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The market for pasteurized foods and beverages is forecast to reach $35 billion by 2025 globally. One of the factors contributing to this growth forecast is that pasteurized milk and drinking water products have seen a strong increase in demand in recent years. Along with that is the demand for products that have a long shelf life and can be stored at room temperature.
Sterilized filling and packaging has become a differentiated process where the product is pasteurized independently of packaging and then filled into cans and bottles which are sterilized in an almost absolute clean environment to ensure sterility and long shelf life. This method requires extremely high temperatures during the compartment period to maintain product freshness and ensure that the product is free from contamination.
This high-temperature pasteurization method UHT is suitable for processing a wide range of foods and beverages. However, it also has pros and cons. To be able to use this method requires the right equipment, processes and technology. This means higher processing costs.
There are many forms of pasteurization of canned foods and beverages, of which two commonly used heat treatments are UHT (Ultra high temperature) and UP (Ultra pasteurization).
UHT Process
This method involves treating the product at a high temperature (135 – 154 degrees Celsius) for a short time (1-2 seconds) to achieve a sterile state for the product. The final product was tested for sterilization by incubating at 55 degrees Celsius for 7 days and at 30 degrees Celsius for 15 days and checking for bacterial growth after this incubation period. When combined with aseptic packaging and hermetic sealing, the final product can be stable for its shelf life (ambient temperature) with a shelf life of 6 to 12 months!
UHT is not a can/bottle pasteurization process. This treatment kills bacteria with less chemicals while inactivating thermophilic bacterial spores. Therefore, the final product, while sterile, must be packaged aseptically. There is also a need to establish a procedure to ensure commercial sterility not only of the product but also to the sterilization of systems, packaging equipment and packaging materials.
ESL Process
ESL processing is in between pasteurization and sterilization. There is no specific time and temperature required for this process in most countries. However, in the US, ESL products are called “super-sterilised”, which must be manufactured by heat treatment above 138º C for more than 2 seconds. However, commercially, some products are processed at 120 degrees Celsius to 140 degrees Celsius for 0.5 seconds – 4 seconds. Such products have reduced microbial counts when compared to pasteurized products, and are packaged without sealing under hygienic conditions, so the open shelf life is extended under cold storage conditions. There are also other methods for ESL products that have been developed but are less commonly used. These methods include microfiltration + HTST treatment, bactofugation + heat treatment, heat treatment + antibacterial addition, or heat treatment combined with a non-thermal technology such as UV irradiation, field technology. pulse or gamma irradiation.
Pros and Cons of the UHT treatment method
Advantages:
- A short processing time of just a few seconds after which the product is cooled and packaged aseptically.
- Longer shelf life and can be stored at room temperature
- Reduce bacterial counts to 99.99% (including pathogens) and inactivate spores. The only timing issue that arises is if milk contaminated with spore forming microorganisms survives UHT treatment, if the storage tank or biofilm formation found in the processing and filling lines cracks, or if the milk is contaminated post-processing, i.e. during packaging or handling. However, ultrahigh temperatures can achieve a 12-log reduction to control Clostridium botulinum and allow safe storage of food at room temperature, where other treatment methods such as pasteurization or ESL treatment fail. Okay.
- Packaging options for cheaper products and more choices
Disadvantages:
- The UHT method can change the taste/quality of the drink: Some flavors can be bitter taste due to peptides generated by heat-stable proteases or a rancid/acid/sour flavor due to residual bacterial enzyme activity.
- The UHT process can reduce the nutritional value of the drink: Some vitamins can be reduced due to the high temperatures in processing.
- Expensive process – complex, technical equipment, energy-intensive: The equipment for the processing usually is expensive investment.
- Milk of unknown origin due to mixing: some products can be combined into one batch for processing so the traceability can be more difficult.
