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Development of Shelf Stable Ready-to-Eat Pork Curry Using Retort Processing

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DOI: 10.1007/s41783-018-0026-5

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Journal of Packaging Technology and Research (2018) 2:61–66
https://doi.org/10.1007/s41783-018-0026-5

RESEARCH ARTICLE

Development of Shelf Stable Ready‑to‑Eat Pork Curry Using Retort

Processing Technology
P. S. Girish1,4 · Lipika Nath1 · R. Thomas1 · V. Rajkumar2 · Tanweer Alam3

Received: 6 December 2017 / Accepted: 20 February 2018

© Indian Institute of Packaging 2018

Abstract
Processed pork products are highly perishable and they need to be stored under refrigeration temperature throughout storage,
distribution, and marketing to maintain quality. Retort processing technology helps obviate the requirement of refrigeration
during storage of food products and thereby enables production of food products which can be stored at ambient temperature.
Keeping this advantage in mind, experiments were undertaken to develop formulation and process schedule for production of
thermally processed shelf stable ‘pork curry’. Curry products are spicy Indian traditional food products prepared with meat,
vegetables, spices, condiments etc. In this experiment, pork chunks were shallow fried in a pan until the core temperature
reaches about 50 °C. Gravy ingredients were prepared separately and semi cooked until temperature reaches about 90 °C.
About 75 g of the fried meat and 125 g of the vegetable curry was put in retort pouches. Filled-in retort pouches were sealed
with impulse sealing machine. For thermal processing, the retort temperature was maintained at 121 °C. Pressure of the
retort was maintained at 20 ± 1 psi throughout the process. Core temperature of the product was measured using copper
thermocouples. F0 of 11.81 was found to be adequate for pork curry. Total process time was 48 min. Retort pouched products
were analyzed for storage stability. Product was found to be of good quality up to 6 months of storage at ambient temperature.

Keywords  Pork · Pork curry · Retort processing · Shelf stable · Ready-to-eat

Introduction it requires cold chain throughout the marketing channel

Pork is the world’s most widely consumed meat from ter-
restrial animals. India constitutes about 3% of the global
pork production with total production of 0.35 million tonnes
in 2014 [8]. Pork is traditionally consumed in the form of
curry products in India. Curry products are gravy type prod-
ucts prepared with meat, vegetables, spices, condiments etc.
India is a tropical country with high average environmen-
tal temperature. Preservation of meat products under these
conditions for distribution and marketing is a challenge as
* P. S. Girish
girishlpt@gmail.com
1
ICAR-National Research Centre on Pig, Rani, Guwahati,
Assam 781131, India
2
ICAR-Central Institute for Research on Goats, Mathura, Uttar
Pradesh, India
3
Indian Institute of Packaging-Delhi, Patparganj Industrial
Estate, New Delhi, India
4
ICAR-National Research Centre on Meat, Chengicherla,
Hyderabad, Telangana 500092, India
[3]. This challenge becomes even greater in remote hilly
areas especially in north-eastern regions of India, wherein
cold storage facilities are not well established. To address
this problem, in this work, experiments were undertaken
to develop shelf stable, ready-to-eat pork curry product
using retort processing technology. Retort pouch processing
involves the application of high temperature thermal treat-
ment to food products in hermetically sealed flexible retort
pouches to destroy all pathogenic and spoilage organisms
of concern. Retort pouches have been successfully utilized
for different meat products like meat biryani [18], buffalo
meat blocks [21], chettinad chicken curry [23], sliced meat
[10], beef curries [15], beef stew [7], and chicken meat [17].
Reports on development of retort processing schedule for
traditional Indian pork products are scanty. The objective of
this study was to address this gap and develop gravy-type
pork curry in retort pouches and to evaluate their shelf life
based on physicochemical, microbiological, and sensory
attributes.

