Validation of radio frequency assisted traditional thermal processing for pasteurization of powdered infant formula milk

An accurate approach to predict Salmonella Enteritidis PT 30 survival based on dynamic thermal resistance during hot air assisted radio frequency pasteurization of in-shell walnuts

A significant variation between experimental and predicted log reductions of Salmonella at a constant water activity level has been previously found during a simultaneous hot air assisted radio frequency (HARF) pasteurization and drying of low-moisture foods (LMFs). However, how the dynamic thermal resistance of Salmonella changes with the changing temperature and water activity during HARF is unclear. Thermal inactivation kinetics of Salmonella Enteritidis PT 30 (S. enteritidis PT 30) in walnut shell powder and on in-shell walnuts were investigated under three temperatures and water activities. The dynamic thermal resistance (D-value) of S. enteritidis PT 30 in walnut shell powder and on in-shell walnuts were quantitatively described by modified Bigelow models during simultaneous HARF pasteurization and drying. The survival of S. enteritidis PT 30 was predicted and validated based on the dynamic thermal resistance on in-shell walnuts during HARF pasteurization. The results showed that the D-values of S. enteritidis PT 30 on in-shell walnuts were significantly (P < 0.05) higher than those in walnut shell powder at different temperatures and water activities, indicating a need to determine the thermal resistance parameters based on real-case pasteurization scenarios. The dynamic thermal resistance of S. enteritidis PT 30 in walnut shell powder and on in-shell walnuts first decreased and then increased during the simultaneous HARF pasteurization and drying. The experimental log reduction (2.06 ± 0.08) of S. enteritidis PT 30 on in-shell walnuts was close to the predicted value (2.07) during the simultaneous HARF pasteurization and drying. Predicting microbial survival based on the dynamic thermal resistance of S. enteritidis PT 30 on in-shell walnuts is more accurate and reliable than that based on the static one. The developed model and proposed approach are valuable and crucial for the commercialization of simultaneous RF pasteurization and drying processes of LMFs.

Radio frequency-only thermal processing of skimmed milk powder: Case study on the influence of RF heating profile on quality and Salmonella Typhimurium inactivation

Radio frequency (RF) is a dielectric heating technology that allows rapid and volumetric heating of milk powder, outperforming the heating uniformity of conventional powder heating methods. Typically, RF milk powder processing consists of a fast RF heating phase, followed by an oven heating phase in temperatures around 90 °C. This methodology can result in milk powder quality deterioration due to non-uniform temperature distributions and local overheating. Radio frequency-only processes with a more gradual heating rate are alternative solutions to minimise the impact on milk powder quality. This study investigated the effect of the heating rate on the microbial inactivation of Salmonella Typhimurium inoculated in skimmed milk powder, as well as the effect of each process on two quality characteristics, colour and solubility. Overall, a slower heating profile resulted in sufficient inactivation rates of Salmonella in skimmed milk powder, while still providing a high-quality end product. A 4-log reduction was achieved by treating the skimmed milk powder up to 95 °C using a slower, longer heating rate. No statistically significant changes were observed in the solubility of skimmed milk powder and only the harshest treatment to 95 °C led to a slight increase in the yellowness of the skimmed milk powder colour.

Effects of emerging food pretreatment and drying techniques on protein structures, functional and nutritional properties: An updated review

Protein is one of the most important components of food which significantly contributes to the structure, functionality, and sensory properties which may affect consumer acceptability of processed products. Conventional thermal processing affects protein structure and induce undesirable degradation of food quality. This review provides an overview of emerging pretreatment and drying technologies (plasma treatment, ultrasound treatment, electrohydrodynamic, radio frequency, microwave, and superheated steam drying) in food processing by assessing protein structural changes to enhance functional and nutritional properties. In addition, mechanisms and principles of these modern technologies are described while challenges and opportunities for the development of these techniques in the drying process are also critically analyzed. Plasma discharges can lead to oxidative reactions and cross-linking of proteins that can change the structure of proteins. Microwave heating contributes to the occurrence of isopeptide or disulfide bonds which promotes α-helix and β-turn formation. These emerging technologies can be adopted to improve protein surface by exposing more hydrophobic groups which restrict water interaction. It is expected that these innovative processing technologies should become a preferred choice in the food industry for better food quality. Moreover, there are some limitations for industrial scale application of these emerging technologies that need to be addressed.

