BR112015032528B1 - PASTEURIZATION IN BOTTLE - Google Patents

Abstract

bottle pasteurization. a system and method for producing a packaged beverage or food item that may include processing a first food source that includes a spoilage microorganism along a first processing path, which may limit the temperature of the first food source drops below a temperature level which causes the spoilage microorganism to be inactivated. a second food source may be processed along a second processing path, which may heat the second food source to be within a predetermined temperature range that causes spoilage microorganisms in the second food source to be substantially inactivated when are in the predetermined temperature range for a predetermined period of time. a pack can be filled with the first and second food sources. the second food source, when mixed with the first food source, may be in the predetermined temperature range for the predetermined period of time on the package to inactivate the spoilage microorganism.

Description

CROSS REFERENCE TO RELATED ORDER

[0001] This Application claims the benefit of U.S. Applications 13/926,881, and 13/926,909, filed June 25, 2013, which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION:

[0002] Food pasteurization is performed by heating food, usually liquids, to a temperature within a certain temperature range for a certain amount of time to eliminate or inactivate microorganisms. By reducing or eliminating microorganisms, food spoilage is slowed down and illnesses that can result from people ingesting pathogens are greatly reduced. As understood in the art, food sterilization is performed by heating the food to higher temperatures than pasteurization. Sterilization results in foods that are less acceptable, from a consumer taste perspective, than pasteurization.

[0003] The pasteurization of different foods uses different sets of pasteurization procedures. For example, pasteurizing juice with a high amount of pulp in a mass production setting is often carried out using a dual stream pasteurization process. One chain or production line processes and pasteurizes the pulp, and another chain or production line processes and pasteurizes the juice. By pasteurizing both juice ingredients (ie pulp and juice), a producer of a juice product with juice and pulp ensures that spoilage microorganisms in minimal amount or no spoilage microorganisms proliferate in the resulting juice product.

[0004] In some traditional methods, the pulp is produced from fruit and frozen in large barrels or other containers to preserve the pulp for a period of time until it is ready for inclusion in a drink, such as orange juice or food. The process of preparing the frozen pulp includes crushing the ice containing the pulp, producing a pulp slurry by mixing the ground frozen pulp with water and syrup, and heating the pulp slurry to a pasteurization temperature under a certain back pressure minimum, usually 0.03 MPa (0.3 Bar) or more, to cause the microorganisms to be inactivated. The pasteurized pulp slurry is then poured into a package, such as an orange juice container, to mix with the pasteurized juice to produce a consumer food or beverage product.

[0005] Pulp pasteurization is both costly and ineffective. The total cost of pasteurizing the pulp is a result of the energy cost to heat the pulp to a pasteurization temperature using heating equipment, the cost of maintaining the pasteurization equipment, the cost of time to pasteurize and process the pulp. , the cost of pulp due to the ineffectiveness of pasteurizing the pulp, the cost of personnel to operate and maintain the manufacturing equipment, and the capital costs of the pulp pasteurization equipment for new food or beverage processing operations.

[0006] The ineffectiveness in pasteurizing the pulp is a result of maceration or destruction of the pulp to a size that is not noticeable or acceptable to a consumer. Pulp maceration is a result of a combination of heating the pulp to pasteurization temperatures under back pressure. It is well understood that pulp maceration due, in part, to the pulp pasteurization process results in a loss of 50% or greater of usable pulp to satisfy consumer acceptable taste requirements. As an example, if the juice contains 5% to 7% pulp, then 15% to 20% or more pulp as a percentage of the pulp slurry is used due to pulp maceration.

SUMMARY

[0007] The principles of the present invention provide for the pasteurization of pulp in a package by mixing unpasteurized pulp with liquid at a pasteurization temperature, thus enabling the heated liquid to pasteurize the pulp. As a result, manufacturing costs and the inefficiency of pulp processing are significantly reduced as pasteurizing the pulp before it enters packaging can be eliminated.

[0008] One embodiment of a method for producing a packaged beverage or food item may include processing a first food source that includes a spoilage microorganism along a first processing path. The first processing path can limit the temperature of the first food source to below a temperature level that causes the spoilage microorganism to be inactivated. A second food source can be processed along a second processing path. The second processing path can heat the second food source to be in a predetermined temperature range which causes spoilage microorganisms in the second food source to be substantially inactivated when they are in the predetermined temperature range for a predetermined period of time. A package can be filled with the first and second food sources. The second food source, when mixed with the first food source, can be in the predetermined temperature range for the predetermined period of time on the package to cause the spoilage microorganism to be inactivated. The packaging can be consumer packaging.

[0009] An embodiment of a system for producing a packaged beverage or food item may include a first processing path configured to process a first food source that includes a spoilage microorganism. The first processing path can limit the temperature of the first food source to below a temperature level that causes the spoilage microorganism to be inactivated. A second processing path may be configured to process a second food source, wherein the second processing path may heat the second food source to be within a predetermined temperature range that causes spoilage microorganisms in the second source of food. food are substantially inactivated when they are in the predetermined temperature range for a predetermined period of time. The first and second processing paths can be further configured to fill a package with the first and second food sources. The second food source, when mixed with the first food source, can be in the predetermined temperature range for the predetermined period of time on the package to cause the spoilage microorganism to be inactivated.

[0010] One embodiment of a method of retrofitting a pulp slurry processing subsystem may include providing the pulp slurry processing subsystem having a fluid path inclusive of a heater element in fluid communication with a slurry tank. merge and a filler. The heater element can be configured to pasteurize the blended pulp slurry from the blend tank. A contour conduit can be fluidly connected along the fluid path between the blend tank and the filler, where the contour conduit causes the blended slurry slurry from the blend tank to bypass the heating element.

