Post on 18-Mar-2019
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
Purwiyatno Hariyadiphariyadi.staff.ipb.ac.id
• Departemen Ilmu dan Teknologi Pangan, Fateta, IPB
• Southeast Asian Food & Agricultural Science & Technology (SEAFAST) Center, Bogor Agricultural University, BOGOR, Indonesia (www.seafast.ipb.ac.id)
• Anggota Institute for Thermal Process Specialist (IFTPS)-USA (www.iftps.org)
Better Thermal Processing of Foods:
In Container Processing
“potentially hazardous foods” (PHF)
“high risk foods (HRF)
Introduction
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
“Potentially Hazardous Foods” (PHF)(1962/US PHS)
Any perishable food which
(i) consists in whole or in part of milk or milk products, eggs, meat, poultry, fish, shellfish, or
(ii) other ingredients capable of supporting the rapid and progressive growth of infectious or toxigenic microorganisms.
Introduction
FDA 2001 – can’t easily define hazardous foods ~
PHF:
Foods with more than a 1 log increase of a pathogen when the food is stored at 24 °C (75 °F) for a period of time that is 1.3 times the shelf life as determined by the manufacturer.
Introduction
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
Potentially hazardous foods are foods that meet both the criteria below:
• they might contain the types of food-poisoning bacteria that need to multiply tolarge numbers to cause food poisoning; and
• the food will allow the food-poisoning bacteria to multiply.
Introduction
Australian Food Standards Code 2002
The following foods are examples of potentially hazardous foods (1):
• raw and cooked meat (including poultry and game) or foods containing raw or cooked meat such as casseroles, curries and lasagne;
• smallgoods such as Strasbourg, ham and chicken loaf;
• dairy products, for example, milk, custard and dairy-based desserts such as
• cheesecakes and custard tarts;• seafood (excluding live seafood) including seafood
salad, patties, fish balls, stews containing seafood and fish stock;
Introduction
Australian Food Standards Code 2002
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The following foods are examples of potentially hazardous foods (2):
• processed fruits and vegetables, for example salads and cut melons;
• cooked rice and pasta;• foods containing eggs, beans, nuts or other
protein-rich foods such as quiche, fresh pasta and soy bean products; and
• foods that contain these foods, for example sandwiches, rolls and cooked and uncooked pizza
Introduction
Australian Food Standards Code 2002
• Species of microorganisms.• Acidity (pH) • Water activity (aw)• Food Oxygen (some of the spores
with high thermal resistance are anaerobic).
• Food composition
Factors Influence the Heat Resistance of Microbial
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
• Species of microorganisms.• Acidity (pH) • Water activity (aw)• Food Oxygen (some of the spores
with high thermal resistance are anaerobic).
• Food composition
Factors Influence the Heat Resistance of Microbial
HM
L
Characteristics of potentially hazardous foods:
M
4.5
0.85
0
1aw
pH1410
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HM
L M
4.5
0.85
0
1aw
pH1410
Pengeringan,Penggaraman, dll
(aw controlled)
Pengasaman(pH controlled)
Managing riks of potentially hazardous foods: food processing
HM
L M
4.5
0.85
0
1aw
pH1410
Managing riks of potentially hazardous foods: food processing
Heating=
Thermal Processing
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
• Menghasilkan produk yang aman: memenuhi persyaratan peraturan/standar (keamanan) pangan
• Menghasilkan produk awet pada (i) suhu kamar (sterilisasi) atau (ii) suhu refrigerasi (pasteurisasi).
• Meminimalkan kerusakan zat gizi dan atribut mutu
• Meningkatkan produktivitas memaksimalkan “yields”
• Mengurangi biaya
Thermal Processing: Tujuan
Better Thermal Processing??~ Optimasi
• Menghasilkan produk yang aman: memenuhi persyaratan peraturan/standar (keamanan) pangan
• Menghasilkan produk awet pada (i) suhu kamar (sterilisasi) atau (ii) suhu refrigerasi (pasteurisasi).