Advancements in Non-Thermal Processing Technologies for Enhancing Safety and Quality of Infant and Baby Food Products: A Review

Breast milk is the main source of nutrition during early life, but both infant formulas (Ifs; up to 12 months) and baby foods (BFs; up to 3 years) are also important for providing essential nutrients. The infant food industry rigorously controls for potential physical, biological, and chemical hazards. Although thermal treatments are commonly used to ensure food safety in IFs and BFs, they can negatively affect sensory qualities, reduce thermosensitive nutrients, and lead to chemical contaminant formation. To address these challenges, non-thermal processing technologies such as high-pressure processing, pulsed electric fields, radio frequency, and ultrasound offer efficient pathogen destruction similar to traditional thermal methods, while reducing the production of key process-induced toxicants such as furan and 5-hydroxymethyl-2-furfural (HMF). These alternative thermal processes aim to overcome the drawbacks of traditional methods while retaining their advantages. This review paper highlights the growing global demand for healthy, sustainable foods, driving food manufacturers to adopt innovative and efficient processing techniques for both IFs and BFs. Based on various studies reviewed for this work, the application of these novel technologies appears to reduce thermal processing intensity, resulting in products with enhanced sensory properties, comparable shelf life, and improved visual appeal compared to conventionally processed products.

Emergent methods for inactivation of Cronobacter sakazakii in foods: A systematic review and meta-analysis

Cronobacter sakazakii is a potentially pathogenic bacterium that is resistant to osmotic stress and low aw, and capable of persisting in a desiccated state in powdered infant milks. It is widespread in the environment and present in various products. Despite the low incidence of cases, its high mortality rates of 40 to 80 % amongst neonates make it a microorganism of public health interest. This current study performed a comparative assessment between current reduction methods applied for C. sakazakii in various food matrices, indicating tendencies and relevant parameters for process optimization. A systematic review and meta-analysis were conducted, qualitatively identifying the main methods of inactivation and control, and quantitatively evaluating the effect of treatment factors on the reduction response. Hierarchical clustering dendrograms led to conclusions on the efficiency of each treatment. Review of recent research trend identified a focus on the potential use of alternative treatments, with most studies related to non-thermal methods and dairy products. Using random-effects meta-analysis, a summary effect-size of 4-log was estimated; however, thermal methods and treatments on dairy matrices displayed wider dispersions - of τ2 = 8.1, compared with τ2 = 4.5 for vegetal matrices and τ2 = 4.0 for biofilms. Meta-analytical models indicated that factors such as chemical concentration, energy applied, and treatment time had a more significant impact on reduction than the increase in temperature. Non-thermal treatments, synergically associated with heat, and treatments on dairy matrices were found to be the most efficient.

Bootstrapping for Estimating the Conservative Kill Ratio of the Surrogate to the Pathogen for Use in Thermal Process Validation at the Industrial Scale

A surrogate is commonly used for process validations. The industry often uses the target log cycle reduction for the test (LCRTest) microorganism (surrogate) to be equal to the desired log cycle reduction for the target (LCRTarget) microorganism (pathogen). When the surrogate is too conservative with far greater resistance than the pathogen, the food may be overprocessed with quality and cost consequences. In aseptic processing, the Institute for Thermal Processing Specialists recommends using relative resistance (DTarget)/(DTest) to calculate LCRTest (product of LCRTarget and relative resistance). This method uses the mean values of DTarget and DTest and does not consider the estimating variability. We defined kill ratio (KR) as the inverse of relative resistance.The industry uses an extremely conservative KR of 1 in the validation of food processes for low-moisture foods, which ensures an adequate reduction of LCRTest, but can result in quality degradation. This study suggests an approach based on bootstrap sampling to determine conservative KR, leading to practical recommendations considering experimental and biological variability in food matrices. Previously collected thermal inactivation kinetics data of Salmonella spp. (target organism) and Enterococcus faecium (test organism) in Non-Fat Dried Milk (NFDM) and Whole Milk Powder (WMP) at 85, 90, and 95°C were used to calculate the mean KR. Bootstrapping was performed on mean inactivation rates to get a distribution of 1000 bootstrap KR values for each of the treatments. Based on minimum temperatures used in the industrial process and acceptable level of risk (e.g., 1, 5, or 10% of samples that would not achieve LCRTest), a conservative KR value can be estimated. Consistently, KR increased with temperature and KR for WMP was higher than NFDM. Food industries may use this framework based on the minimum processing temperature and acceptable level of risk for process validations to minimize quality degradation.

