Thermal Processing Professional Training Program - 2014

Module One
Food Microbiology Short Course:
Do-It-Yourself Spoilage and Pathogen Testing

September 15, 2014

9:00-10:30 am Introduction to Food Microbiology

A. Introduction

B. Basics of Food Microbiology

10:30-10:45 am  Break

10:45-11:15 am Introduction to Food Microbiology (Continued)

C. Pathogens

11:15-12:15 pm Introduction to the Food Microbiology Lab

A. Biosafety Plans and GLP

B. Basics of Aseptic Technique

C. Sample preparation

12:15-1:00 pm    Lunch

1:00-2:15 pm     Laboratory Demo 1 - Quantitative Testing

 A. Sample Preparations, Dilutions, Aseptic Technique

 B. Aerobic Plate Counts, Escherichia coli, Coliforms,
     Bacillus cereus and Staphylococcus aureus

2:15-3:30 pm      Specialized Testing

  A. Environmental Testing

  B. Experiments in Microbiology - Shelf Life
Determination and Challenge Studies

3:15-3:30 pm      Break

3:30-4:45 pm      Lab Demo 2 - Pathogen Testing

   A. VIDAS and VITEK analysis for Listeria spp.
     Salmonella and E. coli O157:H7

4:45 pm              Questions and Adjourn

September 16, 2014

9:00-11:00 am   More Advanced Concepts in Food Microbiology

   A. Significance and Control of Microorganisms in Foods

11:00-11:15 am  Break

11:15-12:30 pm Laboratory Demo 3 - Finalization of Pathogen Testing

12:30-1:30 pm    Lunch

1:30-2:45 pm     Microbial Test Methods

A. Why do we test what we test?

B. Sampling Plans

C. Reference Methods

D. Rapid Methods/Method Validation

E. Confirmation and Identification

F. Interpretation

2:45-3:00 pm    Break

3:00-4:30 pm     Laboratory Demo 4 - Quantitative Results

4:30-4:45 pm     Questions

4:45 pm              Adjourn

Module Two
for Cans and Container Integrity

September 17, 2014

8:30-10:15 am     Spoilage Analysis

           A. Introduction and Course Outline

           B. Microbiology's Role in Thermally Processed Foods

           C. Causes of Spoilage

           D. Container Integrity Testing

10:15-10:30 am     Break

10:30-11:00 am     Spoilage Analysis Continued - Lectures

                              A. Laboratory Methods for Spoilage & Commercial Sterility Testing

11:00-Noon            Laboratory Session

           A. Cause of Spoilage Analysis

Noon-1:00 pm        Lunch

1:00-2:00 pm         Laboratory Session Continued

           A. Cause of Spoilage Analysis - continued

2:00-2:45 pm     Lecture

           G. Container Integrity Testing

2:45-3:30 pm     Laboratory Sessions

           H.  Container Evaluation Equipment and Demo

3:30-4:00 pm     Lecture

           I. Interpretation of Cause of Spoilage Results

          J. Reports

Module Three
Essentials of Thermobacteriology


September 18, 2014

8:00 – 9:30am  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

9:30-9:45am     Break

9:45 – 10:45am  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)

   2) 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

  3) Enumeration of Microorganisms After Thermal Treatment

10:45-Noon     Laboratory Session

Noon - 1:00 pm Lunch

1:00 – 2:30pm  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

2:30-3:15pm   Exercise

3:15-3:30am  Break

3:30–4:00pm Lectures

                       4) Application of D, z, and F-values  

     A.       F-values

     B.      The z-value

     C.       Log-reductions

     D.      Specific Food Types

4:00–5:00 pm  5) 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
Industry Guidance on Acidified Foods


September 19, 2014

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 Five
Thermal Process Development


September 22, 2014

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 23, 2014

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 24, 2014

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 Six
Management and Evaluation of Thermal Process Deviations


September 25, 2014

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 26, 2014

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