Effect of thermal processing on quality and shelf life of black tiger shrimp (Penaeus monodon) curry in retort pouches during ambient storage

Introduction

Ready-to-eat (RTE) seafood products are gaining popularity globally due to changing consumer lifestyles, demand for convenience and improved processing technologies. Among these, thermal processing of retort pouch packed food has proven highly effective in preserving seafood products without compromising safety or quality. The retort pouches, with its multilayer laminate and flexible structure, allows rapid heat penetration, making it ideal for thermally processed high-value species like Penaeus monodon (Murphy et al., 2002) [1] . Black tiger shrimp (P. monodon) is known for its taste, good texture and nutritional benefits. Several culinary recipes are being practiced in India to prepare thermally processed shrimp products. Spices and aromatic compounds can improve flavour of the product but can Sensory evaluation plays a critical role in assessing consumer acceptability. Spice-rich matrices undergo significant alterations in aroma and appearance upon sterilization, requiring refined process optimization to maintain sensory integrity (Manju et al., 2007) [2] . Packaging integrity, seal quality, and barrier properties of retort pouches also influence shelf stability and safety. Laminated structures combining polyester, nylon, aluminium foil, and polypropylene provide excellent protection against oxygen and moisture ingress while withstanding high sterilization temperatures (Murphy et al., 2002) [1] . The synergy between packaging technology and thermal processing conditions is important for successful RTE product development. The current study investigates the thermal characteristics, microbial safety, biochemical parameters, and physical characteristics of P. monodon shrimp in spiced curry packed in retort pouches. It aims to evaluate heat penetration behaviour, sterilization effectiveness through F₀ value assessments, and resultant sensory attributes. By identifying optimal processing parameters, the research contributes to the growing demand for value-added seafood products tailored to modern convenience and quality standards. The findings expected to support innovation in the Indian seafood industry and promote sustainable processing practices.

Materials and Methods

Materials

Fresh black tiger shrimp (Penaeus monodon) with an average length of 21.1 cm and a count of 16-20 per kilogram were procured from the landing center at Mangalore, Karnataka, India. Samples were transported under iced conditions (ice-to-shrimp ratio 1:1) to the processing laboratory. Laminated four-ply flexible retort pouches were used for packaging, composed of 12 μm polyester (outer layer), 9 μm aluminum foil, 15 μm nylon (middle layer), and 70 μm polypropylene (inner cast). Pouches measured 150 × 200 mm and held 300 g of product (Floeter India Retort Pouches Pvt Ltd, Haryana, India). A pilot-scale horizontal overpressure retort (Lakshmi Engineering Works, Chennai, India) comprising a retort vessel, boiler, air compressor and PLC-based control system was employed for thermal processing. All chemicals and glassware used were of analytical (AR) grade.

Preparation of Shrimp in Curry Medium

Black Tiger shrimp were cleaned by washing in chilled potable water (1-2°C), then peeled, beheaded, and deveined. The cleaned shrimp were blanched by immersing them in a 6% salt solution at 100 ± 2°C for 10 minutes and set aside for use in the curry. The curry was prepared using a standard recipe (Table 1). The wet paste was made using onion, tomato, garlic, ginger, green chilli, curry leaves and turmeric. The lightly fried spices, byadagi chilli, black pepper, poppy seeds, cinnamon, coriander, cumin, turmeric, and salt were ground into a fine mixture to prepare dry masala powder. Cooking began with frying chopped onion, green chili, curry leaves, garlic, ginger, turmeric, and shallots in a small amount of refined sunflower oil until lightly browned. The wet paste was then added and cooked until the mixture changed colour, followed by the addition of the dry masala paste, tamarind paste, and coconut milk. The curry was simmered gently to remove raw flavour, then adjusted with salt and water to reach the desired flavour and consistency. Finally, the blanched shrimp were added to the curry, and the mixture was simmered over low heat until it reached a gentle boil, ensuring the shrimp absorbed the rich flavors of the masala.

Filling and Sealing

Approximately 250 ± 5 g of hot shrimp curry was filled into retort pouches. Selected pouches were fitted with stainlesssteel packing glands (Model GKJ 13009C052) and thermocouple tips were inserted into shrimp at the slowest heating point. Sealing surfaces were cleaned using sterile tissue. Pouches were steam-exhausted, hermetically sealed and loaded into the retort for thermal processing to attain desired F 0 values.

