UHT Milk
UHT MILK= Ultra Heat Ttreated MILK
Ultra Heat Treatment basics
Introduction
While pasteurization conditions effectively eliminate potential pathogenic microorganisms, it is not sufficient to inactivate the thermoresistant spores in milk. The term sterilization refers to the complete elimination of all microorganisms. The food industry uses the more realistic term "commercial sterilization"; a product is not necessarily free of all microorganisms, but those that survive the sterilization process are unlikely to grow during storage and cause product spoilage.
In canning we need to ensure the "cold spot" has reached the desired temperature for the desired time. With most canned products, there is a low rate of heat penetration to the thermal centre. This leads to overprocessing of some portions, and damage to nutritional and sensory characteristics, especially near the walls of the container. This implies long processing times at lower temperatures.
Milk can be made commercially sterile by subjecting it to temperatures in excess of 100° C, and packaging it in air-tight containers. The milk may be packaged either before or after sterilization. The basis of UHT, or ultra-high temperature, is the sterilization of food before packaging, then filling into pre-sterilized containers in a sterile atmosphere. Milk that is processed in this way using temperatures exceeding 135° C, permits a decrease in the necessary holding time (to 2-5 s) enabling a continuous flow operation.
Some examples of food products processed with UHT are:
· liquid products - milk, juices, cream, yoghurt, wine, salad dressings
· foods with discrete particles - baby foods; tomato products; fruits and vegetables juices; soups
· larger particles - stews
Advantages of UHT
High quality:
The reduction in process time due to higher temperature (UHTST) and the minimal come-up and cool-down time leads to a higher quality product.
Long shelf life:
Greater than 6 months, without refrigeration, can be expected.
Packaging size:
Processing conditions are independent of container size, thus allowing for the filling of large containers for food-service or sale to food manufacturers (aseptic fruit purees in stainless steel totes).
Cheaper packaging:
Both cost of package and storage and transportation costs; laminated packaging allows for use of extensive graphics
Difficulties with UHT
Sterility
Complexity of equipment and plant are needed to maintain sterile atmosphere between processing and packaging (packaging materials, pipework, tanks, pumps); higher skilled operators; sterility must be maintained through aseptic packaging
Particle Size:
With larger particulates there is a danger of overcooking of surfaces and need to transport material - both limits particle size
Equipment
There is a lack of equipment for particulate sterilization, due especially to settling of solids and thus overprocessing
Keeping Quality:
Heat stable lipases or proteases can lead to flavour deterioration, age gelation of the milk over time - nothing lasts forever! There is also a more pronounced cooked flavour to UHT milk.
UHT Methods
There are two principal methods of UHT treatment:
1. Direct Heating
2. Indirect Heating
Direct heating systems
The product is heated by direct contact with steam of potable or culinary quality. The main advantage of direct heating is that the product is held at the elevated temperature for a shorter period of time. For a heat-sensitive product such as milk, this means less damage.
Indirect vs Direct Heating
There are two methods of direct heating;
1. injection
2. infusion
Injection - High pressure steam is injected into pre-heated liquid by a steam injector leading to a rapid rise in temperature. After holding, the product is flash-cooled in a vacuum to remove water equivalent to amount of condensed steam used. This method allows fast heating and cooling, and volatile removal, but is only suitable for some products. It is energy intensive and because the product comes in contact with hot equipment, there is potential for flavour damage.
Infusion - Food in a free falling film is pumped into a chamber of high pressure steam. The time of the fall matches the desired holding time. The product, therefore, falls onto a cooled surface, followed by flash cooling in vacuum chamber. This method has several advantages:
· instantaneous heating and rapid cooling
· no localized overheating or burn-on
· suitable for low and higher viscosity products
Indirect heating systems
The heating medium and product are not in direct contact, but separated by equipment contact surfaces. Several types of heat exchangers are applicable:
· plate
· tubular
· scraped surface
· double-cone
Plate Heat Exchangers
Similar to that used in HTST but operating pressures are limited by gaskets. Liquid velocities are low which could lead to uneven heating and burn-on. This method is economical in floor space, easily inspected, and allows for potential regeneration.
Tubular Heat Exchangers
There are several types:
· shell and tube
· shell and coil
· double tube
· triple tube
All of these tubular heat exchangers have fewer seals involved than with plates. This allows for higher pressures, thus higher flow rates and higher temperatures. The heating is more uniform
Scraped Surface Heat Exchangers
The product flows through a jacketed tube, which contains the heating medium, and is scraped from the sides with a rotating knife. This method is suitable for viscous products and particulates (< 1 cm) such as fruit sauces, and can be adjusted for different products by changing configuration of rotor. There is a problem with larger particulates; the long process time for particulates would mean long holding sections which are impractical. This may lead to damaged solids and overprocessing
Double-Cone Heat Exchangers
eg APV Jupiter: Suitable for large particulates because it involves separation of solids/liquids and combines indirect heating in double cone (batch) with direct heating of liquid portion (maybe also scraped surface if too viscous). The solid pieces are fed into a double-cone, rotated slowly on horizontal axis with steam injection and heated surfaces. There is no burn-on because they are the same temperature. The liquid is directly heated with steam separately, then added after pre-cooling. The double cone acts as a blender and coats solids. The product is then discharged to an aseptic filler by overpressure with sterile air. Used for soups, stews, carrots, and vegetables.
Packaging for Aseptic Processing
The most important point to remember is that it must be sterile! All handling of product post-process must be within the sterile environment.
There are 5 basic types of aseptic packaging lines:
1. Fill and seal: preformed containers made of thermoformed plastic, glass or metal are sterilized, filled in aseptic environment, and sealed
2. Form, fill and seal: roll of material is sterilized, formed in sterile environment, filled, sealed e.g. tetrapak
3. Erect, fill and seal: using knocked-down blanks, erected, sterilized, filled, sealed. e.g. gable-top cartons, cambri-bloc
4. Thermoform, fill, sealed roll stock sterilized, thermoformed, filled, sealed aseptically. e.g. creamers, plastic soup cans
5. Blow mould, fill, seal:
There are several different package forms that are used in aseptic UHT processing
· cans
· paperboard/plastic/foil/plastic laminates
· flexible pouches
· thermoformed plastic containers
· flow molded containers
· bag-in-box
· bulk totes
http://www.dairyconsultant.co.uk/pages/UHT_Process.htm