Canning process of hilsa shad (Tenualosa ilisha) in Bangladeshi style mustard curry medium: assessment of thermal sterilization and shelf-life evaluation

The Hilsa shad, Bangladesh's national fish, is renowned across the North Indian Ocean region for its unique taste and flavor, soft texture, and high nutritional value. The present study develops a canned hilsa recipe in a mustard curry medium with a shelf life of 14 months at room temperature. Sensory evaluation scored the product over 8 on a 9-point hedonic scale, indicating strong consumer acceptance. Thermal processing was standardized using thermocouple sensors, recording a come-up time of 26 min, heating time of 32 min, cooling time of 15 min, and a sterilizing value (F0) of 17.22 min. Four treatment groups were prepared: one control (no preservatives) and the other three using edible preservatives (E 320, E 249 and their combination). Accelerated Shelf-Life Testing (ASLT) showed that all groups retained safety and quality standards, with no significant differences (p > 0.05) in total volatile basic nitrogen (TVBN). Other parameters such as color, flavor, odor, rancidity, and microbial loads of Escherichia coli, Staphylococcus aureus, yeast and mold counts, and Clostridium botulinum remained stable throughout the shelf-life study. Subsequently, the preservative-free treatment was selected for Real-Time Shelf-Life Testing (RT-SLT). After 14 months of RT-SLT, the selected treatment showed average values of pH, total volatile basic nitrogen (TVBN), and rancidity of 5.76, 4.62 mg/kg, and absent, respectively. The microbiological results from the RT-SLT showed that the levels of Total Plate Count, Yeast &amp; Mold, E. coli, S. aureus, and C. botulinum were <10 cfu/g, <0.3 cfu/g, <3 cfu/g, <10 cfu/g, and absent, respectively. These results meet established safety and quality standards, confirm the product's stability after 14 months of storage, and highlight the potential for developing a value-added, ready-to-eat canned hilsa product for both domestic and international markets.