retortable flexible packaging processing...
TRANSCRIPT
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno Hariyadi
Professor at Department of Food Science & Technology, Faculty of Agricultural Engineering & Technology,Senior Scientist at SEAFAST Center,Bogor Agricultural UniversityBOGOR, Indonesia.
Retortable Flexible Packaging Processing Technology: Emerging Trends
Retortable Flexible Packaging Processing Technology: Emerging Trends
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
Shelf stable Populer teknologi pengolahan pangan pertama
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
M
L
pH1410
0
1aw
M
4.6
0.85
Critical aspect?
RETORTED FOOD = “CANNED” FOODS ?
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
L
LAFspH-controlled
foods
pH1410
0
1aw
aw-controlledFoods
4.6
0.85 Pengeringan,Penggaraman, dll
(aw controlled)
Pengasaman(pH controlled)
RETORTED FOOD = “CANNED” FOODS ?
Controlling?
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Controlling?
L
HM
pH1410
0
1aw
M
4.6
0.85 Pengeringan,Penggaraman, dll
(aw controlled)
Pengasaman(pH controlled)
RETORTED FOOD = “CANNED” FOODS ?
PEMANASAN
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Medium ‐ PHFspH > 4.5 dan aw<0.85pH < 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
Awet pada suhu refriferasi (shelf stable)
Harus refrigerasi Contoh : Sari buah, sos tomat, dll
Proses Panas
Pasteurisasi(NO RETORTING)
REGULATION
RETORTED FOOD = “CANNED” FOODS ?
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
PHFspH > 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
Hanya beberapa hari pada suhu refrigerasi
Harus refrigerasi Contoh : Susu pasteurisasi,
daging udang, kepiting, dan hasil laut lainnya
RETORTED FOOD = “CANNED” FOODS ?
REGULATION
Proses Panas
Pasteurisasi(NO RETORTING)
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
PHFspH > 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
Awet pada suhu ruang (shelf stable)
Tidak memerlukan refrigerasi Contoh : Sardine, tuna dalam
kaleng, susu steril, dll
Proses Panas
SterilisasiKomersial
(RETORTING)
RETORTED FOOD = “CANNED” FOODS ?
REGULATION
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
REGULATION
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
BAB I - Ketentuan Umum
REGULATION
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
BAB I - Ketentuan Umum
REGULATION
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
BAB III- Persyaratan Pangan Steril Komersial
REGULATION
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Pangan Steril Komersial = “canned” Foods? Regulated foods
Karakteristik:
• pH > 4.6
• Water Activity > 0.85
RETORTED FOOD = “CANNED” FOODS ?
LAFs
REGULATION
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Karakteristik:
• pH > 4.6
• Water Activity > 0.85
• Hermetically sealed container
• Thermally processed (atau ekivalen [CAC/RCP 23-1979, Rev.2 (1993)]
• Non-refrigerated, shelf-stable
RETORTED FOOD = “CANNED” FOODS ?
LAFsLACFs
Pangan Steril Komersial = “canned” Foods? Regulated foods
REGULATION
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Karakteristik:
• pH > 4.6
• Water Activity > 0.85
• Hermetically sealed container
• Thermally processed (atau ekivalen [CAC/RCP 23-1979, Rev.2 (1993)]
• Non-refrigerated, shelf-stable
RETORTED FOOD = “CANNED” FOODS ?
LACFs= COMMERCIALLY STERILE= PANGAN STERIL KOMERISAL= Canned Foods= Makanan kaleng
- Diatur dlm Perka BPOM No 24, 2016
Pangan Steril Komersial = “canned” Foods? Regulated foods
REGULATION
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
LACFs
?= COMMERCIALLY STERILE= PANGAN STERIL KOMERISAL= Canned Foods= Makanan kaleng
- Diatur dlm Perka BPOM No 24, 2016
QUIZ …!
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
LACFs
?= COMMERCIALLY STERILE= PANGAN STERIL KOMERISAL= Canned Foods= Makanan kaleng
- Diatur dlm Perka BPOM No 24, 2016
QUIZ …!
