Design and Performance Optimization of a Lab-Scale Pouch Pasteurization System for Crab Meat Using Retort Pouches: A Predictive Modelling Study

Retort pouches, known for their eco-friendly design, reduced material usage, and energy efficiency, present a sustainable solution for seafood including packaging of seafood like crab meat. This study developed and evaluated a lab-scale crab meat pasteurization system using retort pouches, incorporating a pouch-holding basket, immersion water heater, and temperature control with a PID controller. Heating efficiency and heat loss were assessed using preheated hot water (87°C) and cold water (33°C) at full, half, and quarter basket loadings. Maximum heating efficiency (91%) occurred with hot water (half- and quarter-loaded), while cold water (half-loaded) showed the lowest (61%). Heat loss was lowest (0.098 kW/h) with hot water (quarter-loaded) and highest (0.145 kW/h) with cold water (full-loaded). Box-Behnken Design results showed high predictive accuracy (R² adjusted: 0.9973 for preheated, 0.87 for non-preheated). Product quantity and water volume significantly affected heating time in cold water (P<0.0001) but were insignificant in hot water. Model validation showed F-values of 60.14 (hot water) and 974.52 (cold water) with reliable predictions. Crab meat temperature, product quantity, and water volume influenced heating time. Predicted values closely matched experimental results, offering critical insights for optimizing retort pouch pasteurization, ensuring food safety and quality.