J ORNADES DE LA XARXA DE REFERNCIA

EN TECNOLOGIA DELS ALIMENTS

DE LA GENERALITAT DE CATALUNYA
NUTRICI
I SEGURETAT
ALIMENTRIA
Barcelona
15 i 16 de Novembre de 2007
Novel food processing
Novel food processing
technologies
technologies
Gustavo V. Barbosa
Gustavo V. Barbosa
-
-
Canovas
Canovas
Center for Nonthermal Processing of Foods
Center for Nonthermal Processing of Foods
Washington State University
Washington State University
Goal of Novel Technologies
Goal of Novel Technologies
Food
Fresh-like products
Less additives
High quality
Less thermal damage
Nutritious
quality food
Reasonable
cost
Nonthermal technologies
Nonthermal technologies

A
A
growing
growing
success in food preservation
success in food preservation

New products in the market

New products in the market

Industrial adoption
Industrial adoption

Larger equipment
Larger equipment

New regulations
New regulations

New processing applications

New processing applications

Body
Body
of knowledge
of knowledge

New industrial opportunities

New industrial opportunities
through new technologies
through new technologies
NOVEL
NOVEL
TECHNOLOGY
TECHNOLOGY
Consumer
acceptance
Industrial
involvement
Regulatory
approval
Scientific
exploration
Dedicated Publications
Dedicated Publications

Innovative Food Science and Emerging
Innovative Food Science and Emerging
Technologies (IFSET). Elsevier
Technologies (IFSET). Elsevier
Science.
Science.

Several books
Several books

Nonthermal Processing of Foods

Nonthermal Processing of Foods

Novel Processing Technologies

Novel Processing Technologies

PEF book
PEF book

Ultrahigh Pressure Treatment of Foods

Ultrahigh Pressure Treatment of Foods

IFT/ FDA Report
IFT/ FDA Report

NASA Report
NASA Report
Research Funds
Research Funds
Dedicated Research Funds
Dedicated Research Funds

EPRI
EPRI

USDA Food Safety Initiative
USDA Food Safety Initiative

European Union Flair Program
European Union Flair Program

US Army Natick
US Army Natick

CORANET
CORANET

DUST Program
DUST Program
High Pressure High Pressure
Pulsed Electric Fields NASA NRA Program Pulsed Electric Fields NASA NRA Program
Emerging Technologies: Around the world
Emerging Technologies: Around the world
HHP
HHP
PEF
PEF
US
US
Novel food processing
Novel food processing
technologies
technologies

Thermal food processing

Thermal food processing
technologies
technologies
(Heat from different source, shorter times)
(Heat from different source, shorter times)

Nonthermal food processing

Nonthermal food processing
technologies
technologies
(Pressure, electricity, sound, light, chemicals, etc.)
(Pressure, electricity, sound, light, chemicals, etc.)
Thermal novel food processing
Thermal novel food processing
technologies
technologies

Microwave
Microwave

Radio Frequency
Radio Frequency

Ohmic
Ohmic
Heating
Heating

Induction heating
Induction heating
Nonthermal novel food
Nonthermal novel food
processing technologies
processing technologies

High hydrostatic pressure
High hydrostatic pressure

Pulsed electric fields
Pulsed electric fields

Arc discharge
Arc discharge

Ultrasound
Ultrasound

Ultraviolet
Ultraviolet

Oscillating magnetic fields
Oscillating magnetic fields

Light Pulses
Light Pulses

Irradiation
Irradiation

Plasma
Plasma

Chemicals (Ozone, Carbon Dioxide)
Chemicals (Ozone, Carbon Dioxide)

Combined methods
Combined methods
High
High
Hydrostatic
Hydrostatic
Pressure
Pressure
High pressure processing: an
High pressure processing: an
industrial reality
industrial reality