[0011] An embodiment of a packaged beverage or food item may include a consumer package, a processed food composition that includes a microorganism, and a liquid that is at a temperature in a predetermined range applied to the processed food composition to form a first mixture in the consumer package which, as a result of the liquid being in the predetermined range, causes the microorganism to be substantially inactivated.

[0012] One embodiment of a method for manufacturing a packaged beverage or food item may include providing a processed food composition that includes a microorganism. A liquid being used to form the food or beverage article can be pasteurized, where pasteurization includes heating the liquid to a predetermined temperature range. In a consumer package, the liquid in the predetermined range and the processed food composition can be combined to form a first mixture such that the liquid in the predetermined range causes the microorganism to be substantially inactivated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The illustrative embodiments of the present invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference in this document and in which:

[0014] Figure 1 is a schematic diagram of an illustrative system for performing a dual filler process to process pulp and liquid to produce a juice beverage;

[0015] Figure 2 is a schematic diagram of alternative illustrative subsystems for processing pulp in the production of a fruit drink;

[0016] Figure 3 is a schematic diagram of another alternative illustrative subsystem for processing pulp in the production of a fruit drink;

[0017] Figure 4 is a schematic diagram of yet another alternative illustrative subsystem for processing pulp in the production of a fruit drink;

[0018] Figure 5 is a flow diagram of an illustrative pulp processing modality;

[0019] Figure 6 is a graph of illustrative processing results showing the change in temperature and survival of Gluconobacter spp during heating at 68°C in three pH formulations;

[0020] Figure 7 is a graph of illustrative processing results showing the change in temperature and survival of Saccharomyces cerevisiae during heating at 68°C in three pH formulations;

[0021] Figure 8 is a graph of illustrative processing results showing the change in temperature and survival of Penicillium crysogenum during heating at 68°C in three pH formulations;

[0022] Figure 9 is a graph of illustrative processing results showing the change in temperature of a juice formulation, in this case the juice product "Minute Maid Pulpy";

[0023] Figure 10 is a table showing illustrative results showing temperatures at which beverages, which have been pasteurized after inoculation with a spoilage yeast cocktail, are produced;

[0024] Figure 11 is a table showing illustrative results showing the temperatures at which beverages that have been pasteurized after inoculation with a spoilage yeast cocktail are produced with increased microbial load and reduced inversion time;

[0025] Figure 12 is a table showing illustrative process test results with spoilage yeast;

[0026] Figure 13 is a table showing illustrative process test results with mold and/or yeast;

[0027] Figure 14 is a table showing illustrative process test results with peach particles;

[0028] Figure 15 is a flow diagram of a process for producing a packaged beverage or food item;

[0029] Figure 16 is a histogram showing illustrative process results for peach particle hardness; and

[0030] Figure 17 is a series of scatter plots showing illustrative process results for peach particle homogeneity.

DETAILED DESCRIPTION

[0031] According to the principles of the present invention, a food or beverage is pasteurized in a container by combining it with hot fluid. In some modalities this occurs in the absence of aseptic conditions. In certain embodiments, the principles of the present disclosure include mixing unpasteurized beverage or food with liquid at pasteurization temperatures to pasteurize the unpasteurized beverage or food. Mixing may include simply mixing, stirring, shaking, inverting, or any other process that integrates the unpasteurized beverage or food with the liquid at pasteurization temperatures to pasteurize the unpasteurized beverage or food.

[0032] In certain embodiments, the principles of the present invention provide the pasteurizing pulp or food particles in a package, such as, without limitation, a bottle, mixing unpasteurized pulp or food particles with liquid under pasteurizing temperature , thus enabling the heated liquid to pasteurize the pulp. As a result, manufacturing costs and the inefficiency of pulp processing are significantly reduced as pasteurizing the pulp before it enters packaging can be eliminated.

[0033] In certain embodiments, the disclosure provides pasteurized processed food compositions in a package by mixing unpasteurized food compositions with liquid at a temperature in a predetermined range (packaging processing), thus enabling the heated liquid to pasteurize the food. Mix the liquid and food in the package and maintain the temperature for a certain time at a liquid equilibrium temperature or substantially inactivate the microorganisms.

[0034] "Packaging" processing means the pasteurization of food, such as pulp or food particles, by heated liquid in a consumer package. Any consuming packaging is useful in the methods described in this document. In certain embodiments, bottles, which include glass, plastic bottles, or other packaging materials, can be used.

[0035] In general, consumer packaging allows for pasteurization in packaging of the food item or beverage. In various embodiments, consumer packaging can be plastic bottles, glass bottles, aluminum cans, cardboards, cups, or other suitable material.

[0036] In certain modalities, consumer packaging can be composed of metal, polymeric materials such as polystyrenes and polyesters based on polypropylene or polyethylene terephthalate (PET), materials based on paper, silica, ceramic, glass or similar. For example, the bottle can be plastic or glass. For example, the bottle is plastic and formed from a polymer-based thermoplastic material. In various embodiments, consumer packaging can comprise polymeric materials such as polyethylene naphthalate (PEN), polyketones such as ethylene copolymer with carbon monoxide and liquid crystal polymers (LCP) which can be used alone or blended with other polymers such as, for example, PET. In certain arrangements, metal-based consumer packaging such as aluminum cans are employed. Consumer packaging can be disposable or non-disposable.

[0037] In certain embodiments, the consumer packaging may exhibit improved gas permeation barrier properties, odor, taste and/or aroma. In certain embodiments, the consumer package has good stability against tipping, for example, during filling and/or in its empty condition, for example, when the container is handled. Additionally, in certain embodiments, the consumer package has a closure that is easy to remove and/or a neck configuration and/or a good size that makes it convenient to consume the beverage directly from the bottle.

