Chilled Foods: A Comprehensive Guide, Second Edition (Woodhead Publishing in Food Science and Technology)

Developments in the production, distribution, and retailing of food during the last 40 years have facilitated a major change in our lifestyle. Chilled foods represent a larger and increasing proportion of weekly purchases for home consumption as well as in institutional and service catering. Their safety and reliability are of utmost importance.With basic information on packaging, safe process design, and cleaning and disinfecting, Chilled Foods: A Comprehensive Guide, Second Edition addresses biological and nonbiological risks associated with chilled foods, addresses key quality issues in the food industry, and discusses raw materials selection. The first edition of Chilled Foods rapidly established itself as the standard work on the key quality issues in this dynamic sector in the food industry. This new edition has been substantially revised and expanded to provide you with a current, comprehensive guide to ensuring the integrity and safety of chilled foods. Contents......Page 6 Preface......Page 12 List of contributors......Page 14 1.1 Definition......Page 18 1.2 Drivers in the chilled food sector......Page 20 1.3 Overall market size......Page 23 1.4 Individual categories within the chilled food sector......Page 29 1.5 Conclusion......Page 32 1.6 References......Page 33 Part I Raw materials......Page 34 1.1 Introduction......Page 36 1.2 Criteria for selection......Page 37 1.3 Specifications......Page 45 1.4 New trends in raw material production......Page 47 1.5 New trends in plant breeding......Page 48 1.6 Conclusion......Page 49 1.8 References......Page 50 2.2 Milk composition......Page 54 2.3 Functional approach......Page 55 2.4 Sensory properties......Page 56 2.6 Chilled dairy products and milk-based ingredients used in chilled foods......Page 58 2.7 Chilled desserts......Page 69 2.9 Maximising quality in processing......Page 70 2.10 Food safety issues......Page 72 2.11 Future trends......Page 74 2.12 References......Page 75 3.1 Introduction......Page 80 3.2 The influence of the live animal......Page 82 3.3 Pre- and post-slaughter handling......Page 86 3.4 Conclusions......Page 89 3.5 References......Page 90 Part II Technologies and processes......Page 94 4.1 Introduction......Page 96 4.3 Safety and quality issues......Page 98 4.4 Refrigerant fluids and the environment......Page 99 4.5 Chilled foods and refrigeration......Page 100 4.6 Chilling......Page 101 4.7 Chilling equipment......Page 102 4.8 Chilled storage......Page 104 4.9 Refrigerated transport......Page 107 4.10 Refrigerated display cabinets......Page 111 4.11 Regulations and legislation......Page 113 4.13 References......Page 114 5.1 Introduction......Page 116 5.2 Importance of temperature monitoring......Page 118 5.3 Principles of temperature monitoring......Page 119 5.4 Temperature monitoring in practice......Page 122 5.5 Equipment for temperature monitoring......Page 133 5.6 Temperature and time–temperature indicators......Page 143 5.7 Temperature modelling and control......Page 147 5.9 References......Page 148 6.2 Requirements of chilled food packaging materials......Page 152 6.3 Chilled food packaging materials......Page 153 6.4 Packaging techniques for chilled food......Page 156 6.5 Future trends......Page 164 6.7 References......Page 166 Part III Microbiological and non-microbiological hazards......Page 168 7.1 Introduction......Page 170 7.3 Classification of growth......Page 171 7.4 The impact of microbial growth......Page 173 7.5 Factors affecting the microflora of chilled foods......Page 174 7.6 Spoilage microorganisms......Page 179 7.7 Pathogenic microorganisms......Page 184 7.8 Temperature control......Page 190 7.9 Predictive microbiology......Page 191 7.10 Conclusions......Page 195 7.11 References......Page 196 8.1 Introduction......Page 204 8.3 Conventional microbiological techniques......Page 205 8.4 Rapid and automated methods......Page 208 8.6 References and further reading......Page 231 9.1 Introduction......Page 242 9.3 Chemical reactions of significance in chilled foods......Page 243 9.4 Characteristics of biochemical reactions......Page 248 9.5 Biochemical reactions of significance in chilled foods......Page 250 9.7 Physico-chemical reactions of significance in chilled foods......Page 255 9.8 Non-microbiological safety issues of significance in chilled foods......Page 260 9.10 References......Page 265 Part IV Safety and quality issues......Page 274 10.1 Introduction......Page 276 10.2 Factors affecting shelf-life......Page 277 10.3 Modelling shelf-life......Page 285 10.4 Determination of product shelf-life......Page 287 10.5 Maximising shelf-life......Page 295 10.6 Challenge testing......Page 296 10.8 References......Page 300 11.1 Introduction......Page 304 11.2 Definitions......Page 307 11.3 Microbiological hazards......Page 321 11.4 Risk classes......Page 324 11.5 Safe process design 1: equipment and processes......Page 325 11.6 Safe