Thermal Processing Professional Training Program - 2012

Module One: The Basics

September 17, 2012

9:05am - 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-1:00pm Lunch

 D. HACCP and Regulatory Agencies

 E. FDA Regulations Important to the Processor

2:30-3:00pm Spoilage Analysis

  A. Introduction and Course Outline

  B. Microbiology's Role in Thermally Processed Foods

  C. Causes of Spoilage

3:00-3:15pm  Break

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

September 18, 2012

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

   E. Review of Cause of Spoilage Methods

8:45-Noon       Laboratory Session

   F. Cause of Spoilage Analysis (with Break)

Noon-1:00pm  Lunch

1:00-1:45pm   Lecture

   G. Container Integrity Testing

1:45-2:30pm   Laboratory Sessions

   H.  Container Evaluation Equipment and Demo

2:30-2:45pm   Lecture

   I. Interpretation of Cause of Spoilage Results

   J. Reports

Module Two: Industry Guidance on Acidified Foods

September 19, 2012

8:30-10:00am   Lectures

               A. Principles of Acidified Foods

10:00-10:15am  Break

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

Noon-1:00pm   Lunch

1:00-3:00pm    Laboratory Sessions

               C. Standardization of pH Meters

               D. Determination of pHs of Different Products Using pH Meter

               E. Pickle-Making Lab

3:00-3:15pm  Break

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

               G. Interpretation of Results

Module One: The Basics* (Continued)

September 20, 2012

8:30-9:30am  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

9:30-9:45am   Break

9:45-Noon       Laboratory Sessions

             F. Thermocouple Set-ups in Cans

             G. Retort Operation and Data Acquisition

Noon-1:00pm  Lunch

Module Three: Essentials of Thermobacteriology

1:00 – 2:30pm  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

2:30-2:45pm     Break

2:45 – 3:45pm  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

3:45-4:30pm     Laboratory Session

September 21, 2012

8:00 – 9:30am  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

9:30-10:15am   Exercise

10:15-10:30am  Break

10:30–11:00am 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 24, 2012

8:00-8:30am   Breakfast

8:30–9:00am  Overview of Thermal Processing

9:00-10:00am Thermobacteriology Overview                                             

    A.    General Concepts

10:00-10:15am Break

10:15-11:00am B.    Exercise

11:00-Noon   Factors Affecting Heat Penetration

     A.    General Concepts

Noon-1:00pm    Lunch

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

3:00-3:15pm     Break

3:15-4:30pm     Conducting Heat Penetration Tests

September 25, 2012

8:00-8:30am     Breakfast

8:30-10:00am   Establishing Retort Operating Procedures

10:00-10:15am Break

10:15-Noon      Heat Penetration Data Analysis

     A.    General Method Exercise

Noon-1:00pm    Lunch

1:00-2:45pm     B.    Plotting Exercise

2:45-3:00pm     Break

3:00-4:30pm     Process Calculation Methods

     A.    Ball Formula Method Exercise

     B.    Applications Demonstration

September 26, 2012

8:00–8:30am   Breakfast

8:30-10:00am  Process Establishment 

    A.    Process Recommendation Exercise

10:00-10:15am Break

10:15–Noon Process Establishment Case Studies 

    A.    Introduction

Noon-1:00pm    Lunch

1:00-3:00pm     B.    Group Activity

3:00-3:15pm     Break

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

Module Five: Management and Evaluation of Thermal Process Deviations

September 27, 2012

8:00-8:30am      Breakfast

8:30–9:00am     Getting Started

9:00-9:45am      Deviations Overview and Regulatory Requirements   

9:45-10:00am    Break

10:00-10:45am Types of Deviations

10:45-Noon      Strategies for Preventing Deviations

Noon-1:00pm    Lunch

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

2:00-3:00pm     Deviation Recordkeeping and Review

3:00-3:15 pm    Break

3:15-4:30pm     Calculation Overview and Techniques

September 28, 2012

8:00-8:30am     Breakfast

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

9:15-10:15am   Deviation Evaluation Procedures 

10:15-10:30am  Break

10:30-Noon      Deviation Evaluation Procedures (Continued)

Noon-1:00pm    Lunch

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

1:30-2:00pm     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.