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Journal of Food Process Engineering ISSN 1745-4530

GINGERGARLIC PASTE IN RETORT POUCHES AND ITS QUALITY

jfpe_645

1..8

PRIYA NAMRATA TOPNO1, VINOTHINI1, SHILPA HABBANKUPPE JAYAPRAKASH2,

VISHALAKSHI VARADAIAH2, SATHISH HASAN SHESHAGIRI2, PUSHPA MURTHY SRINIVAS1 and
MADENENI MADHAVA NAIDU1,3
1
Plantation Products, Spices and Flavour Technology Department and 2Food Packaging Technology Department, Central Food Technological Research
Institute, Council of Scientific and Industrial Research, Mysore 570020, India

Corresponding author. TEL: +91 821

2512352; FAX: +91 821 2517233; EMAIL:
madhavanaidu45@yahoo.com
Accepted for Publication December 17, 2010
doi:10.1111/j.1745-4530.2011.00645.x

ABSTRACT
Paste samples were prepared by mixing 1:1 (w/w) proportion of ginger and garlic
along with sodium chloride (1%). The pH of the paste was adjusted to 4.0, 4.5 and
5.4 by the addition of citric acid. Xanthan gum (2 g/L) and sodium benzoate
(0.2 g/L) were added to the paste and then filled in retort pouches. The filled pouches
were subjected to thermal processing at 85C with a holding time of 2 and 5 min at
80C at the centre of the paste. The color values a, and b (green and yellow) decreased,
whereas the L (lightness) values increased with decrease in pH. Paste behaved like a
non-Newtonian fluid, and exhibited shear-thinning behavior. Physicochemical and
microbial properties did not show significant changes during storage. This study
showed that gingergarlic paste prepared in retort pouches is convenient because of
its lighter weight, faster heating leading to better quality in terms of taste, color, and
also environmentally acceptable.

PRACTICAL APPLICATIONS
Ginger and garlic have been considered as important traditional herbal medicines
due to their disease prevention effects. Gingergarlic paste is a viscous product
retaining the strong aroma and flavor of the raw materials, namely, fresh ginger and
garlic. Paste is mainly used as a spice in culinary preparations for imparting a characteristic fresh gingergarlic flavor. The product is generally creamy white in color
and is microbiologically stable and free from pathogenic bacteria. It is a ready to use
preparation that can be used in place of fresh ginger in homes, restaurants and institutional catering. Although, few studies have been conducted on the physicochemical characteristics of ginger and garlic pastes, no information is available on
combination of gingergarlic paste in retort pouches. The development of new
packing (retort pouches) for gingergarlic with good nutritional and functional
properties (such as the one proposed in this study) may be of interest in order to
diversify the market supply. Therefore, retort pouch because of its lighter weight, and
faster heating leads to better quality in terms of uniform cooking, taste and color and
also it is environmentally acceptable.

INTRODUCTION
Ginger, botanically known as Zingiber officinale Rosc.,
belongs to the family Zingiberaceae and originated in Southeast Asia (Purseglove et al. 1981). Ginger is one of the principle spices in India and produces 30% of global share now
leads in global production replacing China (~20.5%) folJournal of Food Process Engineering 36 (2013) 18 2011 Wiley Periodicals, Inc.

lowed by Indonesia (~12.7%), Nepal (~11.5%) and Nigeria

(~10%). Gingerols are the major pungent components of the
fresh ginger while during dehydration, shogaols are formed
during extended storage (Pruthi 1998; Wohlmuth et al. 2005).
Thermal degradation of gingerols to gingerone, shogaols and
related compounds was demonstrated (Zhang et al. 1994;
Jolad et al. 2005).
1

