Thermal Processing Professional Training Program

Module One: The Basics*

September 12, 2011

9:05 - Noon Introduction to Food Laws

A. Overview of Food Law in the U.S.

B. Food Labeling

C. FSIS Inspection Overview and
     Regulatory Expections for Thermal Processing

Noon-1:00 Lunch

D. HACCP and Regulatory Agencies

E. FDA Regulations Important to the Processor

2:30-3:00 Spoilage Analysis

A. Introduction and Course Outline

B. Microbiology's Role in Thermally Processed Foods

C. Causes of Spoilage

3:00-3:15  Break

3:15-4:15     D. Causes of Spoilage and Commercial Sterility Analysis

September 13, 2011

8:30-8:45  Spoilage Analysis Continued - Lectures

E. Review of Cause of Spoilage Methods

8:45-Noon Laboratory Session

F. Cause of Spoilage Analysis (with Break)

Noon-1:00  Lunch

1:00-1:45   Lecture

G. Container Integrity Testing

1:45-2:30   Laboratory Sessions

H.  Container Evaluation Equipment and Demo

2:30-2:45   Lecture

I. Interpretation of Cause of Spoilage Results

J. Reports

Module Two: Industry Guidance on Acidified Foods

September 14, 2011

8:30-10:00   Lectures

         A. Principles of Acidified Foods

10:00-10:15  Break

10:15-Noon B. Developing Thermal Process for High Acid and Acidified Products

Noon-1:00   Lunch

1:00-3:00    Laboratory Sessions

         C. Standardization of pH Meters

         D. Determination of pHs of Different Products Using pH Meter

         E. Pickle-Making Lab

3:00-3:15  Break

3:15-4:30    F. Titration Procedure and Calculation of Titratable Acidity

         G. Interpretation of Results

Module One: The Basics* (Continued)

September 15, 2011

8:30-9:30  Basic Heat Penetration Analysis Lectures

        A. Introduction

        B. Product Heating Classification

        C. Heat Penetration Test Design

        D. Number of Tests and Containers per Test

        E. Heat Penetration Test Records

9:30-9:45   Break

9:45-Noon  Laboratory Sessions

        F. Thermocouple Set-ups in Cans

        G. Retort Operation and Data Acquisition

Noon-1:00  Lunch

Module Three: Essentials of Thermobacteriology

1:00 – 2:30  Microbiology of Food Processing                                             

A.    General Microbiology

a.       Bacteria, Molds and Yeast

b.       Factors Influencing Bacterial Growth and Death

c.       Bacterial Spores

B.     Microorganisms of Greatest Importance in Food Processing

a.       Pathogenic Microorganisms

b.       Toxin–producing Microorganisms

c.       Spoilage Microorganisms

2:30-2:45     Break

2:45 – 3:45  Lectures
Determining the Heat Resistance of Microorganisms

A.    Selection of the Target Microorganisms

B.     Preparation of Test Microorganisms

a.      Producing, Harvesting and Cleaning (Vegetative & Spores)

b.      Enumeration of Populations

C.     Heating Medium

a.      Phosphate Buffer

b.      Food

c.      Heat in Product (HIP)/Recovery in Product (RIP)

Methods of Measuring Heat Resistance

A.      Thermal Death Time Tube

B.      Thermal Death Time Can

C.      Three–Neck Flask

D.      Thermoresistometer

E.      Capillary Tube

F.      Thermal Death Time Retort

Enumeration of Microorganisms After Thermal Treatment

3:45-4:30     Laboratory Session

September 16, 2011

8:00 – 9:30  Thermal Resistance Data Interpretation and Calculations 

A.      Survivors Curves

B.      Decimal Reduction Time (The D Value)

C.      Different Methods for Calculating D Values

D.      Nonlinear Survival Curves

E.      Thermal Death Time (TDT) Curve – Construction and Interpretation

9:30-10:15   Exercise

10:15-10:30  Break

10:30–11:00 Application of D, z, and F-values  

A.       F-values

B.      The z-value

C.       Log-reductions

D.      Specific Food Types

11:00–Noon Bacteriological Evaluation for Thermal Process      

A.      Inoculating Pack Studies

B.      Count Reduction

C.      Interpreting and Applying D and z values from the
         Literature to Ensure the Safety of Foods

D.      Integrating Current Modeling Packages and Techniques

Module Four: Thermal Process Development

September 19, 2011

8:00-8:30   Breakfast

8:30–9:00  Overview of Thermal Processing

9:00-10:00 Thermobacteriology Overview                                             

A.    General Concepts

10:00-10:15 Break

10:15-11:00 B.    Exercise

11:00-Noon  Factors Affecting Heat Penetration

A.    General Concepts

Noon-1:00    Lunch

1:00-3:00     B.    Critical Factors Activity

3:00-3:15     Break

3:15-4:30     Conducting Heat Penetration Tests

September 20, 2011

8:00-8:30     Breakfast

8:30-10:00   Establishing Retort Operating Procedures

10:00-10:15 Break

10:15-Noon  Heat Penetration Data Analysis

A.    General Method Exercise

Noon-1:00    Lunch

1:00-2:45     B.    Plotting Exercise

2:45-3:00     Break

3:00-4:30     Process Calculation Methods

A.    Ball Formula Method Exercise

B.    Applications Demonstration

September 21, 2011

8:00–8:30   Breakfast

8:30-10:00  Process Establishment 

A.    Process Recommendation Exercise

10:00-10:15 Break

10:15–Noon Process Establishment Case Studies 

A.    Introduction

Noon-1:00    Lunch

1:00-3:00     B.    Group Activity

3:00-3:15     Break

3:15-4:30     C.    Group Activity and Reports

Module Five: Management and Evaluation of Thermal Process Deviations

September 22, 2011

8:00-8:30      Breakfast

8:30–9:00     Getting Started

9:00-9:45      Deviations Overview and Regulatory Requirements                                           
9:45-10:00    Break

10:00-10:45 Types of Deviations

10:45-Noon  Strategies for Preventing Deviations

Noon-1:00    Lunch

1:00-2:00     Strategies for Preventing Deviations (Continued)

2:00-3:00     Deviation Recordkeeping and Review

3:00-3:15     Break

3:15-4:30     Calculation Overview and Techniques

September 23, 2011

8:00-8:30     Breakfast

8:30-9:15     Correcting In-Process Deviations

9:15-10:15   Deviation Evaluation Procedures 

10:15-10:30 Break

10:30-Noon  Deviation Evaluation Procedures (Continued)

Noon-1:00    Lunch

1:00-1:30     Deviation Evaluation Procedures (Continued)

1:30-2:00     Deviation Management Systems

2:00 PM       Summary and Closure

* Module One participants will benefit from a low student-instructor ratio, maximizing one-on-one instruction and hands-on laboratory experience.  Module One is offered only in conjunction with the TPPT Program and is not offered by GMA at any other time.