[0038] In certain modalities, packaging processing reduces or eliminates heat-sensitive microorganisms that can spoil the food or that are pathogens or spoilage microorganisms. Heat sensitive microorganisms are defined as microorganisms that are substantially inactivated by the in-pack pasteurization process disclosed herein, this includes incubation at an equilibrium temperature for a retention time. Substantially inactivated microorganisms are microorganisms that are eliminated or lack the ability to reproduce. The equilibrium temperature is the temperature reached by the packaged beverage or food item after the processed food composition and the liquid having a temperature in a predetermined range are mixed. The equilibrium temperature can be reached between 1 second and 2 minutes after mixing or up to 3 or 5 minutes after mixing. In various modes, the equilibrium temperature is between 66 °C and 80 °C, 70 °C and 80 °C, 72 °C and 80 °C, or 75 °C to 80 °C. Retention time is the length of time the packaged beverage or food item is within the equilibrium temperature range. In various modes, the hold time can be in the range of 1 to 300 seconds, 1 to 200 seconds, or 1 to 100 seconds.

[0039] By reducing or eliminating heat-sensitive microorganisms, food spoilage is slowed down and diseases that can result from ingesting the food are prevented. In addition to destroying heat-sensitive microorganisms, pasteurization and the packaging process can inactivate unwanted enzymes while retaining optimal flavor.

[0040] In contrast to pasteurization, food sterilization aims to eliminate microorganisms which includes heat-resistant microorganisms. Sterilization of food is performed by heating the food to higher temperatures than pasteurization. Sterilization results in foods that are less acceptable from a consumer taste perspective. In various modalities, pasteurization causes bacteria to inactivate to levels less than the detection limit, less than 50,000, 100,000 or 250,000 colony-forming units per gram of beverage or packaged food item.

[0041] Any food can be pasteurized in this way, for example, processing in packaging provided it is mixed with a liquid or steam of suitable temperature for sufficient time. For example, any fruits, vegetables, oil fruits and the like can be useful in the methods described herein. Certain modalities include citrus pulp, orange pulp, grapefruit pulp, or peach pieces, mango pieces, Aloe vera pieces, or coconut cream. Other modalities can include banana pieces or apple pieces. The processed food composition may include fruit particles or citrus pulp such as oranges, lime oranges, clementine oranges, cunquates, limes, combavas, satsumas, mandarins, tangerines, ciders, pomelos, lemons, wrinkled lemons, grapefruits, mandarins, tangerines , hybrids thereof, or combinations thereof. In addition, the processed food composition may comprise fruit particles or non-citrus fruit pulp such as kiwi, mango, grape, banana, berry, pear, apple, peach, pineapple, melon, apricot, strawberries, raspberry, blackberry, cassis, blueberry, gooseberry, peach, cranberry, passion fruit, papaya, lychee, pomegranate, fig, plum, cherry, gooseberry, cucurbit, persimmon, date palm, guava, rhubarb, coconut, or combinations thereof. In certain embodiments, the processed food composition includes food grade gel particles that are composed of food grade polymers that include, without limitation, gelatin, alginate, or pectin or particles formed through culture.

[0042] Referring to Figure 1, a schematic diagram of an illustrative system 100 for performing illustrative dual filler processes in parallel in the production of a fruit beverage is shown. System 100 can include two subsystems 100a and 100b, wherein subsystem 100a can process a first frozen food source, such as frozen pulp 102, and subsystem 100b can process a liquid, such as juice 104. For the purposes of this description, subsystem 100a is described with reference to frozen pulp, but it is contemplated that alternative foods that are frozen or non-frozen are contemplated.

[0043] In relation to subsystem 100a, in processing frozen pulp 102, an ice crusher 106 or other device for breaking or reducing the ice in which the pulp is being held may be used. The crushed ice with the pulp can be placed or flown into a pulp slurry tank 108 where syrup 110 and water 112 can be mixed to produce a pulp slurry 114. Syrup 110 and water 112 are used to produce the pulp slurry 114 having certain flow, density and taste characteristics as understood in the art.

[0044] The slurry slurry 114 can be fluidized through a conduit path 116 through the use of a pump 118, such as a rotary pump, or other flow mechanism in a blend tank 120. The blend tank 120 can be used to blend the pulp slurry 114 with a feedback pulp slurry 122 via the feedback conduit 124, as described further below herein. Blend tank 120 can be used to maintain a slurry of blended pulp within a given temperature range, water to pulp ratio, and/or any other characteristic. The given temperature can be between approximately 15 °C and approximately 65 °C, which is below a pasteurization temperature. The blended pulp slurry 126 can be flowed through conduit path 128, optionally through a valve 130, to a filler 132 such as a piston filler. Filler 132 may include one or more filler nozzles 134a-134n (collectively 134) to fill containers (not shown) with a given amount of pulp.

[0045] As understood in the art, pulp and other food sources need to continue to flow through the conduits to avoid clogging the conduits or being trapped in the conduits and decomposing in the conduits. As a result, recycling or feedback conduits 136 and 138 are provided to enable the mixed pulp slurry 126 which cannot be used or processed fast enough by filler 132 to be discharged into a recirculation tank 140. The recirculation 140 can be configured to maintain the feedback pulp slurry 122 in a given viscous state by maintaining the feedback pulp slurry in a given temperature range below a pasteurization temperature. For example, the temperature range can be between approximately 15 °C and approximately 65 °C. A valve 142 can be included along conduit 136 to enable, limit, or prevent the mixed slurry slurry 126 from flowing into the recirculation tank 140. The feedback slurry 122 can be fed back through the conduit 124 by means of a pulp 144.

