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ABSTRACT KUMAR, PRABHAT. Aseptic Processing of a Low-Acid

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ABSTRACT KUMAR, PRABHAT. Aseptic Processing of a Low-Acid ABSTRACT KUMAR, PRABHAT. Aseptic processing of a low-acid multiphase food product using a continuous flow microwave system. (Under the direction of K.P. Sandeep.) Continuous flow microwave heating is an emerging technology in the food industry with a potential to replace the conventional retort process for viscous and pumpable food products. Aseptic processing of a low-acid multiphase food product using continuous flow microwave heating system can combine the advantages of an aseptic process along with those of microwave heating. The main objective of this research was to develop a systematic approach for biological validation of aseptic processing of salsa con queso products using a continuous flow microwave system operating at 915 MHz. Dielectric properties of pumpable food products were measured by a new approach (under continuous flow conditions) and compared with the dielectric properties measured by the conventional approach (under static conditions). The results suggested that, for a multiphase product, dielectric properties measured under continuous flow conditions should be used for designing a continuous flow microwave heating system. Thermophysical and dielectric properties of salsa con queso and its vegetable ingredients (tomatoes, bell peppers, jalapeno peppers, and onions) were measured at a temperature range of 20 to 130 EC. The results were used to fabricate design particles from PP (polypropylene) and PMP (polymethylpentene) using a custom developed CPD (Conservative Particle Design) software. These particles could be used as thermo-sensitive implant carriers for bacterial spores in biological validation of a multiphase aseptic process. Salsa con queso was processed in a 5 kW microwave unit with a specially designed focused applicator. The temperature profiles at the outlet during processing of salsa con queso in the 5 kW microwave unit showed a narrow temperature distribution between the center and the wall of the tube. Thus, continuous flow microwave heating could overcome the problems (degradation of color, flavor, texture, and nutrients) associated with the wider temperature distribution between the center and the wall in a conventional heating system. The results from this study will assist processors in designing a safe process for aseptic processing of salsa con queso using a continuous flow microwave system. However, further research is required to biologically validate such a process as the final step in establishing an aseptic process for salsa con queso using a continuous flow microwave system. ASEPTIC PROCESSING OF A LOW-ACID MULTIPHASE FOOD PRODUCT USING A CONTINUOUS FLOW MICROWAVE SYSTEM by PRABHAT KUMAR A thesis submitted to the Graduate Faculty of North Carolina State University in partial fulfillment of the requirements for the Degree of Master of Science FOOD SCIENCE Raleigh 2006 APPROVED BY: __________________________ Dr. K.P. Sandeep (Chair of Advisory Committee) ________________________ ___________________________ Dr. Josip Simunovic Dr. Peter S. Fedkiw DEDICATION To the most important lady in my life my mother ii BIOGRAPHY Prabhat Kumar was born on June 9, 1982 in Patna, India. He graduated from Indian Institute of Technology, Kharagpur in 2003, with a Bachelor of Technology (Honors) degree in Agricultural and Food Engineering. After his graduation, he joined Coca Cola India as a Graduate Engineer Trainee in July 2003. During his tenure at Coca Cola, he had the opportunity to manage bottling lines and to implement projects for improving efficiency of the plants. In the fall of 2004, he began his Master of Science degree program in the Department of Food Science at North Carolina State University and currently works with Dr. K.P. Sandeep and Dr. Josip Simunovic as a graduate research assistant. His research focuses on aseptic processing of low-acid multiphase foods. He has decided to stay at North Carolina State University for his PhD under the supervision of Dr. K.P. Sandeep. iii ACKNOWLEDGMENTS There are many people to be mentioned by name, but you know who you are. Teachers, colleagues, friends and family members -- your investment in me is partly responsible for everything I accomplish. However, the role of certain individuals was absolutely key in completing this work. First of all, I would like to take this opportunity to thank my major advisor, Dr. K.P. Sandeep, for his guidance and encouragement throughout this work. He understands the individual needs of his students and generates thoughtful insight about every aspect of science. His expert advice and wisdom helped me to finish this work and made my studies under his supervision enjoyable. Thanks are dedicated to Dr. Josip Simunovic