• Meminimalkan kerusakan zat gizi dan atribut mutu
• Meningkatkan produktivitas memaksimalkan “yields”
• Mengurangi biaya
Thermal Processing: Tujuan
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Better Thermal Processing??~ Optimasi
Thermal Processing: Tujuan
Mengoptimalkan yield dan produktivitas, meminimalkan kerusakan mutu (dan gizi)tanpa mengkompromikan persyaratan keamanan pangan
Highly PHFspH > 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
Awet pada suhu ruang (shelf stable)
Tidak memerlukan refrigerasi Contoh : Sardine, tuna dalam
kaleng, susu steril, dll
Proses Panas
SterilisasiKomersial
Thermal Processing: Kasus A
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Highly PHFspH > 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
Hanya beberapa hari pada suhu refrigerasi
Harus refrigerasi Contoh : Susu pasteurisasi,
daging udang, kepiting, dan hasil laut lainnya
Proses Panas
Pasteurisasi
Thermal Processing: Kasus B
Highly PHFspH > 4.5 dan aw<0.85pH < 4.5 dan aw>0.85
Terkemas/tertutup dengan kedap (hermetis)
Awet (shelf stable), dengan/tanpa refrigerasi
Bisa tanpa refrigerasi Contoh : Sari buah, sos tomat,
jem/jelly, dll
ProsesPasteurisasi
&/atau Hot-fill-hold
Thermal Processing: Kasus C
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Thermal Processing
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
Thermal Processing
Process Objectives (Process Criterias):
• to kill microorganisms• to keep away microorganisms
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
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Thermal Processing
Process Objectives (Process Criterias):
• to kill microorganisms• to keep away microorganisms
Food Safety Objectives :• Protect public health hazard• (reduce economic spoilage)
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
Thermal Processing
Process Objectives (Process Criterias):
• to kill microorganisms• to keep away microorganisms
Food Safety Objectives :• Protect public health hazard• (reduce economic spoilage)
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
Bagaimana mengevaluasi/menilai keamanan produk pangan yang diproses panas?
?
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Thermal Processing
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
Aseptic/Continuous Processing
Ingredients CuttingAddition of
Liquid, Mixing
Heating(sterilizing/
Pasteurizing)
FormingPackagingMaterial
Sterilizing AsepticFilling
CodingAsepticClosing Filled Pack
Thermal Processing
• Hot-filling (Hot-fill-hold)
• Pasteurisasi
• Sterilisasi
IngredientsPreparation:cutting, etc
Preparationof liquid
Ready madeCAN
Filling(particulates)
Filling(liquid)
Closing Retorting Labelling Filled Can
In-Container Processing
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Produk Kaleng, botol, gelas, dll
Produk steril dalam wadah
Sterilisasi(pemanasan)
In-container thermal processing
Pengi-sian +
tutup
Thermal Processing
• Species of microorganisms.• Acidity (pH) • Water activity (aw)• Food Oxygen (some of the spores
with high thermal resistance are anaerobic).
• Food composition
Factors Influence the Heat Resistance of Microbial
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
• Species of microorganisms.• Acidity (pH) • Water activity (aw)• Food Oxygen (some of the spores
with high thermal resistance are anaerobic).