[0046] Between the blend tank 120 and filler 132, a pump 146, such as the rotary pump, heat exchanger 148, and cooler 150 which historically have been used to pasteurize the blended pulp slurry 126 can be removed or bypassed in accordance with the principles of the present invention, since the blended pulp slurry 126 must be pasteurized into containers (not shown) filled by filler 132. As a result of bypassing or eliminating pump 146 and heat exchanger 148, pasteurization temperatures and back pressures that cause high levels of pulp maceration are eliminated. Cooler 150 in the feedback can also be eliminated or bypassed as the blended pulp slurry 126 is fluid at a temperature below a pasteurization temperature, thus having the ability to flow back into the blend tank 120 without being cold. As described above, the elimination of pump 146, heat exchanger 148, and cooler 150 significantly reduces pulp maceration, cost of heating and cooling resources, capital costs for new equipment, maintenance costs, labor costs. work to maintain the equipment, processing time, and so on.

[0047] With continued reference to Figure 1, subsystem 100b is conventional and may include a blending tank 152 in which juice 104 can be blended with water 154 and flavor 156 to produce a first stage blended juice 158. The blended juice stage 158 may be fluid from the blend tank 152 via conduit 160. A pump 162, such as a centrifugal pump, may be used to control the flow of the first stage blended juice 158 via conduit 160 to the blend tank 164. Blend tank 164 may be used to blend the first stage blended juice 158 with the feedback blended juice 166, as further described herein, to create a second stage blended juice 168.

[0048] Second stage mixed juice 168 can be passed through a conduit 170 using a pump 172, such as a centrifugal pump, to a heating element 174, such as a heat exchanger. Heating element 17 can cause the second stage blended juice 168 to be heated to a predetermined temperature range, such as a pasteurization temperature range, which causes most pathogens to be inactivated and a majority of non-pathogens to remain active. Heating subsystems can include multiple types of equipment such as pressurized tanks, jacketed tanks, steam injection, or any other equipment as understood in the art.

[0049] Further provided in subsystem 100b of Figure 1 is a valve 176 which can be used to cause a back pressure in conduit 170 to limit the flow of pasteurized juice 178 (i.e. heated second stage mixed juice 168). Pasteurized juice 168 can be flowed through conduit 180 to a filler 182 having one or more filler nozzles 184a-184n (collectively 184). The filler 182 may be a piston filler or any other type of filler as understood in the art. Similar to subsystem 102a, recycling or feedback conduits 186 and 188 can be used to discharge pasteurized juice 178 to be dispensed from filler 182 into the containers (not shown). In the event that filler 182 cannot dispense as much pasteurized juice 178 that is being produced. Such recycling limits the potential that the pasteurized juice will remain stagnant in conduit 180 or filler 182, as understood in the art. Discharged or recycled pasteurized juice 178 can be temporarily stored in a recirculation tank 190. Two valves 192 and 194 can be used to limit the flow of pressurized juice 178 to filler 182 and recirculation tank 190, respectively. From the recirculation tank 190, the mixed feedback juice 166, which has already been pasteurized, can be flowed back into the mix tank 164 through conduit 192 by pump 192 through cooler 194. Cooler 194 can be used to reduce the temperature of the pasteurized juice 178, thus preventing the overheating of the second stage blended juice 168 as it passes through the heater 174.

[0050] In one embodiment, the containers can be filled with the pasteurized juice 178 before the containers are filled with the blended pulp slurry 126 dispensed by the filler 132. Alternatively, the blended pulp slurry 126 can be dispensed into the interior of the containers after the containers have been filled with the pasteurized juice 178. Regardless of whether the containers are filled with the mixed pulp slurry 126 before, after, or simultaneously with the pasteurized juice 178, an equilibrium temperature resulting from the temperatures of the pasteurized juice 178 and of the blended pulp slurry 126 should be in a temperature range long enough to pasteurize the blended pulp slurry 126 in the containers. The ability to pasteurize pulp or other food materials (eg, oilseed fruits) by another food product component (eg, fruit juice) in a mass production operation was unexpected and an approach contrary to industry standards and practices .

[0051] Schematic diagrams of alternative illustrative subsystems 200a and 200b for processing pulp in the production of a fruit beverage are shown in Figures 2A and 2B, respectively. Subsystem 200a may include a pulp slurry tank 204, first blend tank 206, second blend tank 208, and filler 210. First blend tank 206 may utilize a heating jacket or other heating element to increase the pulp slurry temperature 212. Second blend tank 208 may also include a heating jacket or other heating element to maintain a pulp slurry filling temperature 212 below that of a pasteurization temperature prior to pulp filling slurry slurry inside the containers by filler 210. As a result of not heating the slurry slurry 212, much cost is saved due to lower energy use, production volume is greater, and less pulp maceration results. The filler 210 may be a piston filler or other filler for filling consumer containers or other containers, as understood in the art. Recirculation, as described in relation to Figure 1, can be used in subsystem 200a. In an alternative, subsystem 200b can be retrofitted to an existing production line with a single filler, thus adding a new parallel production line for pulp and/or fruit particle batch processing as described in this document, and a new slurry dispenser.

[0052] Referring to Figure 3, a schematic diagram of another alternative subsystem 300 for processing pulp in the production of a fruit drink is shown. Subsystem 300 may include an ice crusher 302, pulp slurry tank 304, blend tank 306, heating device 308, and filler 310. In that case, heating device 308 may be a heating coil and may be configured to heat the blended pulp slurry 312 to a temperature below a pasteurization temperature. Recirculation, as described in relation to Figure 1, can be used in subsystem 300.

[0053] Referring to Figure 4, a schematic diagram of yet another illustrative alternative subsystem 400 for processing pulp in the production of a fruit drink is shown. Subsystem 400 may include an ice crusher 402, pulp slurry tank 404, heating device 406, blend tank 408, and filler 410. Heating element 406 may be a heating coil that does not use back pressure to heat the slurry slurry 412. The blend tank may utilize a heating element, such as a heating jacket, to heat the heated slurry slurry 414. Both the heating device 406 and the blend tank 408 can heat the slurry of pulp to a temperature below that of a pasteurization temperature. Recirculation, as described in relation to Figure 1, can be used in subsystem 300.