Pasteurization using 400
Pasteurization using 400
-
-
600 MPa
600 MPa

at room temperature for a few minutes

at room temperature for a few minutes

Fresh
Fresh
-
-
like quality attributes
like quality attributes

Pasteurized shelf stable high acid foods

Pasteurized shelf stable high acid foods

Pasteurized low acid food products

Pasteurized low acid food products
Volume: 300 L - 800 kg/h Processing Capacity
HPP: New batch equipment
HPP: New batch equipment
High Pressure Pump
More than 900 MPa
215 L vessel
25 L vessel
50 mL vessel
PT1 system,
Avure
Technologies
ELMHURST, Inc
Avure Technologies
Recently released commercial
Recently released commercial
UHP Products
UHP Products
Specialty foods
Fruit juices and smoothies
Dips and
salsas
Ham, chicken,
turkey products
Seafood products
High pressure as a sterilization
High pressure as a sterilization
process
process

Combination of pressures (600
Combination of pressures (600
-
-
800 MPa) and
800 MPa) and
temperatures (60
temperatures (60
-
-
90
90

C)
C)
Vegetative cell inactivation Vegetative cell inactivation
Bacterial spore inactivation Bacterial spore inactivation
Minimal thermal degradation Minimal thermal degradation

Foods with superior quality attributes
Foods with superior quality attributes
pressure pressure
temperature temperature
HP-35 L
Sterilization Unit
IMPROVED
QUALITY
Clostridium botulinum spore
HPTS: processing steps
HPTS: processing steps
Vac, pack & load
Preheating
Cooling Unload
Thermal pressurization
Temperature profiles: HPTS
Temperature profiles: HPTS
and retort
and retort
0 10 20 30 40 50 60
T HP Sterilization
T Retort
20
Temperature (C)
100
120
60
40
80
Time (min)
Transfer c/o
pressure vessel
Pressure on
Pressure off
Preheating
Cooling
Shorter processing times Shorter processing times
Lower temperature Lower temperature
HPTS: potential products
HPTS: potential products

Long life chill stable
Long life chill stable

RTE meats
RTE meats

Meat snacks
Meat snacks

Vegetables
Vegetables

Shelf stable
Shelf stable

Breakfast items (eggs)

Breakfast items (eggs)

Meat joints
Meat joints

Pot roasts/stews
Pot roasts/stews

High quality soups

High quality soups

RTD Teas/coffees
RTD Teas/coffees

Dairy
Dairy
desserts/smoothies
desserts/smoothies

Cheese/cream sauces
Cheese/cream sauces

Low acid pasta sauces

Low acid pasta sauces

High quality
High quality
fruit/vegetables
fruit/vegetables

Liquid flavors/herbs
Liquid flavors/herbs
Future needs for HPTS
Future needs for HPTS

Industry must weight
Industry must weight
quality benefit
quality benefit
vs.
vs.
costs
costs

The HPTS process must sell
The HPTS process must sell
Convenience and
Convenience and
Quality
Quality

Consumer acceptance
Consumer acceptance
is imperative
is imperative

Optimal treatment conditions
Optimal treatment conditions
must be identified for
must be identified for
each products
each products

Safety must be assured through
Safety must be assured through
validation and work
validation and work
with regulatory agencies
with regulatory agencies

Process Capability to be determined
Process Capability to be determined
Must optimize formulation and processing steps Must optimize formulation and processing steps
Go beyond squeeze and taste Go beyond squeeze and taste
Reliability and repeatability Reliability and repeatability
Regulatory boundaries Regulatory boundaries easier first: CFR 113 easier first: CFR 113
Meet shelf life goals with proper packaging Meet shelf life goals with proper packaging
HACCP / GMP HACCP / GMP
Pulsed
Pulsed
Electric
Electric
Fields
Fields
Novel food preservation technology
Novel food preservation technology
recognized for its ability to inactivate
recognized for its ability to inactivate
bacteria present in liquid food
bacteria present in liquid food
products at low temperatures.
products at low temperatures.
Pulsed Electric Fields
Pulsed Electric Fields
Technology
Technology
(PEF)
(PEF)
Pulsed Electric Fields (PEF)
Pulsed Electric Fields (PEF)