process design 2: manufacturing areas......Page 333 11.7 Safe process design 3: unit operations for decontaminated products......Page 340 11.8 Control systems......Page 345 11.9 Conclusions......Page 349 11.10 References......Page 350 12.1 Introduction......Page 358 12.2 What defines sensory quality?......Page 359 12.3 Sensory evaluation techniques......Page 361 12.4 Determining consumer acceptability......Page 366 12.5 Future trends and conclusion......Page 368 12.6 References......Page 369 13.1 Introduction......Page 372 13.2 Segregation of work zones......Page 374 13.3 High-risk barrier technology......Page 380 13.4 Hygienic construction......Page 397 13.5 Equipment......Page 406 13.7 References......Page 411 14.1 Introduction......Page 414 14.2 Sanitation principles......Page 415 14.3 Sanitation chemicals......Page 419 14.4 Sanitation methodology......Page 426 14.5 Sanitation procedures......Page 431 14.6 Evaluation of effectiveness......Page 433 14.7 Management responsibilities......Page 438 14.8 References......Page 440 15.1 Introduction......Page 446 15.2 The scope of a quality system......Page 450 15.3 Developing a quality system......Page 452 15.4 Implementation......Page 459 15.5 Performance measuring and auditing......Page 463 15.6 Benefits......Page 465 15.7 Future trends......Page 466 15.8 References and further reading......Page 467 16.2 Food law is reactive......Page 468 16.3 Food laws and international trade......Page 469 16.4 Chilled foods are.........Page 470 16.5 Approaches to legislation......Page 471 16.6 Codex......Page 472 16.7 ATP......Page 474 16.9 European Union......Page 475 16.10 Australia/New Zealand......Page 478 16.11 France......Page 479 16.12 The Netherlands......Page 480 16.13 United Kingdom......Page 481 16.14 United States......Page 482 16.16 References and further reading......Page 485 B......Page 491 C......Page 492 D......Page 493 F......Page 494 H......Page 495 M......Page 496 N......Page 497 P......Page 498 Q......Page 499 S......Page 500 T......Page 502 Z......Page 503 Contents 6 Preface 12 List of contributors 14 Introduction: the chilled foods market 18 1.1 Definition 18 1.2 Drivers in the chilled food sector 20 1.3 Overall market size 23 1.4 Individual categories within the chilled food sector 29 1.5 Conclusion 32 1.6 References 33 Part I Raw materials 34 1 Raw material selection: fruit and vegetables 36 1.1 Introduction 36 1.2 Criteria for selection 37 1.3 Specifications 45 1.4 New trends in raw material production 47 1.5 New trends in plant breeding 48 1.6 Conclusion 49 1.7 Sources of further information and advice 50 1.8 References 50 2 Raw material selection: dairy ingredients 54 2.1 Introduction 54 2.2 Milk composition 54 2.3 Functional approach 55 2.4 Sensory properties 56 2.5 Microbiological criteria for milk products 58 2.6 Chilled dairy products and milk-based ingredients used in chilled foods 58 2.7 Chilled desserts 69 2.8 Ready meals 70 2.9 Maximising quality in processing 70 2.10 Food safety issues 72 2.11 Future trends 74 2.12 References 75 3 Raw material selection: meat and poultry 80 3.1 Introduction 80 3.2 The influence of the live animal 82 3.3 Pre- and post-slaughter handling 86 3.4 Conclusions 89 3.5 References 90 Part II Technologies and processes 94 4 The refrigeration of chilled foods 96 4.1 Introduction 96 4.2 Principles of refrigeration 98 4.3 Safety and quality issues 98 4.4 Refrigerant fluids and the environment 99 4.5 Chilled foods and refrigeration 100 4.6 Chilling 101 4.7 Chilling equipment 102 4.8 Chilled storage 104 4.9 Refrigerated transport 107 4.10 Refrigerated display cabinets 111 4.11 Regulations and legislation 113 4.12 Sources of further information 114 4.13 References 114 5 Temperature monitoring and measurement 116 5.1 Introduction 116 5.2 Importance of temperature monitoring 118 5.3 Principles of temperature monitoring 119 5.4 Temperature monitoring in practice 122 5.5 Equipment for temperature monitoring 133 5.6 Temperature and time–temperature indicators 143 5.7 Temperature modelling and control 147 5.8 Further reading 148 5.9 References 148 6 Chilled food packaging 152 6.1 Introduction 152 6.2 Requirements of chilled food packaging materials 152 6.3 Chilled food packaging materials 153 6.4 Packaging techniques for chilled food 156 6.5 Future trends 164 6.6 Sources of further information 166 6.7 References 166 Part III Microbiological and non-microbiological hazards 168 7 Chilled foods microbiology 170 7.1 Introduction 170 7.2 Why chill? 