[0054] Consequently, in certain embodiments, the frozen food is thawed and reduced in size by placing the food in an ice crusher to break down the material as needed. The thawed and/or reduced food, e.g. food particles, is then added to a consumer package as described herein. The heated liquid, for example, water, sparkling water, juice such as fruit juice or vegetable juice, broth and the like is then added to the consumer package. The heated juice or liquid may have a temperature in the range of 72°C to about 87°C, 75°C to about 87°C, 79°C to about 87°C, 81°C to about 87°C C, 82°C to about 87°C, 85°C to about 87°C, 72°C to about 90°C, 75°C to about 90°C, 79°C to about 90°C C, 81°C to about 90°C; 82°C to about 90°C, 85°C to about 90°C, 83°C to about 86°C, or 84°C to about 85°C. In some modes the temperature is between 81 °C and 87 °C. In certain modalities, the mixture of thawed food and heated liquid can be held at equilibrium temperature for 1 to 300 seconds, 1 to 200 seconds, 1 to 100 seconds, or 1 to 50 seconds or for at least 5 seconds. In certain modalities, the temperature of the mixture will be between 40 °C and 90 °C, 50 °C and 90 °C, 55 °C and 85 °C, 60 °C and 80 °C, 60 °C and 70 °C, or 66°C and 80°C.

[0055] In some embodiments, the mixture may be agitated or inverted to ensure mixing of the food and processed liquid. In certain embodiments, the consumer package can be capped or sealed with a lid. In certain embodiments, the consumer package is capped or sealed by being inverted to ensure pasteurization of the interior of the consumer package.

[0056] In certain embodiments, the principles of the present invention provide a method for producing a beverage having equal food/pulp content that requires less food/pulp during processing.

[0057] In various embodiments, the percentage by weight of the processed food composition (e.g., pulp) in the packaged beverage or food item can be about 1% to about 10%, about 10% to about 20%, about 20% to about 30%, about 30% to about 40%, or about 40% to about 50%.

[0058] Once processing as described herein is completed, in certain embodiments, the principles of the present invention provide a pasteurized beverage mix. The packaged mix can be stored and/or shipped to consumers.

[0059] One of the surprising and unexpected features of the packaging process is that less processed food composition (eg pulp) is needed to achieve the same level of pulp content in a juice/pulp mixture compared to when pulp and juice are pasteurized separately and mixed later. Therefore, packaging processing required less pulp than any other methods. Furthermore, the pulp is of superior quality. For example, pulp that is pasteurized in packaging may end up being longer or larger than any other method.

[0060] Processing in packaging can result in substantial time savings, greater energy efficiency and reduction in energy use and reduction in production cost. For example, estimated minimum energy cost savings include 30-40%, up to about 80%, slurry pasteurizer savings of 5-10%, up to about 30%, savings on the entire hot fill line . Packing processing also improves work safety as the processed food composition does not need to be pasteurized separately.

[0061] In certain modalities, the pulp pasteurization occurs in the packaging as a result of the heat exchanged from the pasteurized juice. This in-pack pasteurization offers several surprising and unexpected results which include: 1) reduced cost of goods (COGs) in pulp as a result of reduced maceration from back pressure requirements for pulp pasteurization, 2) reduced energy through removal/reduction of heating stream, 3) reduced upfront capital costs for new production lines, 4) higher product quality, and 5) greater safety for workers in the processing facility as the processed food composition does not need to be pasteurized separately. In other embodiments, sterilization of the pulp may occur in the packaging as a result of heat exchange of the juice or heated liquid.

EXAMPLE 1 PACKAGING TEMPERATURE MONITORING

[0062] To monitor the change in temperature of the liquid in the package after the pasteurized juice was added, a lid was fitted with a food thermometer by making a small hole in the top of a plastic bottle. In certain modalities, the process was carried out with juice at 84 °C and pulp at 22 °C. After the liquid in the package reached a temperature equilibrium (-45 s), the temperature was recorded with the bottle in a vertical position for 4 minutes near the edges of the bottle (with the expectation that near the edge of the plastic claw was where heat loss would occur at the fastest rate).

[0063] In certain modalities, the temperature in packaging was monitored for more than 3.5 minutes after the hot juice (84 °C) was added to the pulp at room temperature (22.5 °C) (Figure 9). The temperature remained high enough over that length of time to cause a 6-log reduction in representative yeast, mold, or spoilage bacteria in the heat-kill study dataset (Figures 6 through 8).

EXAMPLE 2 THERMAL DEATH STUDIES (D AND Z VALUES)

[0064] To test the effectiveness of the system, heat death studies with a selection of microorganisms including Penicillium crysogenum, Saccharomyces cerevisiae and Gluconobacter spp as examples for heat sensitive microorganisms were conducted. The data demonstrates microorganism inactivation substantially in response to the predetermined temperature, monitored in packaging over time after adding hot pulped juice.

[0065] In certain modalities, a production process was carried out using common spoilage microorganisms to demonstrate that pasteurized juice juice filled on top of unpasteurized pulp can substantially inactivate the microorganisms, which caused the product to be pasteurized and free of microorganisms or having a significantly reduced amount of spoilage microorganisms. In certain studies, heat death studies in the beverage mix were conducted while the temperature change in the packaging was monitored.

[0066] Examples are also disclosed where heated juice was added to the pulp inoculated in PET bottles. The resulting data were used to establish parameters for pasteurization in pulp packaging.

[0067] The microorganisms, such as yeast and bacteria, were cultivated aerobically in adequate broth and at appropriate temperatures. A list of selected microorganisms used in this study is provided in Table 1. TABLE 1 SAMPLE OF MICROORGANISMS USED.

[0068] To determine the effect of pH on the D and z values, the orange juice pulp was used at a pH of 3.8. In this regard, the D value refers to the decimal reduction time and is the time required at a given temperature to eliminate 90% of the organisms being studied, and the z value of an organism is the temperature needed for the thermal destruction curve move through a cycle of one (1) log.