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Materials and Methods
Fresh deboned pork was collected from the Experimental
Slaughterhouse of ICAR-National Research Centre on Pig,
Guwahati, India. Pork was cut into cubes of about 2 inches
using a sterilized meat cutting knife. The recipe for the
preparation of pork curry with mixed vegetable was col-
lected from field survey and by interacting with traditional
processors in Assam State, India. Other ingredients for the
preparation of pork curry were procured from local market
of Guwahati, India.
Product Preparation
In a frying pan, the weighed pork pieces were fried in refined
oil to reach internal temperature of about 50 °C. Gravy was
prepared separately. The ingredients used for preparation of
gravy are as follows: carrot (7.0%), beans (7.0%), tomato
(9.0%), green peas (7.0%), capsicum (6.0%), green chilli
(2.0%), ginger–garlic paste (2.5%), onion (7.0%), turmeric
powder (0.50%), black pepper (0.50%), bay leaves (0.50%),
refined oil (7.0%), salt (2.0%), rice powder (9.0%), cashew
nut (4.0%), raisins (1.0%), coriander leaves (1.0%), and
water (27.0%). Initially, bay leaves, chopped onion, gin-
ger–garlic paste, cashew nut, and raisins were fried in refined
oil until the colour turns brownish. To this mix, predeter-
mined quantities of sliced tomato, beans, carrot, capsicum,
green peas, turmeric powder, and salt were added, mixed,
and cooked for few minutes. Black pepper and rice powder
were also added and mixed properly into gravy mix. Finally,
coriander leaves were added to gravy. Gravy was precooked
until it reaches temperature of about 90 °C and was allowed
to cool. 125 g of cooled gravy mix and 75 g of pork pieces
were put in retort pouches, residual air removed from the
pouches, and sealed using impulse sealing machine (Make:
M/s. Lakshmi Engineering, Chennai). Sealed retort pouches
were placed in retort processing unit (Make: M/s. Lakshmi
Engineering, Chennai) and were thermally processed for
commercial sterilization. Product processing and shelf life
studies were undertaken in triplicate. Normally, production
and distribution cycle of meat and meat products take maxi-
mum up to 6 months. Hence, storage studies of the product
were taken up to 6 months of storage only.
Physicochemical Properties
The pH of the pork curry was determined by the method of
Keller et al. [13] using a digital meter (Systronics Digital
pH Meter 803, serial No. 603). The moisture, ether extract,
protein, and total ash content of the pork products were
estimated as per AOAC [1]. Thiobarbituric acid reactive
13
Journal of Packaging Technology and Research (2018) 2:61–66
substances (TBARS) value was estimated as per the method
of Tarladgis et al. [28]. TBARS number was calculated as
mg of malonaldehyde per kg of meat sample. Free fatty acid
(%) and total acidity (mg/l) in the product were evaluated as
per AOAC [1]. Texture was analyzed using a Texturometer
(Model: Stable Microsystems Ltd., UK) as per Bourne [5].
Evaluation of Retort Pouches
Physical properties of the retort pouches used in the study
are given in Table 1. Retort pouches used in the study were
evaluated for their strength and quality at Indian Institute of
Packaging-Delhi, New Delhi. Retort pouches were made of
four layers: cast poly propylene, biaxially oriented nylon,
aluminium foil, and polyester.
Evaluation of Thermal Penetration Characteristics
Pork meat cubes (75 g) in pouches were filled with (125 g)
gravy medium. Residual air was removed manually and
sealed by an impulse sealing machine. Thermocouples were
carefully introduced to the core of pork meat in two of the
pouches. One thermocouple was kept in the retort chamber
for monitoring the chamber temperature. Filled and sealed
pouches were laid flat on trays in retort processing unit (30
pouch capacity).
Thermal Processing Parameters
Thermal processing of the product was undertaken and
thermo dynamics of the product was calculated as per the
method described by Stumbo [27]. For thermal processing,
temperature of the retort chamber was maintained at 121 °C.
The time required for optimum processing was determined
as per the method of Gopal et al. [9]. Pressure was main-
tained at 20 ± 1 psi throughout the process, using steam–air
mixture. After the completion of the processing time, rapid
Table 1  Physical properties of retort pouches
Parameters Value
Total thickness 114 micron
Pouch length 200 mm
Pouch width 150 mm
Pouch weight 7.86 g
Seal width (side) 10 mm
Seal width (bottom) 9 mm
Tensile strength (Length wise) 574.05 kg/cm2
Tensile strength (Width wise) 523.73 kg/cm2
Heat seal strength (Length wise) 7.74 kgf/15 mm
Heat seal strength (Width wise) 7.319 kgf/15 mm
Peel bond strength 228.71 gf/15 mm