• Food composition
Factors Influence the Heat Resistance of Microbial
Heat Resistance of Microbial
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
Heat Resistance of Microbial
D values of microorganisms of importance in heat processing
Spores D 121.1 D140
(min) (s)
B. stearothermophilus 4.0 - 5.0 0.9C. thermosaccharolyticum 3.0 - 4.0D. nigrificans 2.0 - 3.0C. botulinum – proteolytic 0.1 - 0.23C. sporogenes 0.1 - 1.5B. coagulans 0.01 - 0.1B. Sporothermodurans 3,4 -7.9
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Reaksi E Z(kJ/mole) (oC)
Enzyme reactions 0-33.5 -Chlorophyl loss 21-113 26-142Ascorbic acid 21-167 11.8-142Non-enzymatic browning 37.7-167 -Lipid oxidation 41.9 -Spore destruction 251-335 8.7-11.8 Veg. cell destruction 209-628 4.7-14.2Protein denaturation 335-502 5,9-8.9
Comparison of Z and Ea for Quality Attributes and Microbial Populations of importance in heat processing
• Lethal Rate (LR)= Lethal value (LV)
• Time/Temp Process & LR
• LR Curve for Thermal Process
PROCESS CALCULATIONS
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z121.1-T(t)
zT(t)-121.1 10
10
1LVLR ===
T(oC) T(oF) LR(z=10oC)
90 194 0,00077624795 203 0,002454709100 212 0,007762471105 221 0,024547089110 230 0,077624712115 239 0,245470892120 248 0,776247117121,1 250 1,000000000125 257 2,454708916129 264 6,165950019
PROCESS CALCULATIONS
0,0
0,2
0,4
0,6
0,8
1,0
1,2
0 1 2 3 4 5 6 7 8 9 10 11 12
LR
t, min T(oC)
0 121,11 121,12 121,13 121,14 121,15 121,16 121,17 121,18 121,19 121,110 121,111 121,112 121,1
LR(z=10oC)
1,01,01,01,01,01,01,01,01,01,01,01,01,0
Pemanasan pada suhu konstan,121,1oC
1 unit sterilisasi12 unit sterilisasi
F0=12
0
20
40
60
80
100
120
140
0 1 2 3 4 5 6 7 8 9 10 11 12
Waktu
Su
hu
PROCESS CALCULATIONS
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
0,0000
0,0020
0,0040
0,0060
0,0080
0,0100
0 1 2 3 4 5 6 7 8 9 10 11 12
Waktu
LRt, min T(oC) LR(z=10oC)
0 100 0,0077624711 100 0,0077624712 100 0,0077624713 100 0,0077624714 100 0,0077624715 100 0,0077624716 100 0,0077624717 100 0,0077624718 100 0,0077624719 100 0,00776247110 100 0,00776247111 100 0,00776247112 100 0,007762471
Total sterilitas = 0.007762x12 unit= 0.10091 unit
hanya 0.00776 x pengaruh letal pada 121.1oC
Total letalitas = F0 =??
F0 = Do log t
0(LR)dt
N
N0
F0 = LR.t
Pemanasan pada suhu konstan,100oC
PROCESS CALCULATIONS
PROCESS CALCULATIONS
t = heating time (mini)T = Heating temperature, oC
F0 = 1 pemanasan selama 1 menit pada suhu 121.1oC
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Diketahui : Mikroba A; D0 = 0,21 menitdikehendaki proses 12 D
Pemanasan pada suhu 121.1oC ………> 12(0,21)=2.52 menit Pemanasan pada suhu 100oC 1/LR100C x 2.52 min = 1/0.00776 x 2.52=324.7 min (5.4 jam)
Pemanasan pada suhu 129oC 1/LR129C x 2.52 min = 1/6,166 x 2.52=0.408 min (24.5 detik)
Pemanasan pada suhu 50oC 1/LR50C x 2.52 min = 1/0. 000000078 x 2.52
= 32307692.31 menit= 747.8 bulan????!!!!
