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Sterilization of Scrambled Eggs in Military Polymeric Trays by Radio Frequency Energy KUNCHALEE LUECHAPATTANAPORN, YIFEN WANG, JIAN WANG, JUMING TANG, LINNEA M

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Sterilization of Scrambled Eggs in Military Polymeric Trays by Radio Frequency Energy KUNCHALEE LUECHAPATTANAPORN, YIFEN WANG, JIAN WANG, JUMING TANG, LINNEA M JFS E: Food Engineering and Physical Properties Sterilization of Scrambled Eggs in Military Polymeric Trays by Radio Frequency Energy KUNCHALEE LUECHAPATTANAPORN, YIFEN WANG, JIAN WANG, JUMING TANG, LINNEA M. HALLBERG, AND C. PATRICK DUNNE ABSTRACT: There is a current need for fresh-cooked-like yet shelf-stable egg products for U.S. military combat rations. Novel thermal processes based on radio frequency (RF) energy can shorten the heating time and reduce overheating. This technology was explored to produce shelf-stable egg products for combat ration development. Clostridium sporogenes (PA 3679) spores were used as a surrogate to validate the RF sterilization process to control Clostridium botulinum. Decimal reduction time (D value) of PA 3679 in scrambled eggs was determined using aluminum thermal-death-time (TDT) tubes. The thermal inactivation kinetic information was then used in inoculated pack studies to validate a novel thermal process based on 27.12 MHz radio frequency (RF) pilot scale unit. Trays of scrambled eggs inoculated with PA 3679 were subjected to 3 processing levels: target process (F0 about 5.3 min), under-target process (F0 about 3.0 min), and over-target process (F0 about 9.1 min). The results of the microbial challenge study showed that microbial destruction from the RF process agreed with sterilization values calculated from time-temperature data measured at the cold spot in the treated trays. A comparison of RF- and retort-treated scrambled eggs showed significant differences in the degree of lightness (L*) and redness (a*). RF-processed egg was less brown compared with conventional retorted eggs. Retort treatment of fully cooked scrambled eggs had higher hardness, springiness, and smaller cohesiveness than RF-treated samples. E: Food Engineering & Physical Properties This study suggests that RF thermal processes can produce safe, shelf-stable sterilized scrambled eggs for both military and civilian uses. Keywords: dielectric heating, radio frequency, sterilization, decimal reduction time, scrambled eggs, military rations Introduction least 3 years. Product sterility must be ensured. Due to the high sensitivity of egg components to heat, color, texture, and flavor of helf-stable foods are one of the major food products in the mar- egg products are degraded by conventional thermal processes at ket. Commercial sterilization has been used to ensure that nei- S high temperatures. Two common problems reported in thermally ther spoilage nor pathogenic bacteria can proliferate under normal processed eggs are greenish-black discoloration caused by the for- storage conditions. Quality in terms of appearance, texture, and mation of ferrous sulfide (Tinkler and Soar 1920; Baker and others palatability is highly important to the consumers, as is proof of mi- 1967; Gravani 1969; Wesley and others1982; Song and Cunning- crobiological safety (Brown 1991). In conventional sterilization pro- ham 1985; Cotterill 1995), an undesirable change of texture, and cesses that rely on pressurized hot water or steam, slow heat con- syneresis (Wesley and others 1982; Woodward and Cotterill 1986). duction from the heating medium to the center of pre-packaged Extensive syneresis increases the area of discoloration in sterilized solid or semi-solid foods often results in a long process time and scrambled eggs. Addition of chelating agents or lowering the pH to overheating at the corners and edges of the food package. Radio fre- create acidic condition can prevent formation of ferrous sulfide quency (RF) heating, a method of heating dielectrics, has the po- (Cotterill 1995). Formulation of scrambled eggs suitable for RF ster- tential for fast heating in solid and semi-solid foods. RF energy is ilization was developed in our laboratory in a previous study. In this dissipated through the products based on direct interaction be- formulation, citric acid and a combination of different water-hold- tween electromagnetic waves and foods. RF energy can penetrate ing substances were added to prevent discoloration and syneresis. dielectric materials more deeply than microwave energy due to its But microbial safety of RF sterilized eggs needs to be evaluated. lower frequencies (13.56, 27.12, and 40.68 MHz) and longer wave- Clostridium botulinum is heat resistant and produces botulinum lengths compared with those of microwaves at 915 or 2450 MHz toxin in anaerobic conditions such as in sealed cans or trays. It is (Wang and others 2003b). the target microorganism in the sterilization process of low-acid The U.S. army is in need of fresh-cooked-like shelf-stable food (pH>4.6), high-moisture food. To ensure food safety, a minimum of items such as egg products