Application of Hurdle Technology in Poultry Meat Processing & Preservation

2. Presented By: Dr. Irshad A
Application of Hurdle Technology in
Poultry Meat Processing &
Preservation

3. Introduction
1
Hurdle Technology
2
Characteristics of Hurdles
3
Examples of Hurdle Technology in Products
4
Overview

4. Introduction
What is Hurdle Technology
Combination of preservation which employ the
use of two or more hurdle or barrier to spoilage
micro-organism in a balance and judicious way.
Used for shelf stable food products and IMF
•Many of well established traditional food products having this
concept.
•Evolved at “Federal center for meat research” Germany
•Leistner and Rodel in 1976
Leistner- Father of Hurdle Technology

5. Hurdle Technology
• It is the process/technology used for the preservation
provide shelf stability to a food product by laying hurdle
which are difficult to overcome by the micro-organism
causing food spoilage and poisoning. (Berwal, 1994)
• Also called
 combined process,
 combined methods,
 combination preservation,
 combination technique or
 barrier technology

6. • Hurdle in a food- Substance or process inhibition
deteriorating process
aw (water
activity)
pH
(acidificat
ion)
F (heat
treatment)
t(low
temperatur
e)Eh (reduced
oxygen
potential)
Modified
atmosphere
s
Competitive
micro flora
Preservati
ves
(nitrite)

7. Hurdle Technology
High hydrostatic pressure,
High-intensity pulsed
electric fields,
High-intensity pulsed light,
Oscillating magnetic fields,
Food irradiation
Important in the preservation of IMF & HMF………why?
It can control
1. Microbial Spoilage
2. Food poisoning
3. Desired fermentation process

8. Significance of Hurdle Technology
• An intelligent application of hurdle contributes to both
improvement in product quality and sustainability.
• Calculated application of hurdles could result into saving
money, energy and several resources
• Each hurdle contribute to the safety net against the micro-
organism
• Since SSPs do not require refrigeration, they travel long
distance for finding place in the market to reach the
consumers
• Able to use in products for defense force
• Perishability can be reduced.

9. Physical Hurdles
1. Heat processing – to kill/ destroy micro-organisms and/or
enzymes
• Heating in hermetic ceiling avoid recontamination
Sterilization
Pasteurizat
ionBlanching
Temp≥ 100oC (F Value)
Temp 60-85oC
Not Applicable

10. Physical Hurdles
2. Storage Temperature– Mainly chilling and Freezing during
storage
Chilling
-1oC to +7oC
Freezer
Temperature
≤ -18oC

11. Physical Hurdles
3. Radiation– Process of using a radiation frequency of 109 MHz
or above
UV Radiation
*260nm-most
efficient
*Low pressure
mercury lamp –
emission at 254nm
*G-ve kill easily
*Spore and Moulds
-resistant
Ionization
Radiation
*γ and β
*Very high energy
*Kill organism
depending on dose
*1-10 kGy-
vegetative org
*10-50 kGy- kill
bacterial spores

12. Physical Hurdles
4. Electro-magnetic energy (EME)– results from high voltage
electric fields
Oscillating magnetic field pulses
2-5 T, oscillation frequency 5 to
500 MHz
No temperature raise, single
pulse destroy 99%
Radio frequency energy
1-500 MHz- mild preservation Applied to heat processed food
Microwave Energy
Alternate electric field -500 to
1000 MHz
Fast heating by internal
molecular vibrations

13. Physical Hurdles
5. High Electric field– electric potential of 15Kv/cm *reverse
membrane potential of cell
6. Photodynamic inactivation-
 Light
 Molecular oxygen
 Photosensitizer
Photosensitizer
eg- rose Bengal
Absorb light
Molecular
O2
Reactive
Free Radical
Kill Micro-
organism

14. Physical Hurdles
7. Ultra High Pressure Process– 3000 bar and above
*inactivate enzyme and Microbs.
8. Ultra Sonication- vibrations between 18kHz to 500 Mhz
G -ve
• 3K bar
Y & M
• 4K bar
G +ve
• 6k bar
Spores
• 12k
bar

15. Physical Hurdles
9. Packaging
 Vacuum packaging
 Moderate Vacuum packaging
 Active packaging
 Edible coating
 Modified atmospheric packaging
 Controlled atmospheric packaging
 Hypobaric storage
 Aseptic packaging
1. Prevent the entry of
microorganism, dirt,
insects, etc
2. Act as a barrier for
transfer the water
vapour, gas and
aroma