Journal of Packaging Technology and Research (2018) 2:61–66 63
cooling of the product to 60  °C was undertaken using
water–air mixture and recirculation of the cooling water.
Product core temperature during processing was monitored
using pair of copper thermocouples inserted into core of the
product using ducts. The coldest point was taken as the point
that takes the longest time to sterilize. Real-time temperature
of the product and retort chamber was recorded every min-
ute using the Programmable Logical Control (PLC) device.
Based on the time–temperature data recorded using the PLC,
different thermal parameters like: lag factor for heating (Jh),
slope of the heating curve (fh), time in min for steriliza-
tion at retort temperature (U), and lag factor for cooling (Jc)
were calculated. The parameters fh/U, process time B and
total process time (TB) were calculated by the mathematical
method. The parameters were determined by plotting tem-
perature deficit (RT–Tc) on semi-log paper. RT is the retort
temperature and Tc is the product core temperature. Total
process time (TB) was determined by adding process time
(B) to the effectiveness of the come up time (CUT).
The lag factor for heating (Jh) = (Tr × Tpih)/(Tr × Taih),
where Tr– temperature of retort, Tpih—Pseudo (corrected)
initial heating temperature, Taih—Actual initial heating tem-
perature and fh = time in min, required for the straight line
heating curve to transverse one log cycle which is numeri-
cally equal to the reciprocal of the slope of the straight line.
The lag factor for cooling (Jc) = (Tr × Tpic)/(Tr × Taic),
where Tr—temperature of retort, Tpic—Pseudo (corrected)
initial cooling temperature, and Taic—Actual initial cooling
temperature.
Process time (B)  =  Total process time—CUT where
CUT—Come Up Time.
Microbiological Evaluation
Sterility tests were done as per ISI [11]. Total plate count,
anaerobic count, coliform count, Escherichia coli, Salmo-
nella spp., Clostridium spp., and Staphylococci spp. were
determined as per APHA [2].
Sensory Evaluation
Pork curry was subjected to organoleptic evaluation for qual-
ity and acceptability by trained panellists of ICAR-National
Research Centre on Pig, Guwahati using 8-point hedonic
scale (ranging from 8 = Excellent/extremely acceptable to
1 = Extremely poor/unacceptable) for appearance/colour,
flavour, texture, saltiness, consistency, and overall accept-
ability [12].
Statistical Analysis
The statistical analysis was made based on the procedure
outlined by Snedecor and Cochran [26]. To understand the
effect of thermal treatment on meat product quality, analysis
of variance was applied, while difference between means
was measured using critical difference test.
Results and Discussion
Heat Penetration Studies
Heat penetration characteristics of pork curry in retort
pouch are given in Table 2. Thermal processing experi-
ments and storage studies indicated F0 value of 11.81 as
optimum for achieving commercial sterility of retort pro-
cessed pork curry. F0 was standardized after undertaking
sterility test [11] and microbiological analysis of the retort
processed samples. This finding was as per the F0 range of
8–12 recommended for curried meat products by Ranganna
[24]. Total process time was 48 min. Temperature of retort
chamber and product was below 35 °C prior to processing.
Product reached first lethality rate of 0.001 after 7 min of
processing when the product core temperature was 94.2 °C
and retort chamber temperature was 120.9 °C. To reach the
first lethality, come-up time (CUT) was 7 min. The CUT
as percentage heating time of retort processed pork curry
was 20%. Rajkumar et al. [23] reported CUT percentage of
50.1%, while Ranganna [24] reported CUT percentage of
42%. The total heating time was recorded as 35 min to get
the required F0 value of 11.81. Cooling time after reaching
the required F0 was 6 min at which retort temperature was
35.7 °C and product core temperature was 55 °C which was
below the targeting cooling temperature of 60 °C (Fig. 1).
Proximate Composition and Texture Profile
Proximate composition of pork curry is given in Table 3.
Moisture, protein, ether extract, and total ash of meat before
processing were 75.98 ± 1.84, 16.74 ± 1.26, 6.69 ± 0.46,
Table 2  Heat penetration characteristics of pork curry in retort pouch
Parameters Value
Come up time (CUT) 7 min
Time for sterilization (U) or Heating Time (HT) 35 min
Cooling time (CT) 6 min
Total process time (CUT + HT + CT) 48 min
F0 11.81
Heating rate index (fh) min 38
Heating lag factor (Jh) 1.11
Cooling lag factor (Jc) 1.37
Process time, min 41 min
Cook value, min 103.62 min
fh/U 1.15
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64 Journal of Packaging Technology and Research (2018) 2:61–66