[0069] To conduct the heat inactivation tests and determination of the D and z values, four heating temperatures were planned. An oil bath methodology was used to perform the heat inactivation tests. Each inoculated product formulation was divided into portions (2 ml) and transferred into sterile universal screw top wide-mouth glass ampoules with caps and septum-bonded (Phenomenex, UK) and sealed. The rubber septum allowed the thin wire thermocouples to penetrate into the test material and record its temperature profile. Three probes were reserved to monitor the oil temperature inside the water bath and the remaining probes were reserved to monitor the sample temperature during the warm-up period. Once the oil temperature was balanced to the target heating temperature, the test ampoules containing the inoculated product were immersed in the oil bath, and specific heating profiles were recorded by data acquisition equipment. At the come-up times (time taken to reach the target temperature inside the sample ampoules) and at predetermined intervals during the heating process, the test ampoules (in triplicate per organism) were removed and immediately immersed in ice before sampling and enumeration. For enumeration, each ampoule was opened aseptically and the contents were plated on an agar plate suitable for enumeration. All tests were run in triplicates and datasets were plotted as mean survivor curves together with standard deviation error bars. All microorganisms were inactivated at the lowest target temperature, 68 °C.

EXAMPLE 3 INOCULATION

[0070] The orange pulp and peach particles were mixed at a ratio of 50/50 (w/w) and heated to 80 °C for 10 minutes to eliminate any microorganisms present in the sample. The slurry was cooled to <50 °C (comfortably warm to the touch), and inoculated with the microorganism to mimic the level of microorganism that could be present based on the ingredients. In this example, for orange pulp, 103 and 104 cfu/g pulp was the target inoculation; for peach particles, 105 and 106 cfu/g was the target inoculation. Inoculations were performed by aseptically transferring the microorganisms diluted in phosphate-buffered saline. The inoculated pulp was plated after each experiment to enumerate the microorganisms and to ensure that the inoculation was viable.

EXAMPLE 4 PASTEURIZATION PROCESS IN PACKAGING

The inoculated pulp slurry was heated. Subsequently, the pulp slurry was added to the bottle, the temperature was recorded and pasteurized juice was filled into the top of the bottle. The bottle was capped and inverted for a set period of time and then kept at room temperature for at least 60 seconds. The bottle was then placed in a cold water bath until it cooled to room temperature. The cooled inoculated pulp and pasteurized juice cooled to room temperature (as opposed to hot pasteurized juice) were added together as a positive control to demonstrate that it was the hot pasteurized juice that substantially liquidated or inactivated the microorganisms.

[0072] In one embodiment, both pulp and peach particle slurries were heated to 62 °C (± 2 °C), instead of the standard 88 to 92 °C for pulp and 96 to 99 °C, respectively, while the juice pasteurization temperature remained 90 °C (± 2 °C), but the juice filling temperature was 89 °C (± 2 °C). In another embodiment, the temperature range for the pulp and peach particle slurries, and the pasteurization and juice filling temperatures was 89 °C ± 10 °C.

EXAMPLE 5 TESTS FOR COLONY-FORMING MICRO-ORGANISMS

[0073] The beverages were incubated at 28 °C (ideal temperature for yeast, mold and acidophilic bacteria) and tested on day 2 and day 7 for the presence of colony-forming microorganisms. That incubation period is to ensure that the method has the ability to detect even small amounts or an individual microorganism, such as a yeast cell or mold spore, that has survived the process. The absence of proliferation is the desirable result in certain modalities. A schematic illustration of the packaging pulp processing process 500 is depicted in Figure 5. Process 500 is an embodiment used to test the bottle pasteurization process in accordance with the principles of the present invention. Alternative processes can be used to test the process or manufacture using the process in packaging, too.

[0074] Test process 500 started at step 502, in which a 50/50 slurry of pulp with water was heated to about 80 °C for about 10 minutes to pasteurize the pulp. In step 504, the pulp was cooled before adding the inoculum 103 and 104 cfu/g (colony forming unit per gram) of pulp. A sterilized container or consumer pack 506 (e.g., bottle) that was rinsed with chlorinated water or other sterilization treatment in step 508 was filled with 60 grams of pulp slurry, which contains about 5% pulp. In addition, the juice drink with about 10% juice was pasteurized to a final temperature between about 81°C and about 85°C in step 510, and added to consumer package 506 to form a fruit drink. Alternative temperature ranges can be used, too. In step 512, consumer package 506 was capped and inverted, thereby inactivating any potential pathogens residing on top of package 506. Package 506 remained inverted for about 10 seconds in step 514, and cooled in a water bath in step 516. In step 518, package 506 was incubated at approximately 28 °C for 2 days and tested for yeast proliferation with a 1 ml pour plate technique. The positive control included in the experiment included juice at 21 °C and slurry inoculated with 103 yeast.

EXAMPLE 6 THERMAL DEATH STUDIES

[0075] Heat inactivation of Gluconobacter spp. at 68°C resulted in counts below the detection limit (<10 cfu/ml) at the heating time (time to reach target temperature). A warm-up profile for this organism was run to monitor the effect of temperature change to the target temperature (ie, warm-up time) on organism levels (Figure 6). The results showed that in the product with pH of 3.8 and 4.1, heating for more than 2.5 minutes (corresponding to temperatures greater than 62.05 °C) led to counts below the detectable limits (black arrows on the figure). At pH 3.5, counts below detection limits were obtained after 2 minutes into the heating profile (corresponding to temperatures greater than 59.2 °C).