Tested conditions
Tested conditions
Number of pulses Number of pulses
Intensity of the electric field Intensity of the electric field
Temperature Temperature
Treatment medium Treatment medium
Natural antimicrobials Natural antimicrobials
Pulsed Power Systems : Equipment
Pulsed Power Systems : Equipment
Static PEF chamber designed by Sale Static PEF chamber designed by Sale
and Hamilton (1967) and Hamilton (1967)
Static treatment chamber Static treatment chamber
designed by Dunn and Pearlman (1987) designed by Dunn and Pearlman (1987)
WSU static treatment chamber WSU static treatment chamber
Continuous flow treatment chamber Continuous flow treatment chamber
sketched by Dunn and Pearlman (1987) sketched by Dunn and Pearlman (1987)
a) Chamber; b) electric field versus time or position as fluid a) Chamber; b) electric field versus time or position as fluid switching switching
Structure and equivalent circuit of converged Structure and equivalent circuit of converged
electric field type treatment chamber designed by Matsumoto electric field type treatment chamber designed by Matsumoto
a) Chamber structure; b) Equivalent circuit a) Chamber structure; b) Equivalent circuit
a) a)
b) b)
WSU continuous flow treatment chambers WSU continuous flow treatment chambers
Parallel plate treatment chamber Parallel plate treatment chamber
Coaxial treatment chamber Coaxial treatment chamber
Conceptual
Conceptual
design of the
design of the
WSU coaxial
WSU coaxial
treatment
treatment
chamber
chamber
Pulsed Power Systems :
Pulsed Power Systems :
Equipment
Equipment
Co
Co
-
-
field
field
treatment
treatment
chamber at
chamber at
OSU
OSU
PEF : Equipment
PEF : Equipment
Lab
Lab
scale
scale
PEF : Equipment
PEF : Equipment
OSU PEF processing system OSU PEF processing system
The large tank is filled with oil and contains
the high voltage, solid state components.
System controls are located above the tank.
Liquid flows through the processing unit
shown attached to the right hand side of the
large tank. The PEF system can process
between 1,000 and 5,000 liters per hour
This PEF pilot plant installed at University of University of
Salerno, Italy Salerno, Italy has a capacity up to 400 l/hr.
The pulse/power supply is on the left hand
and the treatment assemblies are in the cart
on the right. Connections between the two units
are not shown.
Microbial characteristics
Microbial characteristics

Size, shape and type of microorganism
Size, shape and type of microorganism
1.0 1.0 m m
0.9 0.9 m m
2.2 2.2 m m
6.0 6.0 m m
Staphylococcus Staphylococcus aureus aureus Escherichia coli Escherichia coli Saccharomyces Saccharomyces cerevisiae cerevisiae
Microbial inactivation : PEF
Microbial inactivation : PEF

Electrical potential
Electrical potential
transmembrane
transmembrane

Critical value:
Critical value:
1 V
1 V
P O R E S
P O R E S
ELECTROPORATION
ELECTROPORATION
Comparison of control cell Comparison of control cell
( (Saccharomyces Saccharomyces
cerevisiae cerevisiae) ) with PEF with PEF
treated cell showing treated cell showing
damage to cell membrane damage to cell membrane
Treatment Medium Characteristics
Treatment Medium Characteristics
Saline solution Saline solution
Phosphate buffer Phosphate buffer
Milk Milk
Yogurt Yogurt
Deionized Deionized water water
Sodium alginate Sodium alginate
Orange juice Orange juice
Potato dextrose agar Potato dextrose agar
Apple juice Apple juice
Simulated milk Simulated milk ultrafiltrate ultrafiltrate
Pea soup Pea soup
Sucrose and Sucrose and xanthan xanthan solution solution
Liquid egg Liquid egg
Cranberry juice Cranberry juice
Dry spices Dry spices
Wheat flour Wheat flour
Rice wine Rice wine
Rice pudding Rice pudding
Apple cider Apple cider
Cheese sauce Cheese sauce
Beef burgers Beef burgers
Horchata Horchata
Products Processed by Pulsed Electric Fields
Milk and dairy products
Milk and dairy products
Pulsed Electric Fields studied in:
Pulsed Electric Fields studied in:

Model solution similar to milk

Model solution similar to milk
ultrafiltrate
ultrafiltrate
(SMUF)
(SMUF)

