Application of hurdle technology in poultry meat processing & preservation
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This document discusses hurdle technology, which uses a combination of preservation methods or barriers to inhibit microbial spoilage. It defines hurdles as physical, chemical, or microbiological factors that microorganisms must overcome to grow. Examples of hurdles include reduced water activity, acidity, heat treatment, packaging, and use of preservatives. The document provides examples of hurdles used in various products and outlines guidelines for developing shelf-stable foods using hurdle technology, including testing products with spoilage microorganisms and modifying hurdles as needed. Overall, it presents hurdle technology as an effective approach for food preservation and stability that can help reduce waste and extend product shelf life.
Application of hurdle technology in poultry meat processing & preservation
- 2. Presented By: Dr. Irshad A Application of Hurdle Technology in Poultry Meat Processing & Preservation
- 3. Introduction 1 Hurdle Technology 2 Characteristics of Hurdles 3 Examples of Hurdle Technology in Products 4 Overview
- 4. Introduction What is Hurdle Technology Combination of preservation which employ the use of two or more hurdle or barrier to spoilage micro-organism in a balance and judicious way. Used for shelf stable food products and IMF •Many of well established traditional food products having this concept. •Evolved at “Federal center for meat research” Germany •Leistner and Rodel in 1976 Leistner- Father of Hurdle Technology
- 5. Hurdle Technology • It is the process/technology used for the preservation provide shelf stability to a food product by laying hurdle which are difficult to overcome by the micro-organism causing food spoilage and poisoning. (Berwal, 1994) • Also called combined process, combined methods, combination preservation, combination technique or barrier technology
- 6. • Hurdle in a food- Substance or process inhibition deteriorating process aw (water activity) pH (acidificat ion) F (heat treatment) t(low temperatur e)Eh (reduced oxygen potential) Modified atmosphere s Competitive micro flora Preservati ves (nitrite)
- 7. Hurdle Technology High hydrostatic pressure, High-intensity pulsed electric fields, High-intensity pulsed light, Oscillating magnetic fields, Food irradiation Important in the preservation of IMF & HMF………why? It can control 1. Microbial Spoilage 2. Food poisoning 3. Desired fermentation process
- 8. Significance of Hurdle Technology • An intelligent application of hurdle contributes to both improvement in product quality and sustainability. • Calculated application of hurdles could result into saving money, energy and several resources • Each hurdle contribute to the safety net against the micro- organism • Since SSPs do not require refrigeration, they travel long distance for finding place in the market to reach the consumers • Able to use in products for defense force • Perishability can be reduced.
- 9. Physical Hurdles 1. Heat processing – to kill/ destroy micro-organisms and/or enzymes • Heating in hermetic ceiling avoid recontamination Sterilization Pasteurizat ionBlanching Temp≥ 100oC (F Value) Temp 60-85oC Not Applicable
- 10. Physical Hurdles 2. Storage Temperature– Mainly chilling and Freezing during storage Chilling -1oC to +7oC Freezer Temperature ≤ -18oC
- 11. Physical Hurdles 3. Radiation– Process of using a radiation frequency of 109 MHz or above UV Radiation *260nm-most efficient *Low pressure mercury lamp – emission at 254nm *G-ve kill easily *Spore and Moulds -resistant Ionization Radiation *γ and β *Very high energy *Kill organism depending on dose *1-10 kGy- vegetative org *10-50 kGy- kill bacterial spores
- 12. Physical Hurdles 4. Electro-magnetic energy (EME)– results from high voltage electric fields Oscillating magnetic field pulses 2-5 T, oscillation frequency 5 to 500 MHz No temperature raise, single pulse destroy 99% Radio frequency energy 1-500 MHz- mild preservation Applied to heat processed food Microwave Energy Alternate electric field -500 to 1000 MHz Fast heating by internal molecular vibrations
- 13. Physical Hurdles 5. High Electric field– electric potential of 15Kv/cm *reverse membrane potential of cell 6. Photodynamic inactivation- Light Molecular oxygen Photosensitizer Photosensitizer eg- rose Bengal Absorb light Molecular O2 Reactive Free Radical Kill Micro- organism