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
LACFs
?= COMMERCIALLY STERILE= PANGAN STERIL KOMERISAL= Canned Foods= Makanan kaleng
- Diatur dlm Perka BPOM No 24, 2016
QUIZ …!
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
LACFs
?= COMMERCIALLY STERILE= PANGAN STERIL KOMERISAL= Canned Foods= Makanan kaleng
- Diatur dlm Perka BPOM No 24, 2016
QUIZ …!
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
LACFs
?= COMMERCIALLY STERILE= PANGAN STERIL KOMERISAL= Canned Foods= Makanan kaleng
- Diatur dlm Perka BPOM No 24, 2016
QUIZ …!
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
RETORTED FOOD = “CANNED” FOODS ?
LACFs
?= COMMERCIALLY STERILE= PANGAN STERIL KOMERISAL= Canned Foods= Makanan kaleng
- Diatur dlm Perka BPOM No 24, 2016
RetortablePackaging (any
retortable) Packaging =
Emerging trend
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
“CANNED” FOODS jenis baru ? Retortable Packaging
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
1950: U.S. Army developed the pouch to replace heavy metal cans food containers for packaging combat rations :• lightweight, • easy-to-pack, • shelf-stable.
1965: First commercial Retortable Packaginges were produced in Italy.
“CANNED” FOODS jenis baru ? Retortable Packaging
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
1970: Large-scale R&D continued to produce “Meal Ready-to-Eat” (MRE) units for the U.S. military.
“CANNED” FOODS jenis baru ? Retortable Packaging
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Contoh produk di pasar internasional
“CANNED” FOODS jenis baru ? Retortable Packaging
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Contoh produk di pasar internasional
“CANNED” FOODS jenis baru ? Retortable Packaging
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Contoh produk di pasar internasional
“CANNED” FOODS jenis baru ? Retortable Packaging
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
“CANNED” FOODS jenis baru ? Retortable Packaging
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
? INDONESIA?
“CANNED” FOODS jenis baru ? Retortable Packaging
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
- Most Retortable Packagings : four-ply laminate
MP PP 138°C (280°F) >> 121°C (250°F).
- Al foil
main barrier (maintain hermetic condition). (Some pouch material contains polyvinylidene chloride
(PVDC, or SARAN®), ethylene vinyl alcohol (EVOH), or nylon instead of aluminum foil as a middle layer).
Retortable Packaging Packaging ?
polyester outside layerNylon
Aluminum foilPolypropylene (PP)
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Advantages of Retortable Packaginges vs. metal cans.
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Advantages of Retortable Packaginges vs. metal cans.
• Reduced cooking time Better taste, nutritional value; faster turn-around time
• Complete product evacuation Improved product yield and consumer value
• Reduced bulk and weight Lower transportation and storage costs
• Environmentally friendly Less waste and fossil fuel consumption
• Package durability Eliminate cuts and promotes employee safety
• Rotogravure printing More attractive graphics on packaging
• Package durability No dented cans
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
1. Kemasan tertutup secara hermetis: Lakukan prosedur pengisian dan penutupan kaleng dengan benar
2. Perlakuan pemanasan cukup Tercapainya sterilitas komersial (dengan tetap mempertahankan kemasan tertutu secara hermetis)
3. Penanganan kaleng dengan baik Sebelum, selama dan setelah pemanasan memastikan bahwa integritas sambungan dan penutupan Hermetis terjaga
Selalu ada kemungkinan bahwa bakteri akan masuk kembali danmencemari produk yang telah disterilisasi (T ~ 121.1C/250F)
Peranan Pengemas
Processing Technology = Canning/Retorting Proses
3 SYARAT Proses “Retorting”/LACFs SUKSES :
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Retort “biasa”:• Pemasak bertekanan (tekanan uap)• PV=nRT
• Suhu 250oF (121oC)• Tekanan 15 Psig
Retort bertekanan lebih (over-pressure)?• Suhu 250oF• Tekanan 20 -25o Psig
Perlu RETORT Khusus? BERTEKANAN LEBIH
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Selama proses pemanasan; akan terjadi peningkatan tekanan di dalam kemasan (Pi),
karena suhu yang semakin meningkat dan volume yang konstant (bahkan vol bisa semakin kecil; karena adanya proses pemuaian bahan).
