Commercial Sterilization of Low-acid Food in Hermetically Sealed Containers: Retort Systems
Record keeping
Maintain comprehensive records to ensure traceability and compliance with food safety standards.
- Preventive Control Plan (PCP)
- Batch production logs
- Thermal processing data
- Packaging inspections
- Deviations and corrective actions
Process design
Design and validate processes to ensure that low-acid foods achieve commercial sterility.
- Temperature distribution test
- Scheduled process
- Heat penetration studies
Thermal processing equipment
Ensure all thermal processing equipment (e.g., retorts, pressure vessels) operates within validated parameters.
- Equipment calibration
- Temperature – time monitoring
- Maintenance schedule
Incoming material control
Inspect and control the quality of all incoming materials to ensure they meet specifications.
- Product specifications
- Supplier approval
- Raw material/ingredient/packaging material inspection
- Visual inspection
- pH determination
- Non-food chemicals inspection
Empty container control
Ensure empty containers (cans, jars) are clean, free from defects, and suitable for use in low-acid food processing.
- Container integrity checks
- Container handling SOPs
- Visual inspection
- Broken glass control
- SSOPs
Product preparation and blending control
Ensure that the preparation and blending of ingredients are controlled to meet formulation requirements and prevent contamination (enterotoxin by Staphylococcus aureus.)
- Critical factor control
- Time – Temperature control
- CCP monitoring records
- Product formula
- Blending records
Filling control
Ensure that containers are filled to the correct level to maintain proper headspace and achieve the desired thermal process effect.
- Filling factors control
- Filling records
- Temperature control records
- Ingredient distribution control records
- Visual inspection
- Weight/volume control records
- Broken/Damaged container SOP
- SSOPs
- Equipment monitoring
- Equipment maintenance
Container closure control
Ensure containers are properly sealed after filling to prevent contamination and maintain product sterility.
- Metal can seam SOP
- Glass cap SOP
- Pouch seal SOP
- Vacuum-packed foods SOP
- Visual and destructive examination SOP and records
Pre-thermal process control
Inspect filled containers before thermal processing to ensure they meet quality standards.
- Sealed container handling
- Container handling systems control
- Elapsed time control
- Retort loading control
- Traffic control and process indicators
- Tag system
- Temperature-sensitive indicator
Process control
Ensure that thermal processing conditions meet validated specifications for time, temperature, and pressure.
- Temperature control monitoring
- Thermal process SOP
- Vent schedule and control
- Process time control
- Process temperature control
- Thermal process records
- Employee training
Post-process control
Inspect containers post-processing to ensure they maintain integrity and are properly cooled.
- Cooling controls
- Cooling water controls
- Water treatment records
- Container handling and drying system controls
- Container integrity verification
- Container integrity evaluation records
Incubation
Incubate samples from each production batch to detect any microbial growth and ensure sterility.
- Incubation testing SOP
- Incubation records
Deviations and corrective actions
Identify and document any deviations from the standard process and ensure corrective actions are implemented.
- Deviation control SOP
- Deviation/Hold records
- Corrective action SOP
- Corrective action reports
Verification of product safety
Verify that final products meet safety and quality standards before distribution.
- In-process and finished product sampling
- In-process and finished product testing
- Microbiological testing
- Internal audit
- External/Third-party audit
- Consumer complaint trends analysis
- Vendor/Supplier audit