RETORT VALIDATION
FOOD SAFETY & PROCESS VALIDATION
New Ground Coffee
The Project
New Ground Coffee engaged DWC FoodTech NZ to conduct the thermal process validation of their newly installed retort for processing coffee beverages in aluminium cans. The client required validation of multiple products to ensure compliance with Good Manufacturing Practice (GMP) standards for commercial sterility whilst optimising processing parameters for quality retention and production efficiency.
Our Approach
Foodscope were subcontracted by DWC FoodTech NZ Ltd to conduct the validation. Temperature distribution studies were performed to identify the worst-case heating location within the retort. Comprehensive heat penetration trials followed using calibrated thermocouples in product positioned at the identified worst-case location. Trials evaluated various formulations to determine critical processing and product parameters which ensured compliance with MPI regulations for commercial sterilisation.
Results Achieved
On behalf of DWC FoodTech NZ Ltd, we successfully validated the retort and associated thermal processing schedules for product safety and to meet GMP requirements. We established optimal processing parameters and manufacturing guidelines including critical control parameters, loading configurations and temperature monitoring protocols to ensure commercial sterility whilst maintaining product quality. The validated process enables New Ground Coffee to confidently scale production across multiple product formulations.