Frozen High-Pressure Sterilization for Texture-Sensitive Products
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Solution Overview
Problem
Current sterilization methods for temperature-sensitive materials, such as food products, pharmaceuticals, and cosmetics, often result in texture loss and undesirable flavor changes due to heat pasteurization or high pressure processing, and existing acidulants can impart an unwanted acid taste.
Innovation Solution
Freezing temperature-sensitive materials to form ice crystals and subjecting them to high pressure (at least 250 MPa) for a specified period, which can be done in multiple pulses with pauses, to achieve microbiological stability without significant texture loss or acid taste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat pasteurization is used to sterilize food products, then microbiological stability is improved, but texture and flavor deteriorate
Solution Approach 1:
The invention changes the sterilization parameters from thermal (heat-based) to high-pressure mechanical treatment. By applying pressures of 250-350 MPa at sub-zero temperatures, the process achieves microbiological sterilization without the thermal degradation that causes texture softening and flavor changes, thus resolving the contradiction between reliability and manufacturing precision.
Solution Approach 2:
The process utilizes phase transition by freezing the food product to sub-zero temperatures before applying high pressure. This phase change to frozen state allows the high-pressure treatment to be more effective against microorganisms while preventing the thermal effects that would otherwise damage texture and flavor during sterilization.
2Duration of action of stationary object
If conventional freezing is used to preserve food products, then shelf stability is improved, but texture quality deteriorates due to ice crystal formation
Solution Approach 1:
The invention applies preliminary high-pressure treatment to the frozen product before distribution and storage. This preliminary action of high-pressure sterilization eliminates microorganisms that would otherwise grow during storage, achieving shelf stability without requiring prolonged freezing that causes texture degradation from ice crystal formation.
Solution Approach 2:
By changing from conventional freezing parameters (low temperature only) to combined parameters (sub-zero temperature plus high pressure), the process achieves both shelf stability and texture preservation. The high-pressure parameter prevents the harmful effects of prolonged freezing while maintaining the beneficial cold storage conditions.
3Reliability
If acidulants are added to extend shelf life, then microbiological stability is improved, but taste quality deteriorates due to acid bite
Solution Approach 1:
The invention replaces the chemical mechanism (acidulants lowering pH to inhibit microbes) with a mechanical mechanism (high-pressure treatment physically destroying microorganisms). This substitution eliminates the need for acidulants that cause unwanted acid taste, achieving shelf stability through mechanical means while preserving the natural flavor of the food product.
4Reliability
If high pressure processing is used to sterilize food products, then microbiological stability is improved, but texture quality deteriorates
Solution Approach 1:
The invention optimizes the pressure parameter by combining high pressure (250-350 MPa) with sub-zero temperatures. This parameter combination enhances the sterilization effectiveness against microorganisms while the cold temperature prevents the pressure-induced texture degradation that occurs with warm high-pressure processing, thus resolving the contradiction between reliability and manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method produces shelf-stable products with no significant acid bite, effectively eliminating vegetative microbiological cells, parasites, and preventing mold and yeast growth while maintaining the original flavor and texture of the products.
Implementation Method 1
freezing the temperature sensitive material to an initial temperature of less than or equal to −2° C.
Implementation Method 2
freezing the temperature sensitive materials to form ice crystals and subjecting them to high pressure
Implementation Method 3
pressurizing the frozen temperature sensitive material to a first elevated pressure of at least 250 MPa for a predetermined first period of time of at least 3 minutes
Data Source
AI summary
Methods of sterilizing a temperature sensitive material, such as an acidified or non-acidified food product, pharmaceutical product or cosmetic product, are disclosed. The methods comprise freezing the temperature sensitive material to an initial temperature of less than or equal to −2° C. and then either (i) pressurizing the frozen temperature sensitive material to a first elevated pressure of at least 250 MPa for a predetermined first period of time of at least 3 minutes or (ii) pressurizing the frozen temperature sensitive material to a first elevated pressure of at least 250 MPa for a predetermined first period of time of at least 90 seconds, releasing the first elevated pressure for a predetermined pause period of time and then pressurizing the temperature sensitive material to a second elevated pressure of at least 250 MPa for a predetermined second period of time of at least 90 seconds.