462 Chapter 17
A general processing procedure for asepti-
cally processed dairy pudding consists of dry
blending sugar, nonfat dry milk, corn syrup
solids, guar gum or other stabilizers, carra-
geenan, salt, and modifi ed starches, and
adding the dry blend slowly with agitation to
water or liquid milk at 26.7 ° C (80 ° F). The
mixture is heated to 48.9 ° C (120 ° F). Next, a
mixture of vegetable oil (if used) and emulsi-
fi er is incorporated at 48.9 ° C (120 ° F) in the
aqueous blend, followed by addition of color
and fl avor. After mixing thoroughly, the mix
is homogenized at 48.9 ° C (120 ° F). It is then
cooked at 121 ° C to 148.9 ° C (250 ° F to 300 ° F)
through sterilization equipment and held for
2 to 3 seconds, as recommended by the
equipment manufacturer. The pudding is
cooled to 26.7 ° C (80 ° F) and held in aseptic
storage. The product is packaged in aseptic
packaging systems.Vegetable Fat Pudding
Table 17.21 shows a formulation for pudding
in which milk fat has been replaced with an
appropriate vegetable fat. This product is
produced by a process similar to other asepti-
cally packaged products. The vegetable fat is
emulsifi ed by homogenization in the pres-
ence of a functional emulsifi er.coconut and palm kernel oils with a melting
point of 38.9 ° C (102 ° F), 0.4% vanilla extract
fl avor, 0.2% salt, 0.15% color/fl avor, and
0.2% sodium stearoyl 2 - lactylate to develop
low on - line viscosity after the cooking and
sterilizing stage. This product develops
optimum viscosity only after refrigeration of
the packaged cups.
Single - serve containers of pudding are
packaged in a form - fi ll system in which
plastic containers are thermoformed or
molded from packaging materials such as
high polystyrene and fi lled with sterile
pudding. Subsequently, the cups are sealed
with lids cut from fl exible lid stock. The lid
material may be foil - laminated polyester
with a heat - sealable coating, which makes a
good seal after heat is applied. All of these
steps are carried out in an enclosed aseptic
system. If preformed cups and lids are used,
they are unscrambled and sterilized with
superheated steam, hydrogen peroxide, ultra-
violet light, or high - intensity light. The fl ex-
ible lid stock also must be sterilized. The fi ll
temperature is 26 ° C to 30 ° C (78 ° F to 86 ° F).
The product fi lling temperature character-
izes a refrigerated dairy dessert. Hot - fi lled
desserts such as fl an are packaged hot into
cups at a temperature above the gelation
point of the gelling agent (for example, car-
rageenan) used. As the product cools, it forms
the texture of a fi rm gel. On the other hand,
to obtain a minimal change in the post -
packaging texture, the processed product is
cooled under shear conditions as the gelling
agent is setting up the gel network. Cold -
fi lling gives a creamy texture without the
appearance of a gel. Puddings and mousses
are, therefore, packaged at below 15 ° C
(below 59 ° F).
In some cases, manufacturers do not have
rigorous aseptic conditions for producing the
truly aseptic product that is suitable for
ambient storage of the pudding product.
However, they can package sterilized pudding
in clean containers in a clean environment to
produce extended shelf life (ESL) refriger-
ated pudding.
Table 17.21. Typical formulation of aseptically
packaged vegetable fat pudding.
% Composition Vanilla Chocolate
Sucrose 14.77 14.77
Nonfat dry milk,
low heat5.18 5.18
Corn syrup solids,
36 DE2.46 2.46
Guar gum 0.12 0.12
Carrageenan 0.05 0.05
Cocoa 0 2.92
Salt 0.09 0.09
Modifi ed starch 3.12 3.00
Emulsifi er 0.13 0.13
Vegetable fat 6.61 6.60
Water 67.47 64.68
Color As needed —
Flavor As needed —
Adapted from Chandan (1997)