Once the minimum retort temperature is regained, operators may incorrectly begin to time the process again without re-venting the retort. Failure to re-vent the retort may make an evaluation by a processing authority impossible. Plant personnel do not always realize that unless the scheduled process has been designed specifically for the product to be reprocessed, its use for reprocessing is not valid. Products of concern are those containing starches, binders, extenders and the like. To optimize product quality, condensed soups or sauces are often formulated with thickeners that activate late in the thermal process or during cooling.
Some products experience thickening of the sauce component during storage.
If changes during storage have not been considered, the reprocess may be inadequate when applied. In one case, a product which had an original process 110 minute cook time, when reprocessed had to be subjected to a 180 minute cook time. Timeliness of reprocessing may also be important depending on the severity of the original processing deviation. If the product is severely under processed, there may be a concern for the failure to destroy Staphylococcus aureus.