VSGCP-N-93-002 C3 l.OARCOPY ONLY SEAFOODPASTEURIZATION AND IVHMMAL PROCESSINGMANUAI. Virginia Tech C!RCUt,ATlNGCOPY Virginia Cooperative Extension Virginia Sea Grant National Fisheries Institute IN%1K al lallfl lePlakW PRL UBRARYBLDG., GSO LNVERSfTYOF R I-'P. "I,i >JD NiSHA$4ASETTF-'< -i .' USA 01! 79dw11 4 SKAFOOD PASTEURIZATION AND MINIMAL PROCESSING MAMJAL Thomas E. Rippen Virginia SeafoodResearch and ExtensioriCenter Hampton, Virginia CameronR. Hackney George J. Flick Geoffrey M. Knobl Departmentof Food Scienceand Technology Virginia PolytechnicInstitute and StateUniversity Dorm R, Ward Departmentof Food Scienceand Technology North Carolina StateUniversity In cooperation with Roy E. Martin National Fisheries Institute Robert Croonenberghs Division of Shellfish Sanitation Virginia Departmentof Health Virginia Cooperative Extension Publication 600-061 993! Virginia Sea Grant Publication VSG 93-09 Virginia Seafood Research and Extension Center Publication VPI-SG-93-01 Virginia PolytechnicInstitute and StateUniversity Acknowledgments We thank John Chandlerof the Virginia Tech Departmentof Food Scienceand Technologyand the staff of the Virginia Tech Photo Lab for their assistance, We alsothank Edmund Nelson and Steeltin Can Company, Baltimore, Maryland, for assistingwith the preparationof the Can SeamEvaluation Section; the Wilkens-Anderson Companyfor photosof their can quality control equipment;and the National Food ProcessorsAssociation for their help with seal evaluationportions of this project. We also thank Keith Gates,University of Georgia, for his very thorough critique of the manuscript and for his valuableinsights. This work is a result of researchsponsored by NOAA Office of SeaGrant, V.S. Departmentof Commerce,under federal Grant No. NA90AA-D-SG045 to the Virginia GraduateMarine ScienceConsortium and the Virginia SeaGrant College Program. The V.S. Governmentis authorizedto produceand distribute reprints for governmentalpurposes, notwithstandingany copyright notation that may appearhereon. VirginiaTech does noi discriminateagainst employees, students, or apphcantson the basisof race, color, scx, sexual orientation,disability, age, veteranstatus, national origin, religion, or political ~on. Anyonehaving cluestions concerningdiscrimination shotdd contact thc Equal Zmploymcnt/A~vs Action Oflice. VirginiaCooperative Extension progranis and cmploymcntarc open to aH, regardlessof race, color, rchgion,scx, agc, veteran status, national origin, disabi7ity,or pohtical a+hation. An equal opportunityl~rmativc action employer. 1ssucd in furtheranceof Coopcrativc&tension worR, Virginia Polytechnic 1nstitute and State University,Virginia Stare University, and the U.S. Departmentof Agriculturecooperating. Wilham A. Allen, 1nterimDirector, VirginiaCooperative Extension, VirginiaCooperative Extension, Virginia Tech, BlacRsburg; Lorenza W. Lyons,1nterim Adnunistrator, 1890 Extension Program, VirginiaState, Petersburg. Table of Contents Introduction SECTION 1 Thermal Processing: Principles and Definitions 3 Definition of Terms.............,.........., Pasteurization 38 8 Definition and Basis Shelf-life............................. ,.11 Pasteurization of Products other than Crabmeat Effect of ContainerType ......... 12 Process Considerations....................... ......, 18 SECTION 2 Cooling and Other Shelf-Life Factors .. 20 Cooling .. 20 Can Seams ,, 23 Under-processing .... 24 Product Temperature............................ Initial Microbial Population ., 25 Conceptof Microbial Survivors in a Batch .. 25 A "New" Spoilage Organism .. 28 CrabmeatSpoilage and Proper Retorting ....,....,..., .. .. 28 HACCP as a Quality AssuranceApproach 29 Case Studies of Pasteurization Procedures............. .. 30 Plant 1 .. 32 Plant 2 .. 32 Plant 3 .. 33 Waterbath circulation .. 33 Microbial Populationsof CookedCrabs and Fresh Crabmeat 34 Discoloration in Pasteurized Crabmeat 37 Cause and Prevention of Blue Discoloration....,...,... 37 Recommendations to Minimize Discoloration........... 38 Other Defects .. 38 Use of Steam Tunnel Processes to Reduce Microbial Levels . 39 Developmentof AtmosphericSteam Process for Flake Crabmeat.. 40 AtmosphericSteam Process for LumpCrabmeat: A Study . 40 Minimally ProcessedSeafoods Sous Vide SeafoodProducts!....... 41 Advantages................,...,, .. .. 42 Safety Considerations .. 42 Clostridium botulinurnType E .. 43 SECTION 3 Temperature Measurements ...... 45 Thermocouples........... ...., . 45 General Application Data .. ...... 46 Thermocouple Installation ...... 51 Procedures ........... ...... 53 Recorders.............. ...... 58 SECTION 4 PasteurizationProcessing Equipment and Controls 62 Recordingand Indicating Thermometers 62 Proportional Flow Steam-ControlValve Agitation of Waterbathto Maintain Uniform Temperature 64 Baskets PasteurizationTank Hook-Up................... Servicing of Equipmen.t 66 Thermometersin RefrigeratedStorage Areas . 