Abstract

Current thermal validation in food engineering commonly depends on rigid, temperature-only endpoints that generate thermal stress and the associated energy cost in the case of high-caliber matrices. To overcome this, this study provides a proof of concept for post-heating cooling inertia as the main kinetic driver of cumulative integrated lethality in mass-transfer-limited geometries (p value framework), followed by separate enzymatic and not microbial (or, e.g., oxidative) degradation following product heat transfer. Time-series and multi-spatial thermodynamic profiling was performed for the commercial validation runs of three pasteurization processes of large-diameter (90 mm) finely minced cooked chicken emulsions packed in polyamide casing. When active heating was stopped at a lower core limit of 71 °C, the thermal cooling inertia led total integrated lethality to increase by more than 216%, leading to an ultimate core p value of 76.87–89.56 min. It systematically exceeded the mandatory food safety limit (p ≥ 40 min) in all spatial coordinates in the forced convection chamber, confirming absolute thermal homogeneity. In a subsequent cold-chain stability challenge at around 70 days (0–4 °C), foodborne pathogens were not detected in the product, and saprophytic microflora was limited below critical spoilage bounds (total viable counts (TVC) and dominant lactic acid bacteria (LAB) progressively increased to 3.7 and 3.5 log10 CFU/g on day 70). The autoxidation pathways for primary and secondary lipids remained low (peroxide at 0.00 mmol/kg and malondialdehyde at less than 0.15 mg MDA/kg). On the other hand, a linear progression of free fatty acids (R2 = 0.9673) determined that the single enzymatic lipid hydrolysis is responsible for the final biochemical limiting effect of the sensory lifespan. Shelf life evaluation via rigorous quantitative descriptive analysis showed that all organoleptic attributes remained well above market acceptance criteria until day 70. At the same time, this study supports a scalable, prediction-based thermodynamic paradigm that ensures biological safety and fundamentally optimizes industrial energy use.

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