file and validate a process authorization application if they are working within these conditions. High-pressure processes inactivate certain microorganisms under specific pressure, temperature and hold-time conditions and according to food matrix. In meat products, the effect is shaped by the salt and fat contents and the calcium ions present. The high process pressures have little effect on meat taste and aroma but do accentuate the perception of salt and spices as the process alters the meat proteins and releases bound sodium. The unsaturated fat gets oxidized, which modifies both the taste and nutritional value of fattier products. Meat colour also gets modified as the myoglobin gets altered. This study found that HPP costs vary between €0.21 and €0.80 per kg of packaged retail-ready product. The HPP process improves both the shelf life and technological yield of charcuterie products. It guarantees Listeria-free retail-ready products. There are still no predictive models available, so each and every HPP treatment must first be validated by on-matrix trials to determine its actual taste-texture and bactericidal effects. Although still expensive, the technology is readying for industrial scale-up on several product families and the EFSA’s scientific opinion is facilitating new application opportunities. Research is pressing ahead to support food business operators on process optimization and re-engineering for a wide range of products. Faisabilité technique et économique des hautes pressions sur les produits de charcuterie Le procédé HPP réduit la flore pathogène et d’altération et allonge la DLC en conservant les qualités sensorielles. Plusieurs agences sanitaires dont l’ANSES, ont rendu des avis favorables concluant à l’innocuité et à l’efficacité des traitements haute pression à froid, sur les aliments et leurs emballages. Les applications industrielles sont possibles sans expertise préalable dans plusieurs pays européens. En 2010, l’Anses a reconnu qu’un traitement HPP n’induisait pas de substances nocives jusqu’à une pression de 600 MPa, pendant une durée de 2 à 5 minutes. Les industriels sont exonérés de la constitution et validation d’un dossier d’autorisation si ces conditions sont respectées. Les hautes pressions inactivent certains microorganismes sous conditions spécifiques de pression, température, durée, et selon le milieu. Les teneurs en sel et gras, et les ions calcium des produits carnés, ont une influence. Les hautes pressions modifient peu leurs saveur et odeur mais accentuent la perception des épices et du sel du fait des altérations des protéines et la libération du sodium fixé. Les lipides insaturés s’oxydent ce qui modifie le goût des produits gras et leur valeur nutritionnelle. La couleur de la viande est aussi modifiée par l’altération de la myoglobine. Dans cette étude, les coûts varient entre 0,21 € et 0,80€/kg de produit fini emballé. Le procédé HPP améliore la conservation et le rendement technologique des charcuteries. Il apporte une garantie d’absence de Listeria dans des produits emballés. Aucun modèle prédictif n’est disponible et tout traitement doit être validé par des essais sur la matrice pour déterminer son effet sensoriel et bactéricide. Bien que chère, cette technologie est en phase d’industrialisation pour plusieurs familles de produits, l’avis de l’EFSA facilitant de nouvelles applications. Les études se poursuivent pour accompagner les industriels dans l’optimisation des procédés et leur adaptation à une large gamme de produits. 2016-Ifip-Institut du porc - All rights reserved rights - All porc du 2016-Ifip-Institut reserved rights - All porc du 2016-Ifip-Institut Keywords: high pressure, pathogenic flora, shelf life, colour, meat products, aroma, taste Mots clés : haut pression, flore pathogène, DLC, couleur, produits carnés, odeur, saveur Les Cahiers de l’IFIP - Vol 3 - n° 1 - 2016 25 Technical and economic feasibility of high-pressure processing on charcuterie foods Introduction controlled by heating or cooling through a jacket surroun- ding the pressure vessel. On industrial-scale equipment, High-pressure treatment is making inroads in the charcute- the temperature of the pressure chamber is not controlled rie industry where it is increasingly being used to improve but equilibrates with ambient temperature. The equipment microbiological stability. This physical-mechanical treat- is typically set up in a refrigerated coldroom. ment also has impacts—some positive, others negative—on Hot or cold the sensory attributes of the products processed. High-pressure Pre-packed product It is currently being