Pasteurization of Salmonella spp. in black fungus (Auricularia auricula) powder by radio frequency heating

Radio frequency (RF) heating has been studied to inactivate bacteria in some powder foods. In this study, a 6 kW, 27.12 MHz RF system was used to pasteurize Salmonella in black fungus (Auricularia auricula) powder. The effects of different conditions (initial aw, electrodes gaps, particle sizes) on RF heating rate and uniformity were investigated. The results showed that RF heating rate was significantly (p < 0.05) improved with decreasing electrodes gap and increasing initial aw, and the heating rate was the slowest when the particle size was 120-160 mesh. However, these factors had no significant (p > 0.05) influence on heating uniformity. RF pasteurization of Salmonella in black fungus powder was also studied. The results showed that, to inactivate Salmonella for 5 log reductions in the cold spot (the center of surface layer), the time needed and bacteria heat resistance at designated temperature (65, 75, 85 °C) decreased with increasing aw, and the first order kinetics and Weibull model could be used to fit inactivation curves of Salmonella with well goodness. Quality analysis results showed that although RF pasteurization had no significant (p > 0.05) effect on Auricularia auricula polysaccharide (AAP) and total polyphenols, obvious changes were found on color. Results suggested that RF pasteurization can be considered as an effective pasteurization method for black fungus powder.

A review on egg pasteurization and disinfection: Traditional and novel processing technologies

Salmonella Enteritidis is a pathogen related to many foodborne outbreaks involving eggs and egg products. Regulations about whether eggs should be pasteurized are very different and inconsistent worldwide. In the United States, eggs are not required to be pasteurized. Hence, less than 3% of the eggs in the country are pasteurized. The standard pasteurization method (57°C, 57.5 min) uses a long thermal process that increases the cost of the product and affects its quality. Foodborne outbreaks can be reduced if eggs are properly pasteurized to inactivate Salmonella spp. However, the technology to pasteurize eggs needs to offer a faster and more reliable method that can be scaled up to industry settings at a low cost and without affecting product quality. Several novel technologies have been tested for eggshell disinfection and egg pasteurization. Some thermal technologies have been evaluated for the pasteurization of eggs. Microwave has limited penetration depth and is a technical challenge for egg pasteurization. However, radio frequency can penetrate eggshells effectively to inactivate Salmonella, considerably reduce processing time, and maintain the quality of the product. Nonthermal technologies such as ultraviolet, pulsed light, cold plasma, ozone, pressure carbon dioxide, electrolyzed water, and natural antimicrobials have been explored for surface cleaning of the intact egg as alternatives without affecting the internal quality. This review presents some of these novel technologies and the current challenges. It discusses the possible combination of factors to achieve the egg's internal pasteurization and the eggshell's disinfection without affecting the quality at a low cost for the consumer.

