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HOT-FILL PROCESSING OF BEVERAGES

Article · January 2013

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Purwiyatno Hariyadi
Bogor Agricultural University
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 technology

HOT-FILL
PROCESSING
OF BEVERAGES By Purwiyatno Hariyadi

H
RWÀOOSURFHVVIRU then inverted (turned upside the container; providing an
beverages is a proven down) for 3 minutes and then anaerobic condition unfavorable
and recognized method may be cooled. Inverting the for aerobic microbial growth.
IRUÀOOLQJRIKLJKDFLGIRRGVS+ container is needed to make As suggested earlier,
less than 4.6) that will be shelf sure that the inner surface KRWÀOOSURFHVVLQJLVDSRSXODU
stable at ambient temperatures. of the closure is exposed to processing method for beverage
$VWKHQDPHLPSOLHVKRWÀOO the “hot” temperature for industry; since it is a simple
process is a food processing decontamination or microbial and an inexpensive technology;
ZKHUHSURGXFWLVÀOOHGLQWR inactivation. Applying closure especially for high acid foods
WKHÀQLVKHGFRQWDLQHUVDQG at high temperature is a and beverages. Basic steps of a
capped the container when critical step. Following the KRWÀOOSURFHVVLQJRIEHYHUDJHV
they are still hot, and then closure, cooling of the product is illustrated in Figure 1. Since
cooled. The question is; how will create a vacuum inside KRWÀOOLQJLVDOZD\VIROORZHGE\
KRWLVKRWÀOOSURFHVV,QWKLV
case, “hot” is characterized by
temperature that is high enough
to assure that all product in the
container is at or above the
minimum prescribed when the
closure (lid) is applied. This is
important to provide a product
free from microorganisms
capable of growing in it
at ambient storage. This
technology is very simple; and
is currently used extensively in
the beverage industry.
In practice, product is
heated (in a heat exchanger),
VHQWWRWKHÀOOHUKRWDQG
WKHQÀOOHGLQWRFRQWDLQHU
capped, and the container is )LJXUH3URFHVVLQJVWHSVRIKRW¿OOLQJSURFHVV