for combat rations with a shelf-life of at 12-log reduction of C. botulinum is required for a commercial ther- mal process. Clostridium sporogenes (PA 3679) has been used as a MS 20040655 Submitted 9/28/04, Revised 11/18/04, Accepted 1/27/05. Authors Luechapattanaporn, J. Wang, and Tang are with Department of Biological surrogate microorganism for C. botulinum in developing processes Systems Engineering, Washington State Univ., Pullman, WA 99164-6120. Au- for sterilized food because of its non-toxin producing and similar thor Y. Wang is with Biosystems Engineering Dept., Auburn Univ., Auburn biochemical requirement to C. botulinum (Ocio and others 1994). Univ., Ala. Author Hallberg is with U.S. Army Natick Combat Feeding Pro- gram Advanced Processing & Packaging Team, Kansas St., Natick, Mass. Decimal reduction time (D value) of a microorganism is greatly af- Author Dunne is with U.S. Army Research, Development and Engineering fected by its environment such as pH, and the composition of sub- Command, Combat Feeding Innovative Science Team, Kansas St., Natick, strate, including carbohydrate, fat, and moisture content (Banwart Mass. Direct inquiries to author Tang (E-mail: [email protected]). 1989). It is, therefore, necessary to determine the D value of PA E288 JOURNAL OF FOOD SCIENCE—Vol. 70, Nr. 4, 2005 © 2005 Institute of Food Technologists Published on Web 4/28/2005 Further reproduction without permission is prohibited Sterilization of scrambled eggs by radio frequency . 3679 in a selected food to validate a new thermal process for this Table 1—Ingredients of the selected scrambled egg food. formulation The objectives of this research were to determine the D value of Ingredients Amount (%) C. sporogenes (PA 3679) in scrambled eggs at 121.1 °C, conduct inoc- Liquid whole eggs 75.08 ulated pack studies, and compare quality attributes of RF-sterilized Water 20.00 scrambled eggs with that of conventional retorted products by in- Vegetable oil 2.98 strumentation. Salt 0.59 Corn starch 1.00 Citric acid 0.15 Materials and Methods Xanthan gum 0.10 Guar gum 0.10 Decimal reduction time (D value) determination Pepper flavor 0.01 The D value of C. sporogenes (PA 3679 at 121.1°C) was deter- Yellow color 0.0075 mined using the multiple-point method in a M/15 phosphate buffer (Na2HPO4 5.675 g, KH2PO4 3.63 g in 1000 mL of distilled wa- ter, pH 7.0) and in scrambled eggs (pH 7.0) using aluminum ther- mal-death-time (TDT) tubes (Figure 1). Scrambled eggs were pre- mocouples (0.51-mm dia, Omega, Stamford, Conn., U.S.A.) through pared with frozen pasteurized liquid whole eggs containing 0.15% air-tight fittings in the caps of the TDT tubes. Temperature data citric acid (Michael Foods Egg Products Co., Gaylord, Minn., U.S.A.), were collected using a data logger (Delta-T devices, Cambridge, water, vegetable oil, salt, additional citric acid, modified waxy corn U.K.). Immediately after the sample reached the designated tem- starch (PenCling® 570, Penford Food Ingredients, Co., Englewood, perature (±0.2 °C), the heating time was recorded and the 1st TDT Colo., U.S.A), xanthan gum (Keltrol® RD, CP Kelco Inc., San Diego, tube was removed from the oil bath. The remaining samples were Calif., U.S.A.), guar gum (Sigma Aldrich, Inc., St. Louis, Mo., U.S.A.), each subjected to 6 different exposure times ranging from 30 s to black pepper flavor (Aquaresin black pepper, Kalsec, Inc., Kalam- 180 s. azoo, Mich., U.S.A.), and yellow color (Vegetone Oil Soluble, Kalsec, After heating, the tubes were immersed promptly into an ice Inc.), in the amounts shown in Table 1. The mixture was scrambled bath at 0.0 ± 0.2 °C. The average come-up time from 0 °C to 121.1 °C on a stainless-steel griddle at 135 °C for 1 min. PA 3679 spores in and cool-down time from 121.1 °C to 0 °C in scrambled egg samples phosphate buffer, with a concentration of 1.6 × 108 colony-forming were 155 s and 120 s, respectively. The unheated control samples units (CFU)/mL (NFPA nr SC 199), were obtained from the Techni- were activated by heating in a test tube for 10 min in a water bath cal Service Center of National Food Processors Association (NFPA) set at 90 °C. in Dublin, Calif., U.S.A. Scrambled eggs were cooled by an ice bath After the heat treatment, spore suspension in phosphate buffer before they were inoculated with a spore suspension to approxi- was diluted in 0.2% peptone water and survivors were enumerated mately 1.0 × 106 CFU/g. The inoculated samples were mixed well in by pour plating with Shahidi Ferguson Perfringens (SFP) agar (Dif- a sterile stomacher bag by hand rubbing for 10 min and kept in an co Laboratories, Inc, Detroit, Mich., U.S.A.). For samples in scram- ice bath at 0 ± 0.2 °C. Inoculated samples of 1 g were transferred to bled eggs, the contents in the tube were aseptically removed with sterile aluminum TDT tubes. The tubes were sealed with screw a sterile spatula to a stomacher bag and homogenized for 2 min in caps and then placed in a rack before being immersed completely a Seward 80 circulator stomacher (Seward, Ltd., London, U.K.).
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