Influence of Radio Frequency Heating on the Pasteurization and Drying of Solid-State Fermented Wolfiporia cocos Products

Rice bran and soybean residue are high in nutrients and active ingredients. They are used as media in the solid-state fermentation of Wolfiporia cocos. They not only reduce raw material costs, but also raise the economic value and applications of soybean residues and rice bran. After 30 days of fermentation, the moisture content (w.b.) of the W. cocos product was approximately 40%, requiring it to be pasteurized and dried later. The objective of this research is to use radio frequency (RF) rapid heating technology to pasteurize and dry the solid-state fermented product. A 500 g bag of solid-state fermented W. cocos product took only 30 and 200 s at the RF electrode gap of 15 cm to pasteurize and reduce the moisture content (w.b.) below 15%, respectively; therefore, the methods can be used instead of the traditional 60 min autoclave sterilization and 100 min hot air drying at 45 °C. After RF treatment, the fermented W. cocos product was white, indicating that browning was prevented; the product contained 5.03% mycelium, 9.83% crude polysaccharide, 4.43% crude triterpene, 3.54 mg gallic acid equivalent/g dry weight (DW) of total polyphenols, and 0.38 mg quercetin equivalent/g DW of flavonoid contents and showed a good antioxidant capacity.

Evaluation of Pilot-Scale Radio Frequency Heating Uniformity for Beef Sausage Pasteurization Process

Radio frequency (RF) heating has the advantages of a much faster heating rate as well as the great potential for sterilization of food compared to traditional thermal sterilization. A new kettle was designed for sterilization experiments applying RF energy (27.12 MHz, 6 kW). In this research, beef sausages were pasteurized by RF heating alone, the dielectric properties (DPs) of which were determined, and heating uniformity and heating rate were evaluated under different conditions. The results indicate that the DPs of samples were significantly influenced (p < 0.01) by the temperature and frequency. The electrode gap, sample height and NaCl content had significant effects (p < 0.01) on the heating uniformity when using RF energy alone. The best heating uniformity was obtained under an electrode gap of 180 mm, a sample height of 80 mm and NaCl content of 3%. The cold points and hot spots were located at the edge of the upper section and geometric center of the sample, respectively. This study reveals the great potential in solid food for pasteurization using RF energy alone. Future studies should focus on sterilization applying RF energy and SW simultaneously using the newly designed kettle.

Effects of radio frequency heating on microbial populations and physicochemical properties of buckwheat

Microbial contamination is a persistent problem for grain industry. Many studies have shown that radio frequency (RF) heating can effectively reduce pathogens populations in low moisture foods, but there is a lack on the efficacy to decontaminate natural microbiome. The main objectives of this study were to investigate the effects of different RF heating conditions on natural microbial populations and physicochemical properties of buckwheat. In this study, 30 buckwheat samples collected from 10 different Provinces in China were analyzed for their microbial loads, and the samples with the highest microbial populations were used for further study to select the suitable RF heating conditions. The results showed that microbial loads in tested buckwheat kernels were in the range of 3.4-6.2 log CFU/g. Samples from Shanxi (SX-3) had significantly higher microbial counts than other samples. The selected four temperature-time combinations: 75 °C-20 min, 80 °C-10 min, 85 °C-5 min, and 90 °C-0 min of RF heating could reduce microbial counts to <3.0 log CFU/g in buckwheat kernels at 16.5% w.b. moisture content. Furthermore, the reduction populations of the inoculated pathogens (Salmonella Typhimurium, Escherichia coli, Cronobacter sakazakii, and Bacillus cereus) reached 4.0 log CFU/g under the above conditions, and almost 5.0 log CFU/g especially at high temperature-short holding time combinations (85 °C-5 min and 90 °C-0 min). Besides, physicochemical properties evaluation also showed the insignificant color changes and nutrients loss after RF treatment at 90 °C-0 min. Therefore, the RF heating at 90 °C-0 min holds greater potential than the other lower temperature-longer holding time combinations for applications in buckwheat pasteurization.

Recent developments in radio frequency drying for food and agricultural products using a multi-stage strategy: a review

Radio frequency (RF) drying is an emerging technology for food and agricultural products, holding features of rapid, uniform, stable, and volumetric heating, high energy efficiency, and moisture leveling. However, the RF drying with a single stage commonly has drawbacks of unexpected product quality, non-uniform moisture distribution, and prolonged drying time. The multi-stage drying approach could overcome the shortcomings of one-stage strategy accordingly by applying different drying methods or operating parameter values in each phase separately. This review describes the principle of RF heating, presents the typical systems and superiorities of RF drying, and provides a comprehensive overview on recent development in applications of both the one-stage and the multi-stage RF drying, and analysis of drying characteristics and merits for different types of the two-stage strategy. This review finally proposes recommendations for future studies in improving and optimizing the existing RF drying protocols and scaling up them to industrial applications.