[0076] Counts below the detection limits were also obtained for Saccharomyces cerevisiae spores in the heating time to the target temperature (68 °C). A heating profile for this strain indicated that in the product with pH of 3.8 and 4.1, heating for more than 2.5 minutes (corresponding to temperatures greater than 62.2 °C) led to counts below the limits detectables (black arrows in the figure). At pH 3.5, counts below detection limits were obtained after 2 minutes into the heating profile (corresponding to temperatures greater than 60.75 °C) (Figure 7).

[0077] Spore counts below the detection limit were also obtained for P. crysogenum at the warm-up time to the target temperature (68 °C) in all three pH formulations. A heating profile for this strain also showed that heating for more than 3 minutes (corresponding to temperatures greater than 66.5°C) led to counts below detectable limits (black arrows in figure) in all pH formulations ( Figure 8).

EXAMPLE 7 PULP PROCESSING

[0078] The examples surprisingly demonstrate that packaging processing produces a pasteurized beverage in which heat sensitive microorganisms are substantially inactivated so that these microorganisms cannot be reproduced. In this regard, Figures 10 to 14 show results from different bench modalities.

[0079] Figure 10 illustrates the temperature range of modalities through which the packaging process produced pasteurized beverages after inoculation with a spoilage yeast cocktail. The data showed that with retention times of 45 to 90 seconds and pulp temperature between about 26 °C and about 65 °C, pasteurization was achieved.

[0080] In Figure 11, the microbial load of the cocktail was increased and the inversion time was reduced (the inversion pasteurizes the empty space of the bottle). The results (Figure 11) were in accordance with Figure 10, with the exception that one of the variables at the lowest temperature was not pasteurized after a 2-day incubation.

[0081] In Figure 12, the bench pack process was conducted at two different temperatures with a larger amount of replicates and with a spoilage yeast cocktail (Figure 12). Only one beverage failed the test (probably due to post-process contamination).

[0082] In Figure 13, the benchtop packaging process using pulp was tested for its ability to pasteurize and substantially inactivate mold contamination. Both yeast and mold are important spoilage microorganisms. The results of this experiment were consistent with all other bench pack tests. All pulp temperature variables tested resulted in pasteurized beverages with higher inoculations than those found in incoming ingredients.

[0083] For pulp processing, the results of these bench tests surprisingly demonstrated that the packaged process 1) maintained temperatures high enough to result in a 6-log reduction of common spoilage organisms, and 2) produced a beverage that has been pasteurized through a wide range of pulp temperatures. In addition, the reduced pulp maceration resulted in a 40 to 110% increase in the amount of pulp in each finished product package when the standard pulp weight was dosed. Surprisingly, the process described in this document has enabled the use and preservation of whole bags of citrus fruits, which was not previously possible using standard sets of pulp pasteurization procedures.

EXAMPLE 8 PEACH PARTICLE PROCESSING

[0084] In certain modalities, peach particles were employed and were subjected to the packaging process. In one embodiment, the peach particles were 6mm x 6mm x 6mm peach pieces instead of the standard 8mm x 8mm x 8mm peach pieces. Figure 15 demonstrates that even with higher inoculation levels of yeast and mold, the microorganisms were substantially inactivated, and the beverages were pasteurized. In other embodiments, the peach particles can be 5mm x 5mm x 5mm, 4mm x 4mm x 4mm, 3mm x 3mm x 3mm, or 2mm x 2mm x 2mm pieces. The ability to use these reduced sizes was a surprising result of the bottle pasteurization process and is achievable because the reduced temperatures used in the process described herein maintain the hardness of the fruit particle.

[0085] The data presented demonstrate that the packaging process delivers the product with equal or better quality at a lower cost by eliminating the pulp pasteurization step and allows the juice pasteurized juice to substantially liquidate or inactivate the microorganisms in the packaging through of heat transfer to the unpasteurized pulp.

[0086] Referring to Figure 15, a flow diagram of a process 1500 for producing a packaged beverage or food item is shown. Process 1500 can begin at step 1502 where a first food source that includes a spoilage microorganism can be processed along a first processing path. The first processing path can limit the temperature of the first food source to be below a temperature level that would cause the spoilage microorganism to be inactivated. The temperature level can be a pasteurization temperature level that substantially inactivates one or more spoilage microorganisms. The first food source can be pulp. The pulp can be frozen pulp.

[0087] In step 1504, a second food source can be produced along a second processing path that heats the second food source to a temperature range that causes spoilage microorganisms to be substantially inactivated. The second food source can be a liquid, such as juice, and more particularly, but not limited to, orange juice. The temperature range can be a pasteurization temperature range for juice, for example.

[0088] In step 1506, a package can be filled with the first and second food sources while the second food source is in the temperature range, thus causing spoilage microorganisms to be substantially inactivated. When substantially inactivated, spoilage microorganisms must have minimal trace levels, as understood in the art. In one modality, the first and second food sources produce a pulped orange juice. Other foods, beverages, juices, or foods or beverages consumable by humans or animals can be produced using the principles of the present invention.

HARDNESS OF PEACH PARTICLE

[0089] The peach particles were also tested for hardness after the packaging process. Five integrated peach particles from each bottle were collected and measured for hardness by a texture analyzer. Figure 16 demonstrates that the packaging process delivers both firmer particles and more particles to the finished product packaging, and thus allows reduced doses in weight to reach the same amount of pulp per package. In fact, the 4 to 12% lower dosage of pulp by weight resulted in a 72% increase in the amount of particles per finished product package. Other types of fruit are believed to yield similar results.

PEACH PARTICLE HOMOGENEITY

[0090] To assess the homogeneity in packaging of the peach particle content, the individual bottles were each poured into #10 and #20 mesh sieves, rinsed with 1 l of water, heated for 2 minutes at 45 °C , and then weighed. Figures 17A-D demonstrate that the packaging process delivers a greater amount of particles in the finished product, and thus allows for reduced weight doses.