Pada prakteknya : efek letal panas untuk sterilisasi, umumnya mulai dianggap nyata
setelah T>90oC Teixeira (1992) : no appreciable lethality at T < 210oF(99oC) suhu produk selama pemanasan tidak konstant …….> T=f(t) Pemanasan produk dilakukan dalam retort pengalengan Pemanasan produk dilakukan dengan HE aseptik suhu produk diukur pada SHP/CP
PROCESS CALCULATIONS
Produk Kaleng, botol, gelas, dll
Produk steril dalam wadah
Sterilisasi(pemanasan)
Pengi-sian +
tutup
PROCESS CALCULATIONS(for ”In-container sterilisation”)
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Heat Penetration Test
• Scheduled Process:Venting and heating procedure
• Come up time• Operator processing
time• Cooling time, ETC
TR = f(t)
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Tipikal kurva penetrasi panas untuk pangan kaleng dan perubahan suhu retort (TR) selama proses seterilisasi
• Suhu retort di”set” (mis: pada 250oF)
CUT
• t untuk mencapai TR : CUT
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
Heat Penetration Test
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Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
SHP
SHP:Slowest Heating Point=Coldest Point
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
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0,0
0,2
0,4
0,6
0,8
1,0
1,2
0 4 8 12 16 20 24
WaktuL
R
t, min T(oC) LR(z=10oC)
0 90 0,0007762474 105 0,0245470898 120 0,77624711712 121 0,97723722116 100 0,00776247120 70 0,00000776224 60 0,000000776
F0 = Do log =t
0
(LR)dtN
N0
Fo = luas area di bawah kurva hubungan antara LR dan t
Fo = jumlah area trapesium
Luas trapesium t2
LR2LR1
+=
020406080
100120140
0 4 8 12 16 20 24waktu
Su
hu
(C
)
3.5068)(122
0.977
0.776A =-
+=
PROCESS CALCULATIONS
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Teixera, 1992. Thermal Process Calculation. Handbook of Food Eng.
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Purwiyatno HariyadiEmail: hariyadi@seafast.orgWeb: phariyadi.staff.ipb.ac.id
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
Tipikal data penetrasi panas : hubungan antara suhu produk (SHP) dan waktu pemanasan
PROCESS CALCULATIONS(for ”In-container sterilisation”)
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T-Tm TP-TR=
Ti-Tm Ti-TR
= exp -(t/L2)
TR-TP
TR-Ti
= exp -(k)t
Log(TR-TP)=Log(TR-Ti)- t(2,303)
k
2. Metoda Formula
T - TR
Ti - TR
= e
hA
CpV- t
= e-kt
Persamaan perubahan suhu selama proses pemanasan :
PROCESS CALCULATIONS
Dari kurva penetrasi panas :
- Tentukan fh
- Buat garis vertikal di t=0.6 CUT- Tentukan jI (baca di sumbu kanan Y)- (hitung/tentukan j
j = jI/I I = RT - IT
Menentukan nilai Fo; jika diketahui B
........hitung log g = log jI – (B/fh)
...... .dengan diketahui log g cari fh/U
...... .hitung Fi = 10(250-TR)/z
Fo = fh/[(fh/U)Fi]
Kasus 1
PROCESS CALCULATIONS
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Dari kurva penetrasi panas :
- Tentukan fh
- Buat garis vertikal di t=0.6 CUT- Tentukan jI (baca di sumbu kanan Y)- (hitung/tentukan j
j = jI/I I = RT - IT
Menentukan nilai B; jika dikehendaki nilai Fo
...... .hitung Fi = 10(250-TR)/z
....... hitung fh/U = fh/(Fo*Fi)
...... .dengan diketahui fh/U cari log g
B= fh(log jI – log g)
PROCESS CALCULATIONS
Kasus 2
Low Acid Food :
a food, other than alcoholic beverages, where any component of the food has a pH > 4.6 and a aw > 0.85.
PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods
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Low Acid Canned Food :
• pH > 4.6• Water Activity > 0.85• Thermally processed• Hermetically sealed container• Non-refrigerated
=COMMERCIALLYSTERILE
Low Acid Canned Food :
PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods
Ope-rator
Proses
Pengen-dalianProses
Arsipproses
=COMMERCIALLYSTERILE
PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods
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Ope-rator
Proses
Pengen-dalianProses
Arsipproses
Perlu GMP yang disiplin
=COMMERCIALLYSTERILE
Faktor Kritis
PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods
The product must be processed to achieve commercial sterility and the container in which the product is enclosed must be hermetically sealed so as to be airtight and to protect the contents of the container against the entry of microorganisms during and after processing.