Milk (different butter fat content)

Milk (different butter fat content)

Yogurt
Yogurt
Juices
Juices
Tested products and characteristics
Tested products and characteristics
Orange Juice Orange Juice
PME, color, PME, color, carotenoids carotenoids, vitamin C, flavor , vitamin C, flavor
compounds, browning index, pH, compounds, browning index, pH, Brix Brix
Tomato juice Tomato juice
Natural flora Natural flora
Apple cider/juice Apple cider/juice
Spoilage microorganisms Spoilage microorganisms
Grape juice Grape juice
Fatty acids and free amino acids Fatty acids and free amino acids
Orange and carrot juice Orange and carrot juice
Physical Physical - -chemical properties chemical properties
Commercial products
Commercial products
Juices
Juices
Eugene, Oregon Eugene, Oregon
USA USA
Genesis Juice Corporation
Genesis Juice Corporation
PEF : Cold
PEF : Cold

pasteurization
pasteurization
Preserves color, flavor and concentration of
Preserves color, flavor and concentration of
phytonutrients
phytonutrients
SHELF LIFE:
SHELF LIFE:
4 weeks
4 weeks
Future needs for PEF
Future needs for PEF
1. Fundamental research
Characterizing the interactions of electric fields with various food matrices at the
molecular level
Studying chemistry and electrochemistry at/near the electrode area during PEF treatment
Screening for microorganisms (pathogen as well as surrogate) most resistant to PEF
Standardizing and quantifying PEF processing variables and their contribution to the
mechanism of inactivation
2. Process dosage uniformity and monitoring
Controlling/monitoring residence time (i.e. the time that foods remain in the chamber)
Controlling residence time distribution by matching the flow profile and fluid conductivity
with the electric field distribution
Designing multiple PEF chambers to ensure minimum treatment time
3. Pulsed power equipment
Identifying the effects of different pulse waveforms
Quantifying the need for and/or benefits of bipolar pulses
Designing a system to detect, avoid, and tolerate occasional arcing during PEF
processing
Improving pulsed power system reliability, controllability and user friendliness
Future needs for PEF
Future needs for PEF
4. Food matrix
Identifying the effects of food composition
Designing PEF systems to process particulate and solid foods
5. Synergy and combination
Understanding the effect of holding temperature and holding time after
PEF process
Identifying the benefits when PEF is combined with other thermal and
nonthermal technologies
Identifying antagonistic effects of other processing and environmental
variables
Testing the use of supplementary chemicals or natural antimicrobials in
combination with PEF to reduce process intensity
Ultrasound
Ultrasound
Ultrasound processing: principle
Ultrasound processing: principle

Energy generated from waves of 20,000 or more
Energy generated from waves of 20,000 or more
vibrations per second
vibrations per second
high frequency high frequency or or diagnostic (2 diagnostic (2- -10 MHz) 10 MHz)
low low frequency frequency or or power (20 power (20- -100 kHz 100 kHz) )

Lyses and inactivates cells
Lyses and inactivates cells
Intracelullar Intracelullar cavitation cavitation

Variables to control:
Variables to control:
Temperature Temperature
Amplitude of the ultrasonic wave Amplitude of the ultrasonic wave
Time of treatment Time of treatment
Cycles Cycles
bubbles microturbulences
US
Cell membrane damage Cell membrane damage
Modes of
Modes of
sonication
sonication

Sonication
Sonication
(US)
(US)

Ultrasound
Ultrasound

Thermo
Thermo
-
-
sonication
sonication
(TS)
(TS)

Ultrasound plus heat

Ultrasound plus heat

Mano
Mano
-
-
thermo
thermo
-
-
sonication
sonication
(MTS)
(MTS)

