Consultancy Services

consultation main
.
.
.
…………………….
I have more than 13 years experience in Processed Food Industry, especially working with retort food processing companies in India and abroad. Apart from supplying the suitable equipment, turn-key-projects, application support, training and validation support, I am also involved in Consultancy Services for the retort food industries.

Our Consultation, Application Support and Training on Retort Processing includes the following :-

1. RETORTS

1. Selection of Retort based on the target products and packing material
2. Selection of best quality retorts
6. Tips for maintenance checking of the retorts.
7. Tips to check the uniformity inside the retort / estimate the quality of retort.
8. Tips for the Validation of Retort – Heat distribution and Heat Penetration Studies.

2. POUCH PERFORMANCE AND SPECIFICATIONS

1. How to select the correct laminate material for retort pouches for processing specific food products.
2. Laminate Film structure and specifications suitable for retort processing.
3. Storage and handling of empty retort pouches.
4. Quality assurance checks for empty retort pouches.
5. Tips to protect the pouches from damage during retort processing
6. Documentation on inspection of retort pouches.

3. FILLING TECHNIQUES

1. Selection of Filling Machines with required accessories and fittings suitable for different types of products
2. Quality assurance checks before filling of pouches.
3. Pouch Loading / Pouch Coding
4. Pouch Opening and cleaning
5. Control of Filled weight and routine checks.
6. Selection of Filling methods based on recipes : Hot Filling / Ambient Filling / Cold Filling
7. Prevention of contamination in seal area.
8. Removal of Entrapped air and headspace during retort filling
9 . Documentation during Filling of pouches

4. POUCH SEALING

1. Sealing Conditions
2. Tips for perfect sealing
3. Quality Assurance Checks – checking of closing of seals prior to retorting
4. Documentation during sealing of pouches

5. FILLED POUCH HANDLING & LOADING ONTO THE RETORT

1. Estimation of Holding Time prior to retorting
2. Holding environment and Product Identification during holding
3. Controlling the Initial temperature for retorting
4. Estimation of Cooking Damage during holding period
5. Tray design and stacking considerations
6. Orientation and positioning of pouches
7. Handling and Loading the retort
8. Loading Pattern inside the retort
9. Tips for the positioning of the sample pouches for quality tests.
10 Tips for observing the cooking damage during processing
11.Documentation during filling and loading of pouches

6. HEAT PROCESS REQUIREMENTS

1. Establishment of the scheduled heat process
2. Foods Sterilization Values and Cook Values estimation
3. Establishment of heat distribution throughout the retort.
4. Tips for the Validation of the Retort and Process
5. Tips for Heat Distribution Studies
6. Tips for the Determination of Heat Penetration within the product
7. Implementing the process technology to the actual production conditions
8. Tips for the selection of Thermal process monitoring and controlling equipments.
9. Estimation of safe zones within the retort
10. Tips to optimize the retort processing
11. Tips to minimize the rejections
12. Tips to make sure that all the products are sterilized and cooked properly
13. Tips to handle if there is a deviation in the heat process procedures.
14. Tips to estimate the counter pressure required for each type of products
15. Tips to save the retort pouches from spoilage during retort processing
16. Listing of the Possible spoilages occurred to the products and pouches during retort processing and the causes .
17. Tips to control the counter pressure
19. Tips for Unloading the retort
20. Post Process Handling of retorted pouches
21. Drying of pouches
22. Quality Assurance checks – post processing
18. Documentation during retort processing

7. FINISHED PRODUCTS TESTING

1. Tips to check the pouches after processing
2. Tips for the Sensory analysis of the products after processing
3. Taste panel for testing the quality of finished products
4. Documentation on finished product checking

8. OUTER PACKING

1.Selection of outer packing
2. Transit Packing
3. Conditions during Transit packing

9. STORAGE

1. Temperature requirements for the storage room
2. Storage room requirements and conditions
3. Documentation on storage rooms.

10. INCUBATION and MICROBIOLOGY

1. How to select the samples for incubation
2. Incubation methods and set temperatures
3. List of equipment required for Microbiology analysis .
4. Handling techniques of products in case of rejection from Microbiology lab.

11. POUCH DEFECTS

1. Different types of Pouch defects
2. Classification of defects – Critical / Major / Minor
3. Procedure for checking the quality of pouches
4. Pouch testing methods and procedures.
5. Handling procedures to prevent pouch damage.

12. THERMAL PROCESSING TECHNOLOGY

1. Thermal Process Fundamentals
2. Establishment and standardization of the Thermal Process
3. Technology behind thermal processing
4. How to develop the thermal processing technology and procedure for specific products
5. Tips to improve the quality of finished products
6. Tips for retort food cooking and pre-cooking methods
7. Tips to preserve nutrients during pre cooking and sterilization
7. Pre cooking methods, – heating, frying , blanching etc.
8. Tips to optimize the thermal processing
9. Tips to minimize the spoilage of products and containers
10. Tips to estimate the cold spots inside the pouches and plastic trays of different sizes and types.

13. PRODUCT and RECIPE STANDARDIZATION

1. Tips to standardize the recipe
2. Tips to standardize the product
3. Tips to standardize the thermal processing of different products
4. Side effects of heat treatment
5. Brief about Cooking damage during retort processing and how to avoid it?

14. RECORDS /Documentation & Protection

1. Importance of keeping records
2. Tips to prepare proper documentation and records
3. Pouch inspection documentation
4. Thermal Processing documentation etc.

15. SYSTEM ANALYSIS & SUGGESTIONS FOR IMPROVEMENT

1. System Analysis of the present production plant setup
2. Merits and demerits of the present structure
3. Suggestions for improvement
4. Follow ups

Consultation 1

You must be logged in to post a comment Login