Cook Validation Perfected
PhoenixTM provides Cook Validation solutions for HACCP Certification
As part of any Food processors HACCP program, validation of cook and chill processes is a critical and significant task taking time, effort and resources.
PhoenixTM have developed a Thru-Process temperature monitoring technology specifically for this task, designed to meet the challenges of the food processing market. Ideal for the validation process for any new cook regime, new product or annual process certification. Whether performing an oven survey “oven mapping to identify cold spots” or validating the cook under production conditions, the Thru-Process profiling solution gives you the accuracy, efficiency, and reliability you need to satisfy your HACCP demands.
As its name suggests Thru-Process profiling is the method by which product and or process temperature is monitored throughout the complete cook / chill process. Monitoring of continuous conveyorised linear and spiral ovens and semi-continuous or rotational batch cooks are feasible where the use of external recorders with trailing thermocouples is tedious, impractical, and unsafe. Employing the Thru-Process principal process monitoring can be performed under true production conditions without compromising line productivity.
At the heart of the Thru-Process monitoring system is the PhoenixTM data logger. The PhoenixTM NT data logger range has been designed specifically for the challenges of monitoring food processing applications with an IP67 case design protecting from moisture. Type K or Type T data logger options allow accurate measurement of both cook and chill processes. The data logger itself can operate between -40 °C to 80 °C with a data logger accuracy of ±0.3 °C operating below +50 °C. Efficient cold junction compensation (CJC) maintains accuracy even with changes in data logger operating temperature. Data logger and thermocouple correction factors can be further applied to maximise measurement accuracy.
To protect the data logger as it passes through the oven it is housed in a thermal barrier. PhoenixTM offer a family of thermal barriers to suit the process type, duration, and temperatures of a wide range of cook regimes. The TS14 range is IP67 so ideal for Fryer & linear/ spiral ovens, Low height quick cook, steam injection/ raining water or brine showers. The TS24 range is designed for dry bake/roast or low-pressure steam cook. (Batch/ DD RevoRack or linear/ spiral ovens). Chillers/ freezers. It is non submersible but has a IP65 rating. The TS44 range is recommended for long low temperature cooks (typically <100 °C) with high levels of steam / water or brine. Typical uses are large joint/ ham stock cook.
TS14 Thermal Barrier Range
TS14-040-1 40 mm high 40 mins @ 200 °C
TS24 Thermal Barrier Range
TS24-064-1 64 mm high 2.5 hrs @ 200 °C
TS44 Thermal Barrier Range
TS44-120-1 120 mm high 16 hrs @ 100 °C
An extensive range of different thermocouple types is also available to suit different product types, sizes and monitoring demands.
As part of any validation testing experimentation, it is essential to identify the cold spot of the product to ensure that safe cook temperature is recorded from the worst-case scenario. Positioning the thermocouple sensor in the correct place repeatably in a protein-based product such as chicken generally requires the use of a needle thermocouple. The sensing point on a thermocouple often referred to as the ‘hot junction’ is located in the tip of the needle point. A tapered collar helps keep the needle fixed in the food core during the whole cook/measurement process.
Needle thermocouples are supplied in most cases with PFA/PTFE cables which allow flexible routing of the cable through the process. Such cable is operational up to 265 °C, meeting the needs of most cook programs. Above 265 °C the only food grade cable material option is a Stainless-Steel mineral insulated thermocouple. This thermocouple does not have a needle but the wire acts as if a needle. The theoretical accuracy of the thermocouple is governed by the type and classification. Type K thermocouple cables are provided with special limits or error ±1.1. °C or 0.4% of reading. Type T are IEC EN 60584-2 class 1 therefore ±0.5. °C (-40 to 125 °C). It is important to note though that the actual measurement accuracy is the combination of the data logger accuracy and thermocouple accuracy. The most accurate combination is a Type T data logger and thermocouple, despite having a tighter measurement range.
The PhoenixTM Thermal View Food Software provides a comprehensive suite of analysis tools to convert the raw profile temperature data into useful process information. The analysis tools include the ability to calculate Fo/Pu values for the process against target micro-organisms. Using the Thermal View Software it’s possible to create a customised full validation report with efficiency and confidence. Generate and share all the certified HACCP information you need. The information gathered, further to process validation, can be used to allow informed process problem solving and optimisation to maximise product quality, yield, process productivity and efficiency.
