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 validation of continuous flow thermal processes for foods comprising:

creating a plurality of carrier particles each comprising first and second components, wherein at least some of the plurality of carrier particles comprise a first component comprising a first polymer and a second component comprising a second polymer;

constructing a plurality of first simulated particles by, for each carrier particle, coupling the first and second components and receiving a first magnetic tag implant in an internal cavity defined by the first and second components;

flowing the plurality of first simulated particles through a thermal processing system;

measuring a residence time in the thermal processing system of each of the plurality of first simulated particles during the flowing step;

creating and constructing a plurality of second simulated particles that have substantially the same physical properties as one or two of the plurality of first simulated particles that have the lowest measured residence time; and

validating the thermal processing system by flowing the plurality of second simulated particles through the thermal processing system along with food comprising particles that are substantially the same size as each of the plurality of second simulated particles and measuring a residence time in the thermal processing system of each of the plurality of second simulated particles.

2. The method of claim 1 wherein the plurality of first simulated particles each have a different density.

3. The method of claim 1 wherein each of the plurality of first simulated particles has a shape of a cube or a sphere.

4. The method of claim 1 wherein the internal cavity of each of the plurality of first simulated particles has an identical size and shape.

5. The method of claim 4 further comprising receiving a thermo-sensitive implant in the internal cavity of each of the plurality of first simulated particles.

6. The method of claim 5 further comprising monitoring an accumulated thermal lethality rate in the thermal processing system of each of the plurality of first simulated particles during the flowing step.