Continuous low temperature pasteurization system and method

A time-temperature method for continuously pasteurizing food products in a heating chamber, the method comprising:

• (a) subjecting the food product comprising a first food product and a second food product to a singular pasteurization step in a heating chamber, the heating chamber comprising an airborne pasteurization medium, wherein:
• the food product is selected from the group consisting of beef, pork, lamb, fish, chicken, turkey, eggs, and combinations thereof,
• the first food product enters the heating chamber before the second food product,
• a set point chamber temperature of the airborne pasteurization medium is greater than a kill temperature of 125.6° F., wherein the set point chamber temperature comprises a first dry bulb temperature and a first wet bulb temperature,
• the set point chamber temperature does not exceed 158° F.,
• the first food product contacts the airborne pasteurization medium at a first operational chamber temperature set to the set point chamber temperature for a first pasteurization time of about 55 minutes or less that is sufficient to kill bacteria on and in the first food product,
• the first pasteurization time is sufficient such that a first internal maximum temperature of the first food product does not exceed a fat rendering temperature when the food product contacts the airborne pasteurization medium for the first pasteurization time and at the set point chamber temperature,
• the fat rendering temperature is about 151° F. when the food product is beef, pork, or lamb, about 140° F. when the food product is fish, about 149° F. when the food product is chicken or turkey, and about 153° F. when the food product is eggs;
• (b) conveying the first food product loaded on a continuous spiral conveyor within the heating chamber during the singular pasteurization step at a first conveyor speed sufficient to retain the first food product in the heating chamber for the first pasteurization time;
• (c) discharging heated air into the heating chamber in a horizontal and downward direction over the food product and restricting an upward return flow of heated air below 400 feet per minute, thereby generating controlled circulation of the airborne pasteurization medium;
• (d) monitoring:
• a first initial temperature of the first food product at a point upstream of the heating chamber prior to conveying the first food product within the heating chamber;
• the first operational chamber temperature;
• a first food temperature of the first food product within the heating chamber;
• the first conveyor speed within the heating chamber;
• and
• a second initial temperature of the second food product at a point upstream of the heating chamber prior to conveying the second food product within the heating chamber;
• (e) modelling a lethality of pathogenic microorganisms on and in the second food product based on:
• the first food temperature;
• the first conveyor speed;
• and
• the first operational chamber temperature,
• wherein the modelling comprises determining if the first conveyor speed and the first operational chamber temperature are sufficient for the second food product to attain a second internal maximum temperature that is sufficient to kill bacteria on and in the second food product but to not exceed the fat rendering temperature;
• and
• (f) based on the modelling, initiating a rectifying procedure when the second food product is subject to the singular pasteurization step in the heating chamber to make real-time adjustments if:
• (i) the first operational chamber temperature does not attain the set point chamber temperature for a second pasteurization time sufficient for the second food product to reach a desired level of lethality of pathogenic microorganisms on or in the food product;
• (ii) a modelled second internal temperature of the second food product does not attain the kill temperature for the second pasteurization time;
• or
• (iii) a second conveyor speed deviates sufficiently from the first conveyor speed so that sufficient pathogenic microorganisms on and in the second food product are not killed so as to achieve pasteurization of the second food product.