Performance Standard (USFDA/USDA) :COMMERCIALLY STERILE
PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods
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For a low-acid Produk that receives thermal or other sporicidal lethality processing, that processing must be validated to achieve :
• a probability of 10-9 that there are spores of C. botulinum in a container of the produk that are capable of growing, or,
• a 12-log10 reduction of C. botulinum, assuming an initial load of 1000 spores per container.
Performance Standard (USFDA/USDA) :COMMERCIALLY STERILE
PROCESS ADEQUACY (for Safety Assurance) Focus : Low Acid Canned Foods
• C. botulinum
• DBot,250F = 0.21 menit
• 12-log10 reduction C. botulinum Fo = 2.52 menit
Performance Standard (USFDA/USDA) :
COMMERCIALLY STERILE
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Dalam prakteknya …
10 Ovals Sliced meat in gravy12-15 All Meats in gravy6-8 Up to A1 Mushrooms in butter
8-10 A1 Mushrooms in brine3-4 A2 Celery6-8 A2 to A10 4-6 Up to A2 Green beans in brine3-4 All Carrots6-8 A2 to A10 6 Up to A2 Peas in brine
4-6 All Beans in tomato sauce3-5 babyfood Babyfoods
Fo values Ukuran KalengsProduk
Beberapa nilai-Fo pangan steril komersial di pasar UK
COMMERCIALLY STERILE
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 39 41 43 45 47 49 51 53 55 149
Calculated F Value
Fre
qu
ency
3 < Fo< 15
UK
• Jumlah data terkumpul= 93 (dari 23 FCE)• Kisaran : 1.9 < Fo <148.4
COMMERCIALLY STERILE di INDONESIA
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• Pangan dgn proses panas minimal (minimally heat processed food): PASTEURISASI
• Dinyatakan dalam PU (F185(z=16))
• Dari 67 data :• Nilai PU 23 < PU < 60• Umumnya berhub dgn keawetan
02468
101214161820
25 30 35 40 45 50 55 602)
Calculated PU-values
Pre
quen
cy
PASTEURIZED PRODUCTS di INDONESIA
Industri perlu melakukan evaluasi untuk pemastian :
i. Good Manufacturing Practices?
ii. Kinerja alat pengolahan/retort?
iii. Kecukupan panas (nilai-Fo)?
KONDISI INDONESIA?
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0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 39 41 43 45 47 49 51 53 55 149
Calculated F Value
Fre
qu
ency
7 < Fo< 19
Indonesia?Optimisi Mutu• Penentuan T-t optimum• Otomatisasi pengendalian suhu?• Pelatihan Operator
Berlebihan?
KONDISI INDONESIA?
KECUKUPAN PANAS?
• Bandingkan dengan target
• Ingat “performance criteria”
• Identifikasi titik kritis
• Buat “scheduled process” = SOP
• Kendalikan titik kritis (next discussion)
• Training operator
• Maintenance
• Perlu authorized person(s)
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3 SYARATPENGALENGAN PANGAN SUKSES :
1. Perlakuan pemanasan yang cukup : tercapainya sterilitas komersial
2. Wadah/kaleng tertutup secara hermetislakukan prosedur pengisian dan penutupan kaleng dengan benar
3. Penanganan kaleng dengan baik : Sebelum, selama dan setelah pemanasan memastikan bahwa integritas sambungan dan penutupan tetap terjaga
Selalu ada kemungkinan bahwa bakteri akanmasuk kembali dan mencemari produk yang telah
Disterilisasi integritas sambungan dan penutupan adalah faktor penting
Terimakasih
phariyadi.staff.ipb.ac.id