GINGERGARLIC PASTE IN RETORT POUCHES

Garlic (Allium sativum L.) belongs to Alliacea family and is

the native of Central Asia (Purseglove et al. 1981). The genus
Allium contains large amount of sulphur compound, which is
primarily responsible for its biological and medicinal properties (Augusti 1996). China is the largest producer of garlic
accounting for 77% of world output, India (4.1%), South
Korea (2%), followed by Russia (1.6%) and the United States
(1.4%) (Peter 1996). Fresh garlic is characterized by having a
distinct aromatic odor, which is seldom carried over to processed garlic (Pezzutti and Crapiste 1997). Quality of garlic
products is evaluated on the basis of their sensory characteristics, mainly color, pH, acidity and flavor intensity or pungency (Garcia et al. 1999). By the action of enzyme, allinase,
allyl-S-cysteine sulfoxide is converted to diallyl thisulfinates
and finally disproportionately to disulfides and thiosulfinates
(Carson 1967).
Retort technology has been developed and perfected for
high-speed commercial application. Retort packaging has
evolved from mostly aluminium foil structure to sophisticated multilayer, high barrier laminate package, because food
packaged in the retort pouches tastes much better than
canned products. Food packed in a conventional can must be
cooked approximately twice as long as food contained in a
retort pouch. Retort packages have a thin profile and a high
ratio of surface area to volume. Retort time is reduced by
3050% in a flexible pouch. Retort pouches have solved all
challenges regarding package such as pouch integrity, product
compatibility and durability (Gary Bell 1990). Therefore
retort pouch market drives to replace cans and glass jars and it
is environmentally acceptable. These pouches can withstand
retorting conditions for low acid foods. Shorter the retort
time, the product will be compact with high quality and is also
competent energy saver.
Commercial preparations of spice mix formulations are
available in the market, which vary widely in their composition, quality and shelf life (Modi et al. 2006). New research
will undoubtedly reveal new values of this paste; until now
only a few studies have been conducted on the rheological
properties of ginger paste, garlic paste, as well as garlic and
onion paste related to processing conditions (Baranowski
1985; Lukes 1986; Ahmed et al. 2002; Ahmed and Shivhare
2002; Ahmed 2004). The flow properties of paste and puree
are essential for the design and evaluation of food processing
equipment (Saravacos 1970; Toledo 1997; Constenla and
Lozano 2005; Oliveira et al. 2010) standardization of formulations and processes. Color measurement is the simplest
instrumental method proved to be valuable in describing discoloration and providing useful information for quality
control of food products (Garza et al. 1999; Maskan 2001).
Although, few studies have been conducted on the physicochemical characteristics of ginger and garlic paste individually, no information is available on mixed gingergarlic paste
in retort pouches. Therefore, the main objective of the work
2

P.N. TOPNO ET AL.

was to determine the effect of processing conditions such as

pH, and additives on physicochemical characteristics of
gingergarlic paste to produce acceptable, shelf stable
product that can retain the delicate spice odor of fresh ginger
and garlic.

MATERIALS AND METHODS

Preparation of Ginger Paste
Fresh ginger rhizomes were procured from a well-established
indigenous ginger supplier. The rhizomes were broken into
pieces to expose the crevices and then washed in running
water to remove the adhering mud. Again the cleaned rhizomes were scraped with a knife to remove dirt as well as
spoiled portion. Ginger rhizomes were soaked in potassium
metabisulphate solution (1 g/L) for 12 h and washed thoroughly; rhizomes were peeled using a vegetable peeler. The
peeled rhizomes were passed through a hammer mill fitted
with 30 mesh (500 mm) to get a fine paste.

Preparation of Garlic Paste

Garlic bulbs were subjected to mild pressure by hand to separate the cloves. Cloves were dried in a tray drier at 40 1C for
30 min. to facilitate peeling. Peeling was done manually. After
peeling, cloves were dipped in hot water followed by grinding
in a laboratory grinder fitted with 30 mm mesh to get a fine
paste, which was used as the raw material for preparation of
gingergarlic paste.

Preparation of GingerGarlic Paste

A mixed paste of ginger and garlic was prepared by mixing
them in equal proportion (1:1 ratio) by weight and passed
through colloidal mill to obtain the product with uniform
consistency. The gingergarlic paste was stabilized by addition of sodium chloride (10 g/L) plus xanthan gum (0.2 %
w/w). Roughly 24 kg of pastes were prepared by blending 12
batches of 2 kg each (Fig. 1). Initial paste had a pH of 5.6 to
serve as a control. The pH of the paste was adjusted to 4.0 and
4.5 by adding citric acid (25% w/v) solution.
Sodium benzoate at a level of 200 ppm was added to the
paste and hot filled in retort pouches, made by 12 mm (polyethylene terephthalate [PET]), 12 mm aluminium foil (Al),
15 mm nylon and 75 mm cast polypropylene (CPP) supplied
by M/s. Pradeep laminates, Pune, India. Then the pouches
were sealed using heavy duty impulse sealer. These sealed
samples were arranged in a rack and then placed in the steam
air retort supplied by M/s. Alpha Steri-Tech, Bangalore,
India. The initial product temperature at the time of filling
into the retort pouch was 6575C. The heat penetration test
was also carried out usingTtype thermocouple in the retort
Journal of Food Process Engineering 36 (2013) 18 2011 Wiley Periodicals, Inc.