Fig. 1  F0 value and thermal

processing characteristics of
pork curry product

Table 3  Proximate composition and texture characteristics of retort conformity with report of Rajkumar et al. [23]. The release
processed pork curry (mean ± SE) of moisture and fat into the gravy during heat denaturation
Before processing After processing of proteins might have contributed for lower moisture and
fat level in retort processed products. Leander et al. [16] also
Moisture (%) 75.98a ± 1.85 67.89b ± 0.28 observed that when meat is cooked, water, soluble proteins
Protein (%) 16.74a ± 1.26 24.75b ± 0.49 and fats are expelled from the tissue. Instrumental texture
Fat (%) 6.69a ± 0.45 4.26b ± 0.19
was measured to know the textural properties of pork, before
Ash (%) 0.28a ± 0.07 3.08b ± 0.24
and after processing. Cohesiveness, springiness (mm), chew-
Cohesiveness (ratio) 0.49a ± 0.07 0.27b ± 0.005
iness (Nmm), and firmness (N) values of the pork before
Springiness (cm) 0.21a ± 0.005 0.40b ± 0.04
processing were 0.49, 0.21, 30.25, and 61.91, respectively.
Chewiness (N/cm) 30.25a ± 17.07 12.51b ± 1.52
Whereas, the same parameters after processing were 0.27,
Firmness (N) 61.91a ± 17.74 4.92b ± 1.21
0.40, 12.51, and 4.92, respectively. This indicates soften-
Work of shear (Ns) 249.27a ± 75.32 40.07b ± 11.52
ing of the pork product due to action of moist heat at high
Means with different superscripts (column wise) vary significantly temperature. Rajkumar et al. (2010) also reported decrease
(P < 0.05) in hardness, cohesiveness, and chewiness scores after retort
processing of chettinad style goat curry product.

and 0.28  ±  0.07%, respectively, while after process- Storage Studies

ing, it was 67.89 ± 0.28, 24.75 ± 0.49, 4.26 ± 0.19, and
3.08 ± 0.24%, respectively. Moisture and fat content of meat
chunks reduced after processing, which may be due to high
temperature processing. Protein and ash content increased,
which may be due to decrease in moisture and fat content
of the product. The moisture content was found higher in
unprocessed pork than that of processed pork. This is in
The pH of the pork curry decreased significantly (P < 0.05)
during storage period (Table  4). Similar trend was also
observed during storage by Prince Devadason et al. [20]
in retort processed buffalo meat block and Rajkumar et al.
[23] in retort processed Chettinad goat meat and Rajan et al.
[22] in retort processed Chettinad chicken. This might be

Table 4  Physicochemical Storage days in pH TBA (mg/kg) FFA (%) Acid value (ml/g)
properties of pork curry during months
storage at ambient temperature
(mean ± SE) 0 6.88a ± 0.25 0.21a ± 0.00 0.31d ± 0.012 0.51a ± 0.015
1 6.24b ± 0.09 0.35b ± 0.024 0.29 cd ± 0.009 0.68b ± 0.017
2 5.57c ± 0.22 0.37b ± 0.006 0.25a ± 0.007 0.74bc ± 0.02
3 5.54c ± 0.12 0.47c ± 0.013 0.28bc ± 0.006 0.84cd ± 0.029
4 5.37c ± 0.3 0.49cd ± 0.006 0.27ab ± 0.003 0.93d ± 0.02
5 5.27c ± 0.03 0.51cd ± 0.006 0.26ab ± 0.012 1.07e ± 0.070
6 5.17c ± 0.03 0.52d ± 0.003 0.25ab ± 0.012 1.08e ± 0.015

Means with different superscripts (row wise) vary significantly (P < 0.05)

13
Journal of Packaging Technology and Research (2018) 2:61–66 65

Table 5  Sensory scores of pork Storage days Appearance Flavour Texture Saltiness Consistency Overall acceptability
curry during storage at ambient
temperature (mean ± SE) 0 7.6 ± 0.20a
7.2 ± 0.15 7.3 ± 0.21 7.1 ± 0.18 7.2 ± 0.15 7.1 ± 0.17
1 7.4 ± 0.17ab 6.9 ± 0.13 7.2 ± 0.10 7.1 ± 0.09 7.1 ± 0.13 7.1 ± 0.09
2 7.4 ± 0.17ab 7.1 ± 0.18 7.3 ± 0.15 7.2 ± 0.18 7.2 ± 0.14 7.3 ± 0.15
3 7.1 ± 0.18ab 7.3 ± 0.28 7.3 ± 0.28 7.1 ± 0.07 7.2 ± 0.14 7.5 ± 0.18
4 6.9 ± 0.13b 7.3 ± 0.21 7.1 ± 0.20 7.1 ± 0.13 7.1 ± 0.18 7.5 ± 0.14
5 7.4 ± 0.17ab 7.1 ± 0.25 7.5 ± 0.28 7.3 ± 0.18 7.1 ± 0.14 7.4 ± 0.17
6 7.1 ± 0.07ab 7.5 ± 0.19 7.5 ± 0.18 7.4 ± 0.17 7.4 ± 0.17 7.5 ± 0.18