67 SECTION 5 Can SeamEvaluation and Can Coding 68 Can Coding............................. 69 Double Sear@Evaluation: Determining Proper Formation 70 Double Seam Defined 70 Visual Inspection of External Seam Formation 70 Possible Causes of Cut Overs 71 Possible Causes of Cut Seam....,...,,,...... 73 PossibleCauses of Droops and Lips 75 Possible Causes of False Seam....,........... 75 PossibleCauses of Spinners Checklist: RecommendedDaily SeamerOperating Procedures . 76 Start-up .. 76 Production ................., .. 77 End of day............................... .. 77 External Seam Measurements...,...,.............. ,.77 Seam Width Height, Length! .. 77 Seam Thickness..........................., .. 78 Countersink .. 79 Inspection of Internal Seam 79 First Operation Seam Formation.................. 80 SecondOperation Seam Formation 81 Tearing Down the Double Seamfor Inspection......... 82 Visual Inspection of Internal Seam....,...,......., .. 85 Cover Hook Tightness Wrinkle! Rating............. 85 Determining Tightness Wrinkle! Rating............. 86 Possible Causes of Jumped Seam 88 Internal Seam Measurements 89 Double SeamEvaluation: Daily Testing and Records ....... 89 Examination of Cans Prior to Use...,............. 89 Double Seam Evaluation Stripping Seamsfor Inspectionand Measurement 93 Testing Cans f'or Leakage,...,...,...,......... Alternative Packaging: Special Considerations Flexible Pouches and Bags Testing Methodsfor Plastic Packaging....,...,..., . 100 Can Handling 105 Empty Can Handling......................... 105 Container Washing.......................... SECTION 6 General Recordkeeping Requirements 108 Process Documentation....,..........., 108 Cooling Record 109 Distribution Records 109 Can Seam Evaluation................., 109 Refrigerated Storage Temperature Documentation 109 Record Retention 109 Recordkeepingto Comply with FederalRegulations in the PasteurizedCrabmeat Industry........................... 110 Hazard Analysis and Critical Control Points HACCP! 110 Critical Control Points and a Pasteurized Crabmeat Process 112 ContainerIntegrity.............,...,.......,,,..., 112 Pasteurization 113 StorageTemperature,.......,...,,...,,,.............. 115 Management Review of Critical Control Point Records 116 Coding Requirementsand Recordsof Initial Distribution 116 Seafood HACCP.........,...,.....,,...,...,..., . 117 Summary......,....,.......,,......... 117 APPENDIX I CrabmeatIndustry PasteurizationHACCP Recommendations 119 APPENDIX II Developing a Hazard Analysis and Critical Control Plan 126 APPENDIX III Exampleof a ProcessingProtocol for ModeratelyThermal-Processed Crabmeat... 146 APPENDIX IV National Blue Crab Industry PasteurizationStandard 152 References 161 Index 168 LiSt Of TableS Table 1 Observedrelationship of blue crab pasteurizationprocess to refrigerated shelf-life .........,...,..........,...,............,, 11 Table 2 Effect of container size on accumulatedF-value when processedin the same batch......................................,....... 17 Table 3 F-valuesachieved in 187-19' waterbath,401 x 301 cans, crabmeatinitial temperature g.T.!=60-65'F............................., .. 25 Table 4 D-value in secondsof nonspore-formingmicroorganisms at either 185'F or 15 PF ............,.............................. 36 Table 5 Upper TemperatureLimits F! for ProtectedThermocouples for Various Wire Sizes ..... 46 Table 6 Limits of Error for Standardand SpecialGrade Thermocouples...,, 49 Table 7 Essentialand Optional SeamMeasurements ..... 91 Table 8 Example Seam Dimensions for Steel 401 x 301 Can............ ..... 98 Table 9 Causes and Solutions to Common Double Seam Defects 101 LiSt Of FigureS SECTION 1 Figure l. Logarithmic survivor curve D-value curve!. Illustration definesan organism or population of organismshaving a D», = 1.0 minute............. 3 Figure 2 Example of a thermalresistance curve z-value curve!, illustrating an organism possessinga z-value of 15'F 5 Figure 3 Hypothetical heatpenetration curve assuminginstantaneous heating and cooling. In this example, F, = 30.9 minutes ................... 6 Figure 4 Heat penetrationcurve for 16 oz. of crabmeatin a 401 x 301 can, where F",= 31 minutes................................. 7 Figure 5 Product type affects heatingrate and the location of the cold point area of slowest heating! ................................, . 9 Figure 6 Heat penetration curves for crabmeat in 4, 8, and 16 oz. cans heated to 185 F, then cooled in ice slush ........................,....., 13 Figure 7 Heat penetrationcurve for crabmeatin a 4 oz. can................. 14 Figure 8 Heat penetrationcurve for crabmeatin