P.N. TOPNO ET AL.

GINGERGARLIC PASTE IN RETORT POUCHES

Fresh ginger
Soaking in KMSO4 & washing with water
Cleaned ginger
Trimming and removal of defectives
Peeling

Sorting and wet grinding

Mixing with ingredients

pH adjustment

pH 5.6
Addition of preservatives
+ Pres.
Pres.
Heat processing
FIG. 1. SCHEDULE OF GINGERGARLIC PASTE
PREPARATION

2 min.

5 min. 2 min.

to ensure that the product reached the processing temperature of 85C. Sealed pouches were thermally processed until
the product attained a temperature of 85C, and were held at
that temperature for 2 and 5 min. Afterwards, these were
cooled down to 35C and stored at ambient temperature.
Samples were taken out after 0, 15, 30, 45 and 60 days of
storage at 25 5C and analyzed for their physicochemical
and microbial quality.

5 min.

pH 4.5

+ Pres.

2 min.

- Pres.

5 min. 2 min. 5 min.

pH 4.0

+ Pres.

2 min.

Pres.

5 min. 2 min. 5 min.

dried under vacuum at 70C to constant weight. The dried

samples were allowed to cool in desiccators for 30 min and
then weighed (AOAC 1995).

Total solids (%) = (mass of dried sample mass of

fresh sample ) 100

Color Measurement
Titratable Acidity and pH
Titratable acidity in the processed paste was measured in
terms of citric acid following the method described by Wang
et al. (1995). For measuring titratable acidity, 5 g paste were
diluted with 95 mL distilled water making the volume to
100 mL, then filtered through Whatman no. 41 filter paper
and titrated against 0.1 N NaOH to pH 8 using phenolphthalein indicator. Acidity was expressed as percent citric acid by
weight.
The paste sample (5 g) was diluted with 45 mL distilled
water, and pH was measured with glass electrode (EUTECH
Instruments, Selangor, Malaysia). Sodium chloride was determined by titration with silver nitrate (Ranganna 1986).

Color measurement was done by the method of Hunt

(1991). Gingergarlic paste color was measured and compared using a Hunter colorimeter model Lab scan XE
(Hunter Associates Laboratory, Reston, VA) using universal
software, based on three color coordinates namely L, a, and
b. The instrument is calibrated using a standard white
(L = 90.70, a = -1.08. b = 0.65) and blank reference tile
under illuminated conditions such as C illumination and
via angle 2. The color values given by L, a, b is generally
expressed as total color of the sample. L represents the
lightness index, a represents red-green, whereas b represents yellow-blue color components.

Volatile Oil Content

Total Solids
Total soluble solids (Brix) were determined with a digital
bench top Abbe Refractometer at 20C (Atago Co., Ltd., Tokyo,
Japan). To determine the total soluble solids, the paste was
Journal of Food Process Engineering 36 (2013) 18 2011 Wiley Periodicals, Inc.

Volatile oil was extracted using Clevengers distillation or

hydrodistillation. About 250 g of gingergarlic paste were
weighed in a 2500 mL round bottom flask and adequate
amount of water was added. The distillation was carried out
3

GINGERGARLIC PASTE IN RETORT POUCHES

P.N. TOPNO ET AL.

Samples

Moisture (%)

Volatile oil (as is basis %)

Ginger paste
Garlic paste
Gingergarlic paste
Processed gingergarlic paste (holding time 2 min.)
Processed gingergarlic paste (holding time 5 min.)