Means with different superscripts (row wise) vary significantly (P < 0.05)

due to degradation of proteins and liberation of free amino sterile. The results were in agreement with Terajima and
acids. The TBARS number in the product increased signifi- Nonaka [29] who reported that commercial heat sterilization
cantly (P < 0.05) during the storage (Table 4). Significant of foods in retort pouches reduced undesirable microorgan-
and linear increase of TBARS number from 0.21 to 0.52 mg isms. Similar findings were reported by Thankamma et al.
malonaldehyde/kg was found with increase in period of stor- [30] in fish paste, Prince Devadason et al. [20] in buffalo
age. A significant and linear increase of TBARS (thiobarbi- meat blocks, and Manju et al. [19] in seer fish curry packed
turic acid reacting substances) during storage was reported in retort pouch. Rajkumar et al. [23] also reported that coli-
by Prince Devadason et al. [20] in retort processed buffalo forms, Clostridium botulinum, Staphylococcus were absent
meat block and Rajkumar et al. [23] in retort processed in retort processed Chettinad goat meat during storage up
Chettinad goat meat and Rajan et al. [22] in retort processed to 10 months.
Chettinad chicken. The increase in TBARS number might
be due to residual oxygen remaining in the pouch as the
Sensory Evaluation
pouches were not vacuum sealed. Chia et al. [6] also reported
the development of slow oxidative rancidity in retort pouch
The sensory scores of the pork curry revealed that there
fish products. It was in the minimum thresh hold value of
was no significant difference found during the entire stor-
TBARS number, i.e., 0.5–1.0 mg malonaldehyde/kg [28].
age period (Table 5) except in scores for appearance of the
Rhee et al. [25] reported increased value of TBARS in raw
products which reduced significantly during storage period.
and cooked muscles of beef, chicken, and pork.
Slight decrease of flavour scores between intervals during
In the present study, the free fatty acid decreased sig-
storage was recorded, but the difference was statistically
nificantly (P < 0.05) during storage period (Table 4). Free
nonsignificant. On the contrary, the significant decrease in
fatty acids are the products of enzymatic or microbial lipoly-
sensory properties viz, flavour, juiciness, texture, and over-
sis of lipids. On the contrary, increase in free fatty acid in
all acceptability of buffalo meat blocks processed in retort
retort processed black clam meat also observed by Bindu
pouches was reported by Prince et al. [20] during room tem-
et al. [4] during a storage up to 12 months. Rajan et al. [22]
perature storage of 90 days. Retention of sensory properties
also reported increase in free fatty acid content in retort
during storage of pork curry product in this study may be
processed Chettinad chicken during storage up to 180 days.
because of moisture rich gravy in the curry product. Rajan
The acid values increased significantly (P < 0.05) in the
et al. [2014] also reported nonsignificant changes in flavour,
product during the storage period (Table 4).
juiciness, and mouth coating of Chettinad chicken, a curry
product, even after storage up to 180 days.
Microbial Quality

Total bacterial counts including E. coli, Salmonella spp.,

Clostridium spp., and Staphylococci spp. could not be
detected in the pork curry samples during the entire stor-
age. Thermal processing leads to commercial sterilization of
the food product. It is a condition achieved by application of
heat which renders the product free of viable forms of micro-
organisms capable of growing in the product at non refriger-
ated conditions at which the product is intended to be held
during distribution and storage [14]. Achievement of the
standardized F0 value ensured that product is commercially
Conclusions
The demand for ready-to-eat meat products in flexible retort
pouches is huge due to changing lifestyle of consumers. In
view of this requirement shelf stable, ready-to-eat pork curry
was developed in flexible retort pouches and physicochemi-
cal, microbiological, and sensory characteristics were stud-
ied. The product was found to have good acceptability and
shelf life up to a studied period of 180 days based on the

13

66
evaluation of physicochemical, microbiological, and sensory
parameters.
16. Leander RC, Hedrick HB, Brown MF, White JA (1980) Compari-
Acknowledgements  Authors thank Ministry of Food Processing
Industries, New Delhi and Science & Engineering Research Board,
New Delhi for funding the studies. Authors also thank Director, ICAR-
National Research Centre on Pig, Guwahati for providing laboratory
facilities for undertaking the work.
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