for his constant advice, care, encouragement, motivation, support, and freedom which helped me to learn things in an enjoyable manner. I would like to thank Dr. Peter S. Fedkiw for his interest and suggestions during the course of this work. Special thanks to Dr. Pablo Coronel for his suggestions and assistance with the experimental setup. He was always available for timely help which is greatly appreciated. I would also like to thank Dr. Mari Chinn, Gary Cartwright, Jack Canady, Penny Amato, and Sharon Ramsey for their assistance in conducting the experiments. Thanks are due to Balram Suman for his constant encouragement and his confidence in me to do well in life. Thanks to all former and current graduate students of the department who have helped me in this work -- Andriana Schirack, Ediz Batmaz, Aswini Jasrotia, Christina Dock, Tiffany Brinley, Prashant Mudgal, Yifat Yaniv, Stelios Viazis, John Lillard, iv Supriyo Ghosh, and Paula Schneider. Thanks are due to all my friends who have been there whenever I needed them -- Saurabh Sharma, Prashant Mudgal, Shashank Shekhar, Vaibhav Srivastava, Deepak Gupta, Vinayak Rastogi, Rameshwar Yadav, Rakesh Ranjan, Ajay Kumar, Gopal Bhatt, Saurabh Prasad, Smita Verma, Alok Nemani, and Abhijeet Nayan. Finally, with warm and nostalgic feelings, I thank my parents, sisters, and brother for their love, affection and support, without which this work would not have been possible. v TABLE OF CONTENTS LIST OF TABLES...................................................... ix LIST OF FIGURES......................................................x INTRODUCTION .......................................................1 REVIEW OF LITERATURE ..............................................6 2.1.1 Methods of thermal processing .............................7 2.1.2 Kinetics in thermal processing .............................9 2.2 Aseptic processing of food materials ...............................11 2.2.1 History of aseptic processing .............................12 2.2.2 Aseptic processing of particulate foods .....................14 2.2.2.1 Challenges in aseptic processing of particulate foods ...16 2.2.3 Components of an aseptic processing system .................18 2.3 Microwave heating of food materials ..............................23 2.3.1 History of microwaves ..................................24 2.3.2 Components of a microwave heating system .................25 2.3.2.1 Microwave generator ............................25 2.3.2.2 Waveguide ....................................29 2.3.2.3 Applicator ....................................32 2.3.2.4 Circulator .....................................33 2.3.2.5 Directional coupler .............................34 2.3.2.6 Tuner ........................................34 2.3.3 Dielectric properties ....................................34 2.3.3.1 Dielectric constant and loss factor ..................35 2.3.3.2 Factors affecting dielectric properties ...............38 2.3.3.2.1 Frequency .............................39 2.3.3.2.2 Temperature ...........................41 2.3.3.2.3 Composition ...........................41 2.3.3.2.4 Density ...............................42 2.3.3.2.5 Change of phase ........................44 2.3.3.3 Measurement of dielectric properties ...............44 2.3.3.3.1. Network analyzer .....................45 2.3.3.3.2 Open-ended coaxial probe method ..........50 2.3.3.3.3 Transmission line method .................58 2.3.3.3.4 Resonant cavity method ..................59 2.3.3.4 Dielectric properties of food materials ..............59 2.3.4 Governing equations for microwave heating .................62 2.3.4.1 Maxwell’s equation .............................62 2.3.4.2 Lambert’s law .................................64 vi 2.3.4.3 Energy equation ..........................65 2.3.5 Applications of microwave heating ........................67 2.3.5.1 Batch heating ..................................67 2.3.5.2 Continuous heating .............................68 2.4 Biological validation of an aseptic process ..........................71 2.4.1 Thermophysical properties of food materials .................74 2.4.1.1 Density .......................................74 2.4.1.1.1 Measurement of density ..................74 2.4.1.2 Viscosity .....................................77 2.4.1.2.1 Measurement of viscosity .................80 2.4.1.3 Specific heat ...................................81 2.4.1.3.1 Measurement of specific heat ..............83 2.4.1.4 Thermal conductivity ............................86 2.4.1.4.1 Measurement of thermal conductivity .......87 2.4.1.5 Thermal diffusivity .............................89 2.4.1.5.1 Measurement of thermal diffusivity .........90 2.4.2 Design of conservative particles ...........................92 2.4.3 Calculation of hold tube length ............................95 2.4.4 Biological
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