- 14. Physical Hurdles 7. Ultra High Pressure Process– 3000 bar and above *inactivate enzyme and Microbs. 8. Ultra Sonication- vibrations between 18kHz to 500 Mhz G -ve • 3K bar Y & M • 4K bar G +ve • 6k bar Spores • 12k bar
- 15. Physical Hurdles 9. Packaging Vacuum packaging Moderate Vacuum packaging Active packaging Edible coating Modified atmospheric packaging Controlled atmospheric packaging Hypobaric storage Aseptic packaging 1. Prevent the entry of microorganism, dirt, insects, etc 2. Act as a barrier for transfer the water vapour, gas and aroma
- 16. Physico-chemical Hurdles 1. aw –Water activity Reduced by dehydration Adding solutes such as salts, sugar, etc… By lowering temperature 2. pH 3. Redox Potential (Eh)- Denote oxidation reduction potential of food system, Express in mV, +300 to -200mV 4. Nitrate (NaNO2) 5. CO2 – above 20%, spoilage bacterial inhibited 6. O2
- 17. Physico-chemical Hurdles 7. Ozone- lethal effect on micro organism due to strong oxidizing capacity O3 treatment destroy G- ve bacteria. Y & M – resistant 8. Lactic acid, Lactate- effective agaist pathogenic organism like M. Tuberculosis, L. Momocytogenes 9. Acetic acid, acetate 10. Ascorbic acid 11. SO2 – used in the form of Sodium meta-bisulphite, or gaseous SO2 Antioxidant Enzyme inhibitor Milliard reaction inhibitor Reducing agent Antimicrobial agent
- 18. Physico-chemical Hurdles 12. Smoking:- important concept in poultry products 13. Phosphates 14. Glucono-d- lactone (GDL) – adding in cured meat GDL Gluconic acid Hydrolysis Lowering the pH Product Safety and stability
- 19. Physico-chemical Hurdles 15. Phenols- Mainly used to prevent oxidative deterioration of food- used in combination with other hurdles eg- BHA, BHT, TBHQ 16. Spices and herbs 17. Lactoperoxides 18. Lysozymes
- 20. Microbially Derived Hurdles 1. Competitive flora- in fresh meat competitive flora inhibit L. monocytogenes 2. Starter culture- 3. bacteriocins- Nicin, best known from lactic acid bacteria * Number of bacteriocins are used experimentally in poultry meat and meat products along with other Hurdle (Harris et al., 1992; Kim, 1993) 4. Antibiotics- in poultry tetracycline are accepted
- 21. Hurdle Undesirable effect Refrigeration Chilling injuries, weight loss Freezing Discoloration, Texture loss, enzymatic browning CAP Softening, discoloration, slow spoilage Pasteurization Nutritional losses, sensory losses Drying Discoloration, Flavour change, mould growth Preservatives Consumer aversion resistance Characteristics of A Hurdle alone
- 22. Guideline for Making Shelf Stable Product Using Hurdle Technology Define the desired sensory properties and shelf-life of meat product Frame a processing technology to be followed Prepare the product analyse for pH, aw, preservatives, or other inhibitory factors Predictive microbiology should be used for testing preliminary stability
- 23. Guideline for Making Shelf Stable Product Using Hurdle Technology The product is then challenged with relevant food poisoning and spoilage organisms, using somewhat higher inocula and storage temperatures than would be ‘normal’ for the products. If appropriate, the hurdles in the product are modified, taking multi- target preservation and the sensory and nutritional quality of the product (i.e. ‘total quality’) into consideration. The food is again challenged with relevant microorganisms and, if necessary, the hurdles in the food are modified again. Predictive microbiology is helpful at this stage for assessing the safety of the food.
- 24. Guideline for Making Shelf Stable Product Using Hurdle Technology After the established hurdles of the modified or new food are precisely defined, including tolerances, the methods for monitoring the process are agreed on. Physical or sensory methods for monitoring should preferably be used. The designed food should now be produced under industrial conditions, because the adequacy for a scale-up of the proposed manufacturing process must be validated. If for an industrial process the Critical Control Points (CCPs) and their monitoring are established, the manufacturing process might be controlled by HACCP. If HACCP seems inappropriate, guidelines for the application of manufacturing control by quantitative GMP must be defined.
- 25. Examples Theoretical Practical Unwanted hurdles F, heating; t, chilling; aw, water activity; pH, acidity; Eh, redox potential; pres., preservatives; V, vitamins; N, nutrients; c.f., competitive flora.
- 26. Examples
- 27. Examples Too much initial load Rich in nutrients Injured spoilage organism Nitrite Depleation
- 29. Products with Hurdle Technology
- 30. Products with Hurdle Technology