16. Physico-chemical Hurdles
1. aw –Water activity
 Reduced by dehydration
 Adding solutes such as salts, sugar, etc…
 By lowering temperature
2. pH
3. Redox Potential (Eh)- Denote oxidation reduction potential of
food system, Express in mV, +300 to -200mV
4. Nitrate (NaNO2)
5. CO2 – above 20%, spoilage bacterial inhibited
6. O2

17. Physico-chemical Hurdles
7. Ozone- lethal effect on micro organism due to strong oxidizing
capacity
 O3 treatment destroy G- ve bacteria.
 Y & M – resistant
8. Lactic acid, Lactate- effective agaist pathogenic organism like
M. Tuberculosis, L. Momocytogenes
9. Acetic acid, acetate
10. Ascorbic acid
11. SO2 – used in the form of Sodium meta-bisulphite, or gaseous
SO2
Antioxidant Enzyme
inhibitor
Milliard
reaction
inhibitor
Reducing
agent
Antimicrobial
agent

18. Physico-chemical Hurdles
12. Smoking:- important concept in poultry products
13. Phosphates
14. Glucono-d- lactone (GDL) – adding in cured meat
GDL Gluconic acid
Hydrolysis
Lowering
the pH
Product
Safety and
stability

19. Physico-chemical Hurdles
15. Phenols- Mainly used to prevent oxidative deterioration of
food- used in combination with other hurdles
eg- BHA, BHT, TBHQ
16. Spices and herbs
17. Lactoperoxides
18. Lysozymes

20. Microbially Derived Hurdles
1. Competitive flora- in fresh meat competitive flora inhibit L.
monocytogenes
2. Starter culture-
3. bacteriocins- Nicin, best known from lactic acid bacteria
* Number of bacteriocins are used experimentally in poultry
meat and meat products along with other Hurdle (Harris et al.,
1992; Kim, 1993)
4. Antibiotics- in poultry tetracycline are accepted

21. Hurdle Undesirable effect
Refrigeration Chilling injuries, weight loss
Freezing Discoloration, Texture loss, enzymatic
browning
CAP Softening, discoloration, slow spoilage
Pasteurization Nutritional losses, sensory losses
Drying Discoloration, Flavour change, mould
growth
Preservatives Consumer aversion resistance
Characteristics of A Hurdle alone

22. Guideline for Making Shelf Stable Product
Using Hurdle Technology
Define the desired sensory properties and shelf-life of meat product
Frame a processing technology to be followed
Prepare the product
analyse for pH, aw, preservatives, or other inhibitory factors
Predictive microbiology should be used for testing preliminary
stability

23. Guideline for Making Shelf Stable Product
Using Hurdle Technology
The product is then challenged with relevant food poisoning and
spoilage organisms, using somewhat higher inocula and
storage temperatures than would be ‘normal’ for the products.
If appropriate, the hurdles in the product are modified, taking multi-
target preservation and the sensory and nutritional quality of the
product (i.e. ‘total quality’) into consideration.
The food is again challenged with relevant microorganisms and, if
necessary, the hurdles in the food are modified again.
Predictive microbiology is helpful at this stage for assessing the
safety of the food.

24. Guideline for Making Shelf Stable Product Using
Hurdle Technology
After the established hurdles of the modified or new food are precisely
defined, including tolerances, the methods for monitoring the
process are agreed on. Physical or sensory methods for monitoring
should preferably be used.
The designed food should now be produced under industrial
conditions, because the adequacy for a scale-up of the proposed
manufacturing process must be validated.
If for an industrial process the Critical Control Points (CCPs) and their
monitoring are established, the manufacturing process might be
controlled by HACCP. If HACCP seems inappropriate, guidelines
for the application of manufacturing control by quantitative GMP
must be defined.

25. Examples
Theoretical
Practical
Unwanted
hurdles
F, heating; t, chilling; aw, water activity; pH, acidity; Eh, redox potential;
pres., preservatives; V, vitamins; N, nutrients; c.f., competitive flora.

26. Examples

27. Examples
Too much initial
load
Rich in nutrients
Injured spoilage
organism
Nitrite
Depleation

28. Examples
Fermentation of
salami
Synergetic
effect of hurdle

29. Products with Hurdle Technology

30. Products with Hurdle Technology

31. For a greener
Environment