Invited review: Stress resistance of Cronobacter spp. affecting control of its growth during food production

Members of the Cronobacter genus include food-borne pathogens that can cause infections in infants, with a mortality rate as high as 40 to 80%. The high fatality rate of Cronobacter and its isolation from numerous types of food, especially from powdered infant formula, demonstrate the serious nature of this organism. The source tracking of Cronobacter spp. and the analysis of high-frequency species from different sources are helpful for a more targeted control. Furthermore, the persistence during food processing and storage may be attributed to strong resistance of Cronobacter spp. to environment stresses such as heat, pH, and desiccation. There are many factors that support the survival of Cronobacter spp. in harsh environments, such as some genes, regulatory systems, and biofilms. Advanced detection technology is helpful for the strict monitoring of Cronobacter spp. In addition to the traditional heat treatment, many new control techniques have been developed, and the ability to control Cronobacter spp. has been demonstrated. The control of this bacteria is required not only during manufacture, but also through the selection of packaging methods to reduce postprocessing contamination. At the same time, the effect of inactivation methods on product quality and safety must be considered. This review considers the advances in our understanding of environmental stress response in Cronobacter spp. with special emphasis on its implications in food processing.

Validation of process technologies for enhancing the safety of low-moisture foods: A review

The outbreaks linked to foodborne illnesses in low-moisture foods are frequently reported due to the occurrence of pathogenic microorganisms such as Salmonella Spp. Bacillus cereus, Clostridium spp., Cronobacter sakazakii, Escherichia coli, and Staphylococcus aureus. The ability of the pathogens to withstand the dry conditions and to develop resistance to heat is regarded as the major concern for the food industry dealing with low-moisture foods. In this regard, the present review is aimed to discuss the importance and the use of novel thermal and nonthermal technologies such as radiofrequency, steam pasteurization, plasma, and gaseous technologies for decontamination of foodborne pathogens in low-moisture foods and their microbial inactivation mechanisms. The review also summarizes the various sources of contamination and the factors influencing the survival and thermal resistance of pathogenic microorganisms in low-moisture foods. The literature survey indicated that the nonthermal techniques such as CO₂ , high-pressure processing, and so on, may not offer effective microbial inactivation in low-moisture foods due to their insufficient moisture content. On the other hand, gases can penetrate deep inside the commodities and pores due to their higher diffusion properties and are regarded to have an advantage over thermal and other nonthermal processes. Further research is required to evaluate newer intervention strategies and combination treatments to enhance the microbial inactivation in low-moisture foods without significantly altering their organoleptic and nutritional quality.

Heating of milk powders at low water activity to 95°C for 15 minutes using hot air-assisted radio frequency processing achieved pasteurization

Salmonella persistence in milk powders has caused several multistate foodborne disease outbreaks. Therefore, ways to deliver effective thermal treatment need to be identified and validated to ensure the microbial safety of milk powders. In this study, a process of hot air-assisted radio frequency (HARF) followed by holding at high temperatures in a convective oven was developed for pasteurization of milk powders. Heating times were compared between HARF and a convection oven for heating milk powders to a pasteurization temperature, and HARF has been shown to considerably reduce the come-up time. Whole milk powder (WMP) and nonfat dry milk (NFDM) were inoculated with a 5-serotype Salmonella cocktail and equilibrated to a water activity of 0.10 to simulate the worst case for the microbial challenge study. After heating the sample to 95°C using HARF, followed by 10 and 15 min of holding in the oven, more than 5 log reduction of Salmonella was achieved in WMP and NFDM. This study validated a HARF-assisted thermal process for pasteurization of milk powder based on previously collected microbial inactivation kinetics data and provides valuable insights to process developers to ensure microbial safety of milk powder. This HARF process may be implemented in the dairy industry to enhance the microbial safety of milk powders.