46 FOODREVIEW International | VOL. I/NO. 1 FOODREVIEW International | VOL. I/NO. 1 47

View publication stats
)LJXUH7HPSHUDWXUHSUR¿OHRISURGXFWWKHUPDOO\SURFHVVHGE\KRW¿OOLQJ
FROG¿OOLQJDQGDVHSWLFSURFHVVLQJ
(in-container) holding process
then many literatures also name
WKHSURFHVVDVKRWÀOOKROG
processing.
Thermal Preservation
Effects of Hot Fill
Process.
Hot Filling has been
applied to successfully extend
the shelf life of beverage
products, such as fruit and
vegetable juices, nectars, soft
drinks, enhanced water, and
RTD teas, at room temperature.
(IÀFLHQF\DQGHIIHFWLYHQHVV
RIKRWÀOOSURFHVVLQJLVÀUVW
determined by the thermal
SURFHVVLQJSULRUWRÀOOLQJ$V
we can see from Figure 1, the
product should be heated
takes place. Temperature
SURÀOHRISURGXFWWKHUPDOO\
SURFHVVHGE\KRWÀOOLQJDV
FRPSDUHGWRFROGÀOOLQJDQG
aseptic processing can be seen
in Figure 2.
To assure the
HIIHFWLYHQHVVRIKRWÀOOSURFHVV
then it is required to have a
proper control of the product
DVZHOODVWKHKRWÀOOSURFHVV
including decontamination
process of the container and
closure. Beside microbial
parameter/criteria of raw
material; critical aspect need
to be controlled is pH value
of the product. Value of pH
is an important factor in the
processing of many foods,
especially when a thermal
important to be stressed here
that the equilibrium pH of the
food after processing that is of
particular importance.
 +RWÀOOSURFHVVLQJ
parameters to be controlled
properly are heating process,
especially temperature (Thold)
and time (thold) at holding tube
or holding cell, temperature
RIÀOOLQJDQGFDSSLQJ7ÀOOLQJ),
in-container holding time (t).
For the same temperature-
time process parameters,
pasteurization value of heat
process experienced by the
product is depend on the
container dimensions. Filling
temperature is very important
in minimizing process time
and ensuring adequate
pasteurization process. It
ZDVUHSRUWHGWKDWIRUKRWÀOO
process parameters described
above was enough to ensure
adequate shelf stability. For
KRWÀOOKROGSURFHGXUHVRI
fruits with a pH value lower
than 4.0, the National Canners
Association recommends
WKHIROORZLQJSURFHVVDÀOOLQJ
temperature higher than 85°C
followed by can sealing and
2 min immersion in steam or
water at 88°C before cooling.
Guidance from Food Science
Australia suggested that in most
cases the product temperature
ZKHQKRWÀOOLQJVKRXOGQRWEH
less than 85°C and preferably
)LJXUH,QWHJUDWLRQRIFRQWLQXRXVV\VWHPRISDVWHXUL]DWLRQIRUKRW¿OOSURFHVVLQJ
recommended for products
above that pH.
 +RWÀOOSURFHVVDOVR
effective in reducing oxidation
deterioration of product. As
we are aware, one of the most
damaging effects resulting from
oxygen activity in beverages is
the oxidative degradation of
vitamin C. Oxidation reaction
is also closely associated with
ÁDYRUFKDQJHVDQGGLVFRORUDWLRQ
of the beverages during storage.
3URSHUKRWÀOOSURFHVVLQJZLOO
also create natural de-aeration,
generating an internal vacuum
within the container after
cooling. In addition to inhibiting
microbial growth, vacuum
condition also prevent oxidative
GDPDJHVRWKDWWKHKRWÀOOHG
products are generally shelf
Packaging for Hot
Filled Beverages
Traditional packaging for
KRWÀOOHGEHYHUDJHVLVXVXDOO\
made from steel cans, glass
bottles and jars. This type of
packaging material are selected
for beverages because of their
best oxygen barrier properties.
Steel cans, glass bottles and jars
is very thermo-stable; so that
ÀOOLQJWHPSHUDWXUHFDQEHGRQH
at higher temperature; usually
between 90 to 98°C, follow by
holding time for 2-3 minutes
before the container is cooled
in a cooling tunnel. Preheating
of glass bottles is necessary
EHIRUHÀOOLQJLQRUGHUWRUHGXFH
the risk of glass splintering.
Prior to closure the headspace
of the container (can, bottle
packaging material for hot
ÀOOHGEHYHUDJHSURGXFWVLV3(7
polyethylene terephthalate,
a plastic resin and a form
of polyester. Manufacturers
RIKRWÀOOHGEHYHUDJHVXVH
PET plastic for its container
due to its strength, thermo-
stability, transparency, and
price. Furthermore, another
advantages for PET is
lightweight, resealable, shatter-
resistant and recyclable.
Thermo-stability of packaging
LVFULWLFDOIRUKRWÀOOSURFHVVLQJ
VLQFHÀOOLQJQHHGWREHGRQH
at high temperature; capable
of causing distortion or
deformation of bottle used.
As described earlier, the
KRWÀOOLQJJHQHUDWHVDQLQWHUQDO
vacuum within the container
(PET bottle) after cooling.
This is due to, especially after
cooling, the shrinkage of the
liquid beverage (by 3% to 4%)
coupled with condensation of
water vapor in the headspace.
Vacuum created by proper hot
ÀOOSURFHVVPD\UHDFKRIXSWR
0.5 bar (7 psi). consequently;
the tightness of closure is
very crucial to maintain the
vacuum and to avoid post
contamination. Recently,
special PET technology is
VSHFLÀFDOO\GHYHORSHGIRUKRWÀOO
processing, as a PET preforms
made from special resins,
heated to a higher temperature
to 90-95oC for about 15-30
seconds; depending on pH value
and other microbial factors.
7KHKRWSURGXFWLVWKHQÀOOHG
into the container, holding and
then cooling by conduction
48 FOODREVIEW International | VOL. I/NO. 1
processing is applied for
the purpose of inactivating
organisms. Consequently,
monitoring of pH during
production runs must be
made regularly; using a proper
standardized pH meter. It is
between 90° and 95°C. The
container is closed and then
inverted or turned on its side
for 2 or more minutes prior to
cooling. Where possible foods
are processed below pH 4.0
with extended processing times
stable at ambient temperature.
To assure total elimination
RIR[\JHQKRWÀOOWHFKQRORJ\
is now also equipped with
QLWURJHQJDVÁXVKLQJDWWKH
container headspace before the
capping process.
RUMDUPD\EHÁXVKHGZLWK and blown into hot blow molds
VWHDP6WHDPÁXVKLQJLV in order to reduce shrinkage
intended to create vacuum, and more thermo-stability.
reduces the oxygen content of
the neck space and lowers the
recontamination risk.
Nowadays, popular
FOODREVIEW International | VOL. I/NO. 1 49