171 7.3 Classification of growth 171 7.4 The impact of microbial growth 173 7.5 Factors affecting the microflora of chilled foods 174 7.6 Spoilage microorganisms 179 7.7 Pathogenic microorganisms 184 7.8 Temperature control 190 7.9 Predictive microbiology 191 7.10 Conclusions 195 7.11 References 196 8 Conventional and rapid analytical microbiology 204 8.1 Introduction 204 8.2 Sampling 205 8.3 Conventional microbiological techniques 205 8.4 Rapid and automated methods 208 8.5 Microbiological methods – the future 231 8.6 References and further reading 231 9 Non-microbial factors affecting quality and safety 242 9.1 Introduction 242 9.2 Characteristics of chemical reactions 243 9.3 Chemical reactions of significance in chilled foods 243 9.4 Characteristics of biochemical reactions 248 9.5 Biochemical reactions of significance in chilled foods 250 9.6 Characteristics of physico-chemical reactions 255 9.7 Physico-chemical reactions of significance in chilled foods 255 9.8 Non-microbiological safety issues of significance in chilled foods 260 9.9 Conclusions 265 9.10 References 265 Part IV Safety and quality issues 274 10 Shelf-life determination and challenge testing 276 10.1 Introduction 276 10.2 Factors affecting shelf-life 277 10.3 Modelling shelf-life 285 10.4 Determination of product shelf-life 287 10.5 Maximising shelf-life 295 10.6 Challenge testing 296 10.7 Future trends 300 10.8 References 300 11 Microbiological hazards and safe process design 304 11.1 Introduction 304 11.2 Definitions 307 11.3 Microbiological hazards 321 11.4 Risk classes 324 11.5 Safe process design 1: equipment and processes 325 11.6 Safe process design 2: manufacturing areas 333 11.7 Safe process design 3: unit operations for decontaminated products 340 11.8 Control systems 345 11.9 Conclusions 349 11.10 References 350 12 Quality and consumer acceptability 358 12.1 Introduction 358 12.2 What defines sensory quality? 359 12.3 Sensory evaluation techniques 361 12.4 Determining consumer acceptability 366 12.5 Future trends and conclusion 368 12.6 References 369 13 The hygienic design of chilled foods plant 372 13.1 Introduction 372 13.2 Segregation of work zones 374 13.3 High-risk barrier technology 380 13.4 Hygienic construction 397 13.5 Equipment 406 13.6 Conclusion 411 13.7 References 411 14 Cleaning and disinfection 414 14.1 Introduction 414 14.2 Sanitation principles 415 14.3 Sanitation chemicals 419 14.4 Sanitation methodology 426 14.5 Sanitation procedures 431 14.6 Evaluation of effectiveness 433 14.7 Management responsibilities 438 14.8 References 440 15 Total quality management 446 15.1 Introduction 446 15.2 The scope of a quality system 450 15.3 Developing a quality system 452 15.4 Implementation 459 15.5 Performance measuring and auditing 463 15.6 Benefits 465 15.7 Future trends 466 15.8 References and further reading 467 16 Legislation 468 16.1 Introduction 468 16.2 Food law is reactive 468 16.3 Food laws and international trade 469 16.4 Chilled foods are... 470 16.5 Approaches to legislation 471 16.6 Codex 472 16.7 ATP 474 16.8 Canada 475 16.9 European Union 475 16.10 Australia/New Zealand 478 16.11 France 479 16.12 The Netherlands 480 16.13 United Kingdom 481 16.14 United States 482 16.15 Summary 485 16.16 References and further reading 485 Index 491 A 491 B 491 C 492 D 493 E 494 F 494 G 495 H 495 I 496 J 496 K 496 L 496 M 496 N 497 O 498 P 498 Q 499 R 500 S 500 T 502 U 503 V 503 W 503 Y 503 Z 503 The first edition of Chilled foods quickly established itself as the standard guide to quality issues in one of the most rapidly growing sectors in the food industry. This major new edition is set to consolidate and extend that reputation. This new edition has been thoroughly revised and updated and includes three new chapters on the subject of raw material selection. This book provides a comprehensive guide to all the factors involved in providing the consumer with safe, high quality products. Since the publication of the first edition of Chilled foods there have been important developments i The first edition of Chilled foods quickly established itself as the standard work on key quality issues in this sector of the food industry. This latest edition has consolidated and extended that reputation. It has been comprehensively revised and updated and includes four new chapters on the subject of raw material selection. The editors introduce this important collection with a discussion of key trends and influences in the various sectors of the chilled foods market. Subsequent chapters look at the key safety and quality issues in the manufacture of chilled foods The first edition of this book rapidly established itself as the standard work on the key quality issues in one of the most dynamic sectors in the food industry, the second edition has been substantially revised and updated. Chilled foods examines all aspects of this industry including: the market, applicable legislation, variety selection, refrigeration, temperature control, quality and safety, microbiology and shelf-life. The first edition of this book rapidly established itself as the standard work on the key quality issues in one of the most dynamic sectors in the food industry. This new edition has been substantially revised and expanded and now includes three new chapters on raw material selection for chilled foods. Examines aspects of the chilled food industry including the market, applicable legislation, variety selection, refrigeration, temperature control, quality and safety, microbiology, and shelf-life