~ PiV=nRT
Perlu RETORT Khusus? BERTEKANAN LEBIH
KRITIS
Po
Po
Po
Pi
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Kenapa over pressure ?melindungi integritas pengemas :
KRITIS
Po
Po
Po
• Kritis Pi >> Po
• Retort biasa:
• Po ~ 15psig, terlalu kecil untuk mengimbangi Pi
untuk jenis kemasan tertentu kerusakan kemasan (terutama pada bagian-bagian sambungan, heat seal)
Pi
Perlu RETORT Khusus? BERTEKANAN LEBIH
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Kenapa over pressure ?melindungi integritas pengemas :
1. Terutama untuk pengemas yang kurang kuat terhadap “internal pressure”, atau
2. Sistem pengemas yang mempunyai“penutup” yang kurang kuat
Contoh : wadah plastiksemi-kaku, flexible pouches, gelas
Perlu RETORT Khusus? BERTEKANAN LEBIH
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
1. Harus cukup kuat untuk menjamin keamanan
2. Dilengkapi dengan katup pengatur tekanan dalam retort
3. Di dalam retort terdapat cukup ruang (antara dinding dengan wadah) untuk menjamin sirkulasi uap
4. Jika proses termal dilakukan dengan medium pemanas air, maka harus ada ruangan cukup diantara permukaan air dengan tutup retort untuk tempat overpressure
RANCANGAN RETORT UNTUK PROSES TERMAL
DENGAN OVERPRESSURE (2)
Perlu RETORT Khusus? BERTEKANAN LEBIH
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
5. Medium pemanas yang umum adalah air yang dipanaskan dengan uap
6 inci
Uap/ dan campuran uap+udara
Air
RANCANGAN RETORT UNTUK PROSES TERMAL
DENGAN OVERPRESSURE (2)
Perlu RETORT Khusus? BERTEKANAN LEBIH
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
6. Selain itu sumber overpressure adalah kompresor udara
7. Udara bertekanan yang masuk ke dalam retort yang berisi air berfungsi sebagai pengaduk (re: sifat insulator udara?)
8. Validasi? www.iftps.org- Heat distribution test keseragaman pemanasan
- Heat penertration test Evaluasi kecukupan panas penentuan nilai F0
RANCANGAN RETORT UNTUK PROSES TERMAL
DENGAN OVERPRESSURE (3)
Perlu RETORT Khusus? BERTEKANAN LEBIH
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Kecukupan panas untuk mencapai kriteria sterilisasi komersial ini dinyatakan sebagai nilai F0
Suatu nilai/dosis panas yang dinyatakan sebagai ekivalen waktu pemanasan pada suhu acuan; 250oF atau 121.1oC.
Penentuan Kecukupan Pangan (- Heat Penetration test)
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
• Tipikal kurva penetrasi panas untuk makanan kaleng dan perubahan suhu retort (TR) selama proses seterilisasi
• Suhu retort di”set” pada250oF
• T untuk mencapai TR : CUT
Penentuan Kecukupan Pangan (- Heat Penetration test)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Penentuan Kecukupan Pangan (- Heat Penetration test)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
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Hariyadi, P. 2016. Retortable Flexible Packaging Processing & Packaging Technology: Emerging Trends. [email protected]
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
BAB III- Persyaratan Pangan Steril Komersial
Penentuan Kecukupan Pangan (- Heat Penetration test)
INGAT !!!
Purwiyatno [email protected] Hariyadi Blog: phariyadi.staff.ipb.ac.id Email: [email protected]
Thank You