[0091] The foregoing detailed description is of a small amount of modalities to implement the invention and is not intended to be limiting in scope. One of skill in the art will readily anticipate the methods and variations used to implement this invention in areas other than those described in detail. The following claims present several of the embodiments of the invention disclosed with greater particularity.

Claims (15)

1. A packaged beverage or food item characterized in that it comprises: a consumer package comprising: a processed food composition that includes a spoilage microorganism; and a liquid that is in a temperature range ranging between 72°C and 87°C applied to said processed food composition to form a first mixture in the consumer package which, as a result of said liquid being in a temperature range ranging between 72°C. oC and 87 oC for a period of time that varies between 1 and 300 seconds, causes the spoilage microorganism to be inactivated. 2. Drink or packaged article, according to claim 1, characterized in that said consumer packaging is a plastic, glass, aluminum or cardboard packaging. 3. Beverage or packaged article, according to claim 1, characterized in that said consumer packaging is a bottle, can or cup and includes a cover. 4. Beverage or packaged food item, according to claim 1, characterized in that said consumer packaging is a bottle or cup and includes a cover. 5. Packaged beverage or food item according to claim 1, characterized in that said processed food composition is fruit pulp, citrus fruit bags, nuts, vegetables, particulates, food particles or any combination thereof . 6. The beverage or packaged food item according to claim 5, characterized in that said first mixture includes about 2% by weight of pulp to about 50% by weight of pulp. 7. The beverage or packaged food item according to claim 1, characterized in that said processed food composition includes citrus fruit pulp or fruit particles selected from the group consisting of oranges, lime orange, clementine orange , quinch, lemons, combava, satsumas, mandarins, tangerines, cider, grapefruit, yellow lemons, wrinkled lemons, grapefruit, tangerines, tanja, hybrids thereof, and combinations thereof. 8. The beverage or packaged food item according to claim 1, characterized in that said processed food composition includes non-citrus fruit pulp or fruit particles selected from the group consisting of kiwi, mango, grape, banana, berry, pear, apple, peach, pineapple, melon, apricot, strawberries, raspberry, blackberry, blackcurrant, blueberry, blackcurrant, nectarine, cranberry, passion fruit, papaya, lychee, pomegranate, fig, plum, cherry, currant, zucchini, persimmon, date, guava, rhubarb, coconuts, and combinations thereof. 9. Packaged beverage or food item according to claim 1, characterized in that the spoilage microorganism includes a heat-sensitive spoilage microorganism, wherein the heat-sensitive spoilage microorganism is inactivated by temperature in the temperature range which varies between 66 oC and 80 oC. 10. Packaged beverage or food item, according to claim 1, characterized in that the first mixture has a maximum equilibrium temperature, where the maximum equilibrium temperature has the ability to pasteurize the first mixture, but does not have the ability to inactivate heat resistant microorganisms. 11. Method (500) for manufacturing a packaged beverage or food item as defined in any one of claims 1 to 10, said method characterized in that it comprises: providing a processed food composition that includes a spoilage microorganism (504) ; pasteurizing a liquid being used to form the food or beverage article (510), the pasteurizing including heating the liquid to a temperature range ranging from 72°C to 87°C; and combining, in a consumer package, the liquid in the temperature range ranging from 72°C to 87°C and the processed food composition to form a first mixture (506) so that the liquid in the temperature range ranging from 72°C oC and 87 oC causes the spoilage microorganism to be inactivated. 12. Method according to claim 11, characterized in that said consumer packaging is a plastic, glass, aluminum or cardboard packaging. 13. Method (1500) for producing a packaged beverage or food item as defined in any one of claims 1 to 10, characterized in that it comprises: processing a first food source that includes a spoilage microorganism along a first path processing (1502), with the first processing path limiting the temperature of the first food source to below a temperature level that causes the spoilage microorganism to be inactivated; processing a second food source over a second processing path (1504), with the second processing path heating the second food source to be in a temperature range ranging from 72 °C to 87 °C which causes spoilage microorganisms in the second food source to be and inactivated when they are in the temperature range that varies between 72 oC and 87 oC for a period of time that varies between 1 and 300 seconds; e filling a package with the first and second food sources (1506), the second food source, when mixed with the first food source, is in the temperature range ranging from 66 oC to 80 oC, for the period of time that varies between 1 and 300 seconds on packaging to cause the spoilage microorganism to be inactivated. 14. A system for producing a packaged beverage or food item as defined in any one of claims 1 to 10 in the absence of aseptic conditions, characterized in that it comprises: a first processing path configured to process a first food source that includes a spoilage microorganism, wherein the first processing path limits the temperature of the first food source to below a temperature level which causes the spoilage microorganism to be inactivated; a second processing path configured to process a second source of food, with the second processing path heating the second food source to be in a temperature range that varies between 72 oC and 87 oC which causes spoilage microorganisms in the second food source to be inactivated when in the range of temperature ranging from 72 oC to 87 oC for a period of time ranging from 1 to 3 00 seconds; and said first and second processing paths are further configured to fill a package with the first and second food sources, the second food source, when mixed with the first food source, which is in the temperature range ranging from 66°C. oC and 80 oC for a period of time that varies between 1 and 300 seconds in the package to make the spoilage microorganism inactivated. 15. Method for retrofitting a pulp slurry processing subsystem (100a, 100b, 200a, 300, 400) to produce a packaged beverage or food item as defined in any one of claims 1 to 10, said method characterized by the fact which comprises: providing the pulp slurry processing subsystem having a fluid path inclusive of a heater element in fluid communication with a blend tank (120, 152, 164, 206, 208, 306, 408) and a filler (132, 182, 210, 310, 410), wherein the heater element (148, 174, 308, 406) is configured to pasteurize the blended pulp slurry from the blend tank; and fluidly connecting a bypass conduit along the fluid path between the blend tank and the filler, the bypass conduit causing the blended pulp slurry from the blend tank to bypass the heating element.

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