83.12 0.61a
63.04 0.38e
75.08 0.35b
72.50 0.66c
71.70 0.26d

0.62 0.005a
0.11 0.005e
0.37 0.020b
0.24 0.015c
0.18 0.020d

TABLE 1. MOISTURE AND VOLATILE OIL IN

GINGER, GARLIC AND GINGERGARLIC PASTE

Mean values followed by different superscript letters in a column differ significantly (P < 0.05).

for 45 h for isolation of volatile oil. The oil was measured

and percent volatile oil was calculated using:

Volatile oil =

Volume of oil collected

100
Total weight of sample

Rheological Properties of Paste

Flow properties (shear stress, shear rate and apparent
viscosity) of the gingergarlic paste were determined by
employing a viscometer (model # VT 550, Haake, Karlsruhe,
Germany) with a coaxial cylinder attachment. The paste was
placed in a graduated beaker with flat bottom. The SV-2
spindle was selected for the sample. The rheological parameters for gingergarlic paste were studied at the temperature
of 30 1C. Shear rate was been increased up to 200/s in
3 min. Apparent viscosity was obtained by dividing the shear
stress by shear rate. The moisture content of this paste was
72.5 %. The well-known HerschelBulkley model was used to
fit the shear stress (t) and shear rate data (Eq. 1).

= 0 + K

(1)

Here, g is the shear rate (s-1), t is the shear stress (Pa), K is

the consistency index (Pasn), n is the flow behavior index
(dimensionless) and t0 is the yield stress (Pa). The extent of fit
was obtained by calculating the goodness of fit (r2) between
data sets of shear rate and shear stress. The rheological
parameters (t0, K, n) were computed by using the software
supplied by the viscometer manufacturer.

Microbiological Analysis
Enumeration of coliforms, mesophilic aerobes and yeasts and
molds were done by pour plate and spread plate method following the procedure of the International Commission on
Microbiological Specifications (ICMSF 1992). Violet red bile
agar for coliform bacteria, plate count agar (PCA) for mesophilic aerobes and potato dextrose agar (PDA) for yeast and
molds procured from Himedia, India were used. Ten grams of
ginger garlic paste sample were weighed in duplicates into
90 mL of 0.1% peptone water aseptically, homogenized and
serial dilution was carried out. One milliliter of the appropriate dilution of the sample was taken in sterile Petri plates and
4

15 mL of respective agar maintained at 45C were poured into

plates and allowed to solidify. Set plates were incubated at 37C
for 48 h and colony count was taken after 2448 h of incubation for bacteria. The potato dextrose plates for yeasts and
molds were incubated at 27C for 34 days and colony count
was recorded. All tests were carried out in duplicate and the
average mean values are reported.

Statistical Analysis
Statistical analysis of the data obtained for each treatment was
carried out by analysis of variance followed by Duncans new
multiple range test (Duncan 1955) to found out differences
between treatments at the probability level of P < 0.05.

RESULTS AND DISCUSSION

Physicochemical Characteristics
The moisture and volatile oil contents in fresh and processed
gingergarlic paste determined and results are presented in
Table 1. The highest moisture content was found in fresh
ginger (83.1%) followed by fresh gingergarlic paste (75.1%).
The volatile oil contents of fresh ginger, fresh garlic and
gingergarlic paste were 0.62, 0.11 and 0.37%, respectively.
Thermally processed (2 min) gingergarlic paste showed
72.5% moisture and 0.24% volatile oil. The volatile oil loss
was observed with increasing thermal processing. In the
present study, the moisture and volatile oil contents were
found to vary among the treatments. It was observed that
there were significant (P < 0.05) differences between pastes
obtained from thermally processed gingergarlic paste with
duration and control pastes with regard to physicochemical
characteristics. Gingergarlic paste can be classified under the
category of minimally processed foods, which are products
that have the attributes of convenience and very little alteration in quality from the basic ingredient. The addition of salt
would preserve the sample. The paste needs to be given some
treatment to improve its stability and quality during storage.
It is necessary to apply preservation treatments on the
assumption that their effects are synergistic and the rate of
degradation is minimized. Spoilage in the ginger and garlic
paste may result in the degradation of the physical characterJournal of Food Process Engineering 36 (2013) 18 2011 Wiley Periodicals, Inc.

P.N. TOPNO ET AL.