run as a semi-continuous process that chamber generates production-line input losses and stockpiles of intermediates, all of which drums up extra costs for the pro- duct-maker. This study set out to review the state of the art on technical, economic and regulatory factors to inform industry on the right conditions for employing HPP in the charcuterie business. HPP treatment is analyzed in terms of effects on product attributes, the costs entailed, and the economic feasibility of the process in order to determine the key conditions for applying HPP on charcuterie products. Materials and Methods High pressure processing (HPP), also known as high hydrostatic processing (HHP) or high-pressure pascaliza- High-pressure tion (HPP), is a food preservation technology for microbial pump inactivation (cold pasteurization) developed commercially in the 1990s. Although originally geared to inactivating enzymes, its effects on the physical and taste–texture attri- Water inlet port Water outlet port butes of foods have served as a platform for wider integra- tion into the processing of numerous different products. Pressure HPP offers an alternative to ionizing radiation or thermal relief values Low-pressure oil pump treatments (sterilization). Figure 1: Mechanism of high-pressure effects (CEP 2015) HPP—How it works The temperature of the pressure-transmitting fluid tank can HPP technology is premised on increasing the pressure in a be controlled by heating or cooling through a plate or ser- heavy-duty pressure-proof air-tight vessel, which compres- pentine heat exchanger. The high-pressure leak-before-burst sively shrinks the volume of the products inside and thus seals used on the end-cap closures are the main driver of has effects on the component molecules of the HPP-treated maintenance costs. There are subjected to repetitive wear foods, i.e. conformation interactions, chemical reactions cycles and have to withstand multiple series of a huge number and phase changes. The pressure increase is delivered via HPP treatment cycles—each of which severely stresses the a pressure transmission fluid—typically water . hardware. Like any other food-contact equipment, the whole The process pressure delivered is isostatic as it is identical assembly must be readily cleanable by design. at all points in the vessel—and thus all points in the pro- duct. The target product has to be vacuum-packed in a pac- The indirect compression mode is the food–farming kaging that is flexible enough to let it deform. Typical HPP industry standard (at 200 to 800 MPa, or 2000 to 8000 system equipment found at the big food–farming industry atmospheres) processors today counts: 1. The baskets carrying the products to be HPPed are placed • a pressure-proof process vessel, in the chamber which is then hermetically sealed and • a pressure intensifier pump, flooded full of water. • a high-pressure circuit governing fluid transfer between 2. A high-pressure pump forces waterProduct into load-in the chamber, Vessel reinsertion pump and process vessel, thus producing an instantaneous and uniform (isostatic) • a system control and instrumentation cabinet. increase in pressure. 3. Once the pressure has come up to setpoint, it is held reserved rights - All porc du 2016-Ifip-Institut Untreated batch On lab-scale equipment, the temperature of the pressure for a pre-determined time somewhere between 2 and 7 chamber, carrier basket and pressure-transmitting fluid is minutes, Low pressure Water tank 26 Les Cahiers de l’IFIP - Vol 3 - n° 1 - 2016 Product load-out Vessel reinsertion Source : N.C. hyperbaric Source Low High Treated batch pressures pressure Hot or cold High-pressure Pre-packed product chamber High-pressure pump Water inlet port Water outlet port Pressure relief values Low-pressure oil pump Technical and economic feasibility of high-pressure processing on charcuterie foods Product load-in Vessel reinsertion Untreated batch Low pressure Water tank Product load-out Vessel reinsertion Source : N.C. hyperbaric Source Low High Treated batch pressures pressure Figure 2: Schematic of a high-pressure process 4. At the end of the treatment, the vessel is quickly depres- to control the pressure vessel operations and keep elec- surized before the chamber is opened and the product tronic records of the processes. The computer system will baskets recovered. typically monitor process pressure, temperature, and hold time. The pressure vessels can be either vertically or horizon- Process control remains limited by the shortage of in-sys- tally oriented.
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