Knowledge of experimental residence time distribution of foods containing particles being processed aseptically is crucial to designing safe thermal processes while simultaneously ensuring optimum product quality. Past attempts at designing high-temperature short-time process recommendations depended on conservative estimates for residence time in a holding tube while ignoring the effect of the scraped-surface heat exchangers. This resulted in excessive thermal treatment and a consequent loss of textural and nutritional quality attributes. Experiments were conducted to determine residence time of particles in food being processed in a commercial scale aseptic processing system at 135-140 degrees C. Residence time data, which included among others, the effect of particle-particle interaction in a viscous fluid product made up of a 6% starch solution containing 15% diced potatoes, were collected and treated statistically. The data show that the methodology developed yields reproducible data, which when treated statistically, allows prediction of fastest particle residence time with a high level of confidence. In addition, data presented for the high-viscosity starch-based product, showed a marked absence of any channeling effects as the product passed through scraped-surface heat exchangers, a holding tube, and interconnecting piping of a commercial processing system.