GINGERGARLIC PASTE IN RETORT POUCHES

TABLE 2. TITRATABLE ACIDITY, pH AND

TOTAL SOLUBLE SOLIDS IN PROCESSED
GINGERGARLIC PASTE

Initial pH of
the paste
4.0
4.0
4.5
4.5
5.4
5.4

Holding time
(min.)

pH

2
5
2
5
2
5

4.16 0.02
4.18 0.02c
4.51 0.05b
4.62 0.02b
5.36 0.01a
5.45 0.02a

TA (%)
c

TSS (%)

1.53 0.02
1.50 0.02a
1.52 0.02a
1.65 0.03b
0.44 0.02c
0.46 0.03c
a

19.13 0.03a
18.05 0.04b
17.25 0.03c
16.98 0.07c
13.43 0.05d
13.26 0.14d

Mean values followed by different superscript letters in a column differ significantly (P < 0.05).
TA, titratable acidity; TSS, total soluble solids.

istics like color, texture, flavor or aroma as well as microbial

degradation. Similarly, the addition of xanthan gum into
paste overcomes the water formation/separation from the
paste during storage.
The initial pH of the paste was around 5.4 at which level
microbial spoilage will be rapid. Therefore, lowering of the
pH to 4 to 4.5 by addition of an acidulant such as citric acid
(25% solution) would help in reducing the spoilage. This
would impart slight acidic or sour taste to the products, but
would not affect to any describe level the eating quality of the
food product to which this paste is added. In the present
study, pH was slightly increased with increasing processing
time. The titratable acidity and total soluble solids varied
depending on pH conditions with different processing durations (Table 2). Ahmed and Shivhare (2001) reported similar
observations for garlic paste. It has been reported that citric
acid acts as an antioxidant and an acidified food (pH < 4.6)
requires pasteurization (Baranowski 1985; Garcia et al. 1999).
The Hunter color (L, a, b) values of fresh gingergarlic
paste were 53.8, 3.0 and 21.7, respectively. The color values a
and b (green and yellow) decreased, whereas the L (lightness)
values increased with decrease in pH (Table 3). Slight
decrease in green color was observed during addition of salt
whereas the addition of citric acid alone substantially
increased the greening of gingergarlic paste. The Hunter
color value of the paste containing both sodium chloride and
citric acid was -1.3. Hence, the acidic condition of paste considerably favored the formation of green pigment. Lukes
(1986), Rejano et al. (1997) and Ahmed et al. (2001) have
reported similar observations. TSS, sodium chloride, titrat-

able acidity and pH of ginger paste did not change significantly (P > 0.05) during storage (data not shown).
A plot of shear rate versus shear stress yielded a nonlinear
curve indicating that the apparent viscosity decreased with
increase in the rate of shear (Fig. 2).The goodness of fit (r2)
values for HeschelBulkley model is high (r2 = 0.982) indicating the suitability of this model to predict the flow characteristics of paste; shear thinning has also been observed, which is
common for many food batters and dispersions. The flow
behavior index (n) of gingergarlic paste of the Herschel
Bulkley model is 0.251 indicating a highly non-Newtonian
system as it deviates widely from a Newtonian fluid having
n = 1. The yield stress (Pa), consistency index (Pasn) and flow
behavior index (dimensionless) values of gingergarlic paste
derived from the HerschelBulkley model are shown in
Table 4.

Retort Pouches

Sample pH

Retort pouches are basically heat resistant plastic laminates

having different multilayer structures like PET/Al.Foil/Ny/
CPP, PET/EVOH/Ny/CPP, PET/SiO2 on PET/Ny/CPP, PET/
Al2O3 on PET/Ny/CPP and PET/PVDC on PET/ Ny/CPP.
These are used for processing low acid food products whose
pH is less than 4.5. In the present study we have used retort
pouches of PET/Al. Foil/Ny /CPP structure withstands
process temperature of up to 122C and also has zero permeability for oxygen and water. Because of the thin profile of
retort pouches, the quality attributes of the product are of
superior rating when compared with the same product
packed and processed in tin plate cans and glass bottles. The
aluminum foil laminate used in this study was intact after
thermal processing (no wrinkles and delamination was
found). The heat seal was also intact and no leakage was
observed.

