| Summary: | Globally, beer is the most popular alcoholic beverage. To accomplish microbial stabilization and extend the shelf life of beer, it is typically subjected to in-package pasteurization using a tunnel pasteurizer. However, high internal pressure can cause can bulging during pasteurization, leading to significant product loss. In this study, an empirical mathematical model was constructed to describe the effects of can thickness (0.245–0.270 mm), fill volume (320–338 mL), carbon dioxide content (5.70–6.10 g/L), and pasteurization temperature (59–66 °C) on the internal pressure inside canned beer. A laboratory-scale pasteurization setup was used to pasteurize samples based on the worst-case scenario of commercial pasteurization. The mathematical model (R2 = 0.90) showed that all parameters significantly influenced the internal pressure of pasteurized canned beer (p < 0.05). Additionally, the physical, chemical, and biological properties of pasteurized canned beer were assessed. All values fell within an acceptable range of industrial standards. A simplified 2nd-order polynomial equation (R2 = 0.90) was created and verified for industrial use. The data are well represented by the simplified model, which suggests that it could be used for optimization of product- and process parameters to reduce the occurrence of can bulging in commercial pasteurization of canned beer.
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