Thermal processing of Black tiger shrimp in curry medium

Shrimp curry pouches were thermally processed to achieve target lethality (F 0 values of 8 and 9 minutes), followed by cooling and air drying prior to storage and subsequent analysis. Thermal validation was conducted using the Ellab E-val Flex Four Channel System (Cat. 21401004; Ellab A/S, Trollesmindealle 25, DK-3400 Hilleroed, Denmark), which recorded real-time core and retort temperatures, F 0 values, and cook values (CV) at 60-second intervals. Measurements were captured using Ellab SSATS copper/cupronickel thermocouples with stainless-steel electrodes (4 cm length, 1.2 mm diameter, accuracy < 0.2°C). F 0 calculations were performed with system settings of T = 121.1°C and Z = 10°C, while cook value constants (for thiamine degradation) were applied at T = 100°C and Z = 33°C. Processing time was determined using Ball's mathematical model as per the protocol established by Stumbo (1973) [7] .

Proximate, Biochemical, and Microbiological Analyses

Moisture, ash, protein, and fat contents of raw and processed black tiger shrimp were determined using AOAC (2010) [8] methods. The values were expressed as % (wet weight basis). Biochemical parameters like TVB-N, TMA-N, PV, FFA, TBA-RS, Indole were performed for raw as well as processed shrimp. TVB-N and TMA-N were determined by Conway's micro diffusion method (Conway, 1962) [9] . TBA value was determined using the method of Raghavan and Hultin (2005) [10] . Peroxide value was determined using the method of Kirk and Sawyer (1991) [11] . Free fatty acid (FFA) value was determined using the method of Dyer and Morten (1956) [12] . pH was determined using the pH meter. Indole is determined by modified colorimetric method described by Cheuk et al., (1981) [13] . The total plate count (TPC) was estimated for raw shrimp by the spread plate technique.

Commercial sterility test

To evaluate commercial sterility, shrimp curry pouches processed at two different F 0 values were incubated under conditions designed to detect mesophilic and thermophilic bacterial survivors. Samples were held at 37°C for 15 days and at 55°C for at least 5 days. Following incubation, the pouches were aseptically opened, and 1-2 g of sample was transferred using sterilized forceps into sterile test tubes containing fluid thioglycolate broth. To establish anaerobic conditions, sterilized liquid paraffin was layered over the broth surface. The tubes were then incubated at 37°C for 48 hours and at 55°C for 4 days. The assessment protocol adhered to the guidelines specified in IS:2168 1971 [15] .

Texture Profile Analysis

Textural characteristics of raw and thermally processed Black Tiger shrimp at varying thermal lethality (F 0 ) values were evaluated using a texture analyzer (TA-XT Plus, Stable Micro Systems, UK). A cylindrical probe (75 mm diameter) equipped with a 50 N load cell was employed to perform a double compression test. Samples were compressed twice to 40% of their original height at a crosshead speed of 12 mm/min, following the standard method described by Bourne (1978) [16] and further adapted by Mohan et al. (2006) [17] .

Colour Analysis

Colour measurements of all samples were carried out using a colourimeter (ColorFlex EZ, HunterLab, Reston, VA, USA) equipped with an 8° diffuse geometry and a D65/10° standard illuminant. The instrument was calibrated prior to analysis using standard black and white reference tiles provided by the manufacturer. Colour was recorded in the CIELAB colour space, providing L* (lightness), a* (redgreen), and b* (yellow-blue) values.

Sensory Evaluation

The organoleptic quality of processed product in curry medium was assessed using a 9-point hedonic scale (Meilgaard et al., 1999) [18] by a trained panel comprising 25 members, including researchers, scientists, and postgraduate students. Processed retort pouches were conditioned and stored under ambient conditions for 180 days. Post-storage, samples were randomly selected for sensory analysis. Prior to evaluation, pouches were reheated in boiling water for 10 minutes. The contents were then served warm on coded, white enamel plates to ensure unbiased assessment.

Attributes assessed included appearance, color, flavor, chewiness, succulence, toughness, and overall acceptability.

Statistical Analysis: A minimum of triplicate samples was analysed for all the analyses. For sensory analysis, mean values from 25 are presented. The results were expressed as mean ± standard deviation. Duncan multiple range test was performed to find out the difference in mean (p<0.05). The SPSS 26.00 statistical package was used for the analysis of the experimental results.

Results and Discussion

Thermal processing Shrimp curry packed in retortable pouches was processed at two lethality values, F 0 8 and F 0 9 minutes. Heat penetration characteristics were calculated (Table 2) using data gathered from the Ellab system. The come-up times were 6.5 minutes (F 0 8) and 4.5 minutes (F 0 9), indicating that the retort chamber reached sterilization temperature quickly under both conditions (Figure 1). Minimal variation in heating lag (Jh) and cooling lag (Jc) factors between treatments suggested stable heat transfer dynamics throughout processing. The heating curve slope (fₕ) was 22 minutes for F 0 8 and 20.5 minutes for F 0 9. Total process times to achieve sterilization were 30.54 minutes and 30.04 minutes, respectively. Cook values (CV), which represent the cumulative thermal impact on product quality, were 87.23 minutes for F 0 8 and 86.44 minutes for F 0 9. A slight reduction in total processing time and CV was observed at the higher F 0 value, likely due to faster heat penetration and optimized sterilization kinetics. These results aligned with the recommended F 0 range of 5-20 minutes for seafood products (Frott & Lewis, 1994) [19] . Comparable findings were reported by Mohan et al. (2006) [17] , who documented a CV of 86.14 minutes and a total process time of 33.79 minutes for shrimp kuruma at F 0 8 min. Majumdar et al.