4.0
4.5
5.4

61.681.11a
61.201.27b
53.830.99c

-1.360.19b
-1.340.11b
3.000.14a

20.430.77a
20.660.33a
21.760.33b

Microbiological Quality

TABLE 3. EFFECT OF pH ON HUNTER COLOR VALUES ON

GINGERGARLIC PASTE

Mean values followed by different superscript letters in a column differ

significantly (P < 0.05).

Journal of Food Process Engineering 36 (2013) 18 2011 Wiley Periodicals, Inc.

In the present study microbiological result showed that all

samples were sanitarily appropriate for human consumption,
5

GINGERGARLIC PASTE IN RETORT POUCHES

P.N. TOPNO ET AL.

FIG. 2. RHEOGRAM OF GINGERGARLIC

PASTE

as the level of microorganisms present in gingergarlic processed paste was below the recommended level (APHA 2001).
Initially, total plate count (TPC) in fresh gingergarlic paste
was 2 102 colony-forming unit (cfu)/g, whereas the
coliform and yeast and mold counts were below 10 and
100 cfu/g, respectively. Thermal processing of paste at 85C for
2 and 5 min. reduced TPC to 65 while coliforms, yeast and
mold were found to be nil. Addition of sodium benzoate
(200 ppm) helped in controlling microbial load completely
(Table 5).
In control (pH 5.4) sample the TPC increased from 65 to
200 cfu/g, coliform was nil and yeast and mold counts
increased from 0 to 25 cfu/g during 6 months storage at
25 5C (Data not shown). The presence of bacteria of public
health significance was typically low in the product and was
considerably lower than the prescribed count (Pimm 1994). It
can therefore be inferred that prepared gingergarlic paste in

retort pouches stored more than 6 months was microbiologically safe. The product was packed in retort pouches made by
12 mm PET, 12 mm Al, 15 mm nylon, and 75 mm CPP is the
most commonly used in retort pouches and is the only one
used indigenously at present (Vijayalakshmi et al. 2003).
Baranowski (1985) and Giridhar et al. (1996) recommended
a process temperature of 80C for gingergarlic paste with a
pH of approximately 4.0. The combination of antioxidant
stabilizer and preservative was very important for the preparation of a high-quality gingergarlic paste.

CONCLUSIONS
Results demonstrate that retort pouches have solved all challenges regarding pouch integrity, product compatibility and
durability. High quality paste could be prepared by mixing
ginger and garlic in equal proportion with added sodium

Yield stress (t0 [Pa])

Consistency index K (Pasn)

Flow behavior index, n

Goodness of fit r2

2.304

15.020

0.251

0.982

TABLE 4. HERSCHELBULKLEY PARAMETERS

FOR GINGERGARLIC PASTE (30 10C)

Mean values of five readings.

Journal of Food Process Engineering 36 (2013) 18 2011 Wiley Periodicals, Inc.

P.N. TOPNO ET AL.

GINGERGARLIC PASTE IN RETORT POUCHES

TABLE 5. MICROBIAL QUALITY OF GINGERGARLIC PASTE

pH

Duration
(min)

4.0
4.0
4.5
4.5
5.4
5.4

2
5
2
5
2
5

TPC (cfu/g)

Yeast and mold (per gram)

Coliforms (per gram)

With preserv.

Without preserv.

With preserv.

Without preserv.

With preserv.

Without preserv.

0
0
0
0
0
0

26 2.6b
22 2.5a
33 2.5b
31 3.6a
65 30b
52 3.5a

0
0
0
0
0
0

0
0
03
0
02
02

0
0
0
0
0
0

0
0
0
0
0
0

Mean values followed by different superscript letters in a column differ significantly (P < 0.05).
TPC, total plate count.

chloride (10 g/L), xanthan gum (2 g/L), sodium benzoate

(0.2 g/L) and hot filling in retort process followed by thermally processing at 85C with holding time of 2 min. The paste
thus produced is acceptable, and is shelf stable, which retains
the delicate spice odor of fresh ginger and garlic. Therefore
retort pouch market drives because of its lighter weight, and
faster heating, which lead to better quality in terms of taste
and color, and it is environmentally acceptable.

ACKNOWLEDGMENTS
We thank Dr. V. Prakash, Director, CFTRI, Mysore, India, for
his keen interest in this study and the facilities provided. The
financial support from CSIR, New Delhi, is gratefully
acknowledged.
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