Method for design and control of properties of simulated food particles for process monitoring and validation of aseptically processed multiphase foods and biomaterials

1. A method for construction and use of implant-carrying simulated particles for validation of continuous flow thermal processes for biomaterials comprising:

i) establishing a size and shape of each carrier particle among a plurality of carrier particles;

ii) establishing a size or volume of an internal cavity of each carrier particle among the plurality of carrier particles;

iii) separating a particle design for each carrier particle among the plurality of carrier particles into at least two components different in size and weight, wherein the at least two components are configured to be coupled to define the interior cavity;

iv) identifying and using, for the at least two components of at least some of the plurality of carrier particles, at least one polymer less dense than water at room temperature, and at least one polymer with a higher density than water at room temperature;

v) fabricating each of the components from one or more different polymers;

vi) assembling each carrier particle among the plurality of carrier particles based on the particle design by coupling the at least two components to form a hermetically sealed assembly with at least one detectable or recoverable implant received in the internal cavity;

vii) using the assembled carrier particles to generate a first population of particles with a range of critical properties comprising at least one of density and thermal conductivity;

viii) using the assembled first population of particles as a test set to determine limits of residence times and lethalities accumulated within a thermal processing system by the processed products; and

ix) identifying a fastest flowing configuration of the first population of particles and using the design to generate a larger second population of test particles and using the second population of test particles for process validation of biomaterials within the thermal processing system.

2. The method of claim 1 , wherein the biomaterials comprise food.