(2017) [20] observed significantly longer process durations and higher cook values in freshwater prawn curry, with CV reaching 107.93 and 117.55 minutes for F 0 8 and F 0 9, respectively. Sreenath et al. (2007) [21] reported a cook value of 95.4 minutes in shrimp curry processed in tin-free steel cans. More recently, Puthanangadi et al. (2021) [22] documented process times of 37.11 and 39.88 minutes and CV of 84.07 and 92.41 minutes for masala-packed shrimp processed at F 0 8 and F 0 9 min.

Proximate composition of raw black tiger shrimp

The proximate composition of raw and processed shrimp curry is presented in Table 3. In this study, the average moisture content of P. monodon was 79.36 %, crude protein content was 17.15 %, crude fat content was 1.23 %, and ash content was 1.05 %. This indicates that the shrimp used in the study is a lean variety with a good quantity of protein.

Similar results were reported for black tiger shrimp, with 80.47% moisture, 17.1% protein, 1.23% fat, and 0.95% ash, as reported by Sriket et al. (2007) [23] . Akintola et al.

(2013) 24] and Marichamy et al. (2011) [25] reported that the moisture and protein contents of fresh P. monodon were 75.18% and 20.34%, respectively.

Biochemical Analysis:

The biochemical quality of shrimp curry was evaluated for 180 days at room temperature. [17,26,27] . All samples stayed below the spoilage threshold of 20 mg N/100 g. TMA-N content of raw shrimp was 2.84 mg N/100 g in raw shrimp. Retorted samples had slightly higher values of 3.06 mg N/100 g (F 0 8) and 3.88 mg N/100 g (F 0 9). After 180 days, TMA-N reached [28,22,29] . The values remained well below rejection limits. Initial PV in raw shrimp was 1.86 mEq O₂/kg. Retorted samples had values of 1.12 mEq O₂/kg (F 0 8) and 1.58 mEq O₂/kg (F 0 9). After storage, PV increased steadily to 9.39 mEq O₂/kg and 9.57 mEq O₂/kg. This was attributed to oxidative changes in lipids caused by heat and oxygen exposure. Earlier studies reported that PV levels between 10-20 mEq O₂/kg mark the onset of rancidity in fish products (Connell, 1995; Ahn & Min, 2005) [30,31] . TBA-RS values were 0.30 mg malonaldehyde/kg in raw samples. Retorted products had values of 0.52 mg/kg (F 0 8) and 0.58 mg/kg (F 0 9). By day 180, the values reached 1.21 mg/kg and 1.47 mg/kg. The increase reflected secondary oxidation of lipids due to prolonged storage. Previous research confirmed similar TBA-RS trends in heat-treated mussels (Biji et al., 2015 [27] . Raw shrimp contained 0.18% FFA. Retorted samples started at 0.21% (F 0 8) and 0.29% (F 0 9). FFA levels rose to 1.11% and [34] . Commercial sterility test: The commercial sterility of thermally processed shrimp curry packed in flexible retort pouches was tested. No signs of turbidity or microbial growth were observed in thioglycolate broth following incubation at 37 °C for 48 hours and at 55 °C for 4 days.

Samples processed at

Both the products processed at F 0 8 and F 0 9 min remained sterile throughout the 180-day ambient storage period. This result confirmed that the total lethality imparted during retort processing was sufficient to inactivate vegetative cells and heat-resistant spores, including Clostridium botulinum, the primary safety concern in low-acid seafood products. These findings are consistent with earlier studies on tilapia fish curry (Taral et al., 2023) [35] and cobia chunks curry (Tameshwar et al., 2024) [36] , prawn curry (Majumdar et al., 2017) [20] , and shrimp curry in tin-free steel cans (Sreenath et al., 2007) [21] . The application of validated retort conditions and effective heat penetration ensured microbial safety for extended shelf life.

