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Thermal Processing & Pasteurization Optimization

Course Description This course focuses on thermal processing technology, including pasteurization, sterilization, and commercial aseptic processing. Students will learn microbial…

momenjomaa July 11, 2026

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Thermal Processing & Pasteurization Optimization

Categories Courses, Food Science & Technology

course code

FS-TP301

course duration

7 Weeks (35H)

course type

Online + calculation workshops + case studies

What will you learn

Course Description
This course focuses on thermal processing technology, including pasteurization,
sterilization, and commercial aseptic processing. Students will learn microbial destruction
kinetics, thermal death time calculations, D-value and z-value concepts, heat penetration,
and process optimization for safety while minimizing quality loss.

Target Audience

  • Food science students
  • Food industry process engineers
  • Quality assurance and production professionals

Requirements

  • Food microbiology
  • Heat transfer basics (recommended)

Course Curriculum

Lecture 1: Fundamentals of Microbial Destruction Kinetics
- Introduction to thermal processing in food preservation: pasteurization, sterilization, and commercial aseptic processing — scope and objectives - Microbial destruction kinetics: first-order reaction model for thermal death - Logarithmic order of death and survivor curves - D-value (decimal reduction time): definition, calculation, and significance - Factors affecting D-value: microbial species, strain, growth conditions, suspending medium, pH, water activity - z-value: definition as temperature sensitivity parameter, relationship to thermal death time - Endpoint criteria for pasteurization vs. sterilization

  • Fundamentals of Microbial Destruction Kinetics
1 Topic

Lecture 2: Thermal Death Time Calculations and Process Equivalency
Topics Covered -Thermal Death Time (TDT): concept and determination methods -F-value (lethal rate): integrating lethality over time -Lethal rate curve and graphical integration methods -General Method: Bigelow's method for process calculation - Formula Methods: Ball's formula method and Stumbo's approach -Thermal death time paper (TDT paper) and semi-logarithmic plots

1 Topic

Lecture 3: Heat Penetration and Process Optimization
Topics Covered -Heat transfer mechanisms in thermal processing: conduction, convection, and mixed modes -Heat penetration curves: plotting retort temperature (RT) vs. product cold-point temperature -Come-up time (CUT) and its influence on total lethality -Cold point location: factors influencing its position in conductive vs. convective heating foods -Broken heating curves: handling products with phase transitions or changing heat transfer modes -Process optimization: balancing microbial safety against quality degradation -Quality factor kinetics: thiamine retention, color changes, texture degradation -Arrhenius model for quality loss vs. thermal death kinetics

1 Topic

Lecture 4: Aseptic Processing, Commercial Systems, and Quality Assurance
Topics Covered Commercial aseptic processing: principles and system components Typical aseptic processing line: product sterilization (scraped-surface or tubular heat exchangers), holding tube, cooling, sterile surge tank, aseptic packaging UHT (ultra-high temperature) processing: 135–150°C for 2–10 seconds Comparison of in-container sterilization vs. aseptic processing for quality retention Heat exchanger types: plate, tubular, scraped-surface — selection criteria Holding tube design: residence time distribution, minimum residence time Process validation and assurance: Temperature monitoring and recording Critical control points (CCPs) in thermal processing Regulatory requirements: FDA (21 CFR 113, 114), USDA-FSIS File maintenance for scheduled processes

1 Topic

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