Colour Analysis

The colour parameters of shrimp curry underwent noticeable changes during 180 days of ambient storage (Figure 2). Samples processed at F 0 8 and F 0 9 minutes showed a progressive decline in lightness (L*), with values dropping from 49 to 40.16 and from 48.96 to 39.81, respectively. This reduction in L* indicated darkening of the product with time and thermal intensity. Simultaneously, both redness (a*) and yellowness (b*) increased significantly (p < 0.05), suggesting enhanced pigment intensity and browning reactions. The increase in a* and b* values was attributed to heat-induced denaturation of carotenoid proteins and muscle proteins (Tekade et al., 2024) [29] . This alteration exposed and intensified carotenoid pigments, particularly astaxanthin, which imparted reddish-orange hues to the muscle tissue (Okada et al., 1994) 34] . These findings were in line with earlier studies showing similar trends in retorted shrimp and prawn products. [20] observed decreasing L* values of 54.00, 49.36, and 46.42 as F 0 increased from 6 to 9 in freshwater prawn curry. These results confirmed that prolonged heat exposure affected colour intensity. The darkening and pigment concentration were more evident at higher F 0 values, but no major visual difference was noted between F 0 8 and 9, indicating that both treatments induced comparable colour transitions. Instrumental Texture profile analysis Texture Profile Analysis (TPA) was used to assess mechanical changes in shrimp curry after thermal processing and storage (Figure 3). Raw shrimp showed hardness (3.14 Kgf), springiness (0.69 mm), cohesiveness (0.55), gumminess (1.73 Kgf), and chewiness (1.20 Kgf•mm). These values increased after retorting due to protein denaturation and structural tightening (Mohan et al., 2006) [17] . After 180 days of ambient storage, samples processed at F 0 8 showed reduced hardness (1.98 Kgf), springiness (0.51 mm), and chewiness (0.47 Kgf•mm). This decline was attributed to heat-induced muscle weakening and moisture loss. Samples at F 0 8 retained better texture than F 0 9, suggesting that higher F 0 caused more softening and breakdown of myofibrillar structures (Sreenath et al., 2007; Mallick et al., 2010) [21,37] . Springiness and gumminess both declined with increasing F 0 values, consistent with earlier studies on prawn curry and heattreated fish products (Majumdar et al., 2017) [20] . Cohesiveness remained relatively stable but trended slightly lower during storage. Overall, extended heating reduced structural integrity and impacted bite quality. The changes were similar to those reported for retorted shrimp and surimi-based products (Ali et al., 2005; Shah et al., 2017, Lingaraju et al., 2025) [38,39,40] . These findings confirmed that thermal intensity strongly influenced textural properties. Milder processing at F 0 8 preserved firmness and elasticity better, contributing to improved sensory characteristics over time

Sensory Evaluation

Sensory attributes of shrimp curry were assessed by a trained panel over 180 days of storage. Samples processed at F 0 8 and F 0 9 minutes were evaluated for appearance, colour, flavour, firmness, succulence, toughness, and overall acceptability (Table 5). At day 0, both treatments received high scores across all attributes. Appearance ranged from 8.70 to 8.80, colour from 8.70 to 8.90, and overall acceptability was above 8.80. The scores declined gradually over the storage period. By day 180, samples processed at F 0 8 retained higher ratings than those at F 0 9. Final scores for overall acceptability were 8.30 (F 0 8) and 8.20 (F 0 9), while colour dropped to 8.10 and 7.90, respectively. The decrease in sensory quality was more evident in the F 0 9 sample. The reduction in scores over time was attributed to pigment oxidation, texture softening, and accumulation of lipid oxidation products. The milder F 0 8 treatment preserved firmness, flavour, and colour better than the higher F 0 value. No significant differences were observed in toughness across the storage period, indicating that both treatments maintained acceptable texture integrity. These findings confirmed that shrimp curry processed at F 0 8 minutes offered superior sensory retention during storage. Similar trends were reported by Majumdar et al. (2017) [20] and Sreenath et al. (2007) [21] , who noted better consumer acceptance in mildly retorted prawn and shrimp curry products. The results emphasized the importance of optimizing thermal load to balance safety and sensory quality in ready-to-eat seafood.

Conclusion

The study successfully developed ready to eat thermally processed shrimp curry packed in flexible retort pouches. The product was thermally processed at two different lethality (F 0 value of 8 and 9 min) using commercial pilot scale over pressure retort. The study clearly proved the reduction in moisture content post thermal processing and increase of crude protein, crude fat and ash content of the samples after thermal processing and all biochemical constituents such as TVB-N, TMA-N, TBARS, FFA, PV values were increasing but were within the acceptable limit. pH was observed very marginal variation throughout the storage period which indicated that product maintained its microbial quality during storage life. The products processed at F 0 value of 8 and 9 min were commercially sterile and have good sensorial acceptance. These findings confirmed that shrimp curry processed at F 0 8 minutes offered superior sensory retention during storage.

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