Ultrasound plus heat and pressure

Ultrasound plus heat and pressure
Current ultrasound equipment
Current ultrasound equipment
Ultrasonic processor Hielscher UIP
4000
Operating frequency: 20kHz Operating frequency: 20kHz
Pressure 1 bar Pressure 1 bar
Sonotrode Sonotrode material: titanium alloy material: titanium alloy
WSU Food Science Australia
Ultrasound treatment of milk
Ultrasound treatment of milk
at WSU
at WSU
Ultrasonic processor
Ultrasonic processor
Hielscher
Hielscher
UP400S
UP400S
(400 W, 24 kHz) with a 22 mm
(400 W, 24 kHz) with a 22 mm
probe
probe
Enzyme Inactivation
Enzyme Inactivation
Pectinmethylesterase (PME) Pectinmethylesterase (PME)
- - tomatoes & oranges tomatoes & oranges
Polygalacturonase (PG) Polygalacturonase (PG)
- - tomatoes tomatoes
Time (min)
0 10 20 40 60 80
R
e
s
i
d
u
a
l

P
M
E

A
c
t
i
v
i
t
y

(
l
o
g
)
.6
.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
0.000 ppm/min
0.005 ppm/min
0.007 ppm/min
0.012 ppm/min
Thermosonication of Tomato
Thermosonication of Tomato
PME at 61
PME at 61
o o
C
C
Treatment Time (min)
0 10 20 30 40 50 60 70 80 90 100
L
o
g

R
e
s
i
d
u
a
l

A
c
t
i
v
i
t
y

(
%
)
.6
.8
1.0
1.2
1.4
1.6
1.8
2.0
Thermal (61
o
C)
Sonication (50
o
C)
Thermosonication (61
o
C)
36 36 0.8 0.8

2
Additive effect
curve (

)
Feng, 2005 Feng, 2005
Research needs
Research needs
Study the cavitation phenomenon
Investigate the microbial and enzyme inactivation mechanism and
inactivation kinetics
Examine the effect of ultrasound on quality attributes of food
products
Study the effect of ultrasonic treatment on food components (starch,
protein, lipids, biopolymers, etc.)
Identify the most resistant pathogenic microorganism(s) in selected
food systems to a power ultrasound treatment
Examine the economic feasibility of an ultrasonic processing and
preservation technology for a targeted application
Ultraviolet
Ultraviolet
Ultraviolet light
Ultraviolet light
processing: principle
processing: principle

Radiation at UV different
Radiation at UV different
wavelength ranges
wavelength ranges
Energies around Energies around 400 J/m 400 J/m
2 2
in all product in all product
Application in fluid foods Application in fluid foods

Microbial inactivation
Microbial inactivation

chemical
chemical
modifications and
modifications and
cleavage of bacterial
cleavage of bacterial
DNA
DNA
UV Germicidal Effect
UV Germicidal Effect

Bacteria
Bacteria

Molds
Molds

Yeasts
Yeasts

Viruses
Viruses

Protozoa
Protozoa

Algae
Algae
The Germicidal properties of UV irradiation
The Germicidal properties of UV irradiation
(200
(200

280 nm) are due to

280 nm) are due to
DNA
DNA
mutations
mutations
induced by
induced by
DNA absorption
DNA absorption
of the UV light
of the UV light
Current UV Equipment
Current UV Equipment
Concentric Tube UV
Disinfection System:
Infinity, Atlantic UV, Co.
Co-Axial UV-Reactors
Helix UV-Reactors
Co-Axial UV-Reactors
Helix UV-Reactors
Current UV Equipment
Current UV Equipment
UV Light Food Processing
UV Light Food Processing

Variables:
Variables:

Flow rate of the juice

Flow rate of the juice

UV exposure time
UV exposure time

Type of fruit juice

Type of fruit juice

J uice color
J uice color

J uice composition and

J uice composition and

Suspended solids in
Suspended solids in
juice
juice
UV applications
UV applications

Bacterial, mold reduction, pasteurization
Bacterial, mold reduction, pasteurization
and enzyme inactivation (PPO)
and enzyme inactivation (PPO)

Mainly fruit juices and nectars
Mainly fruit juices and nectars

Apple juice
Apple juice

Mango nectar
Mango nectar
Current limitations: Intensity / Particles / Opaqueness
Current limitations: Intensity / Particles / Opaqueness
Advantages of UV light
Advantages of UV light

Easy to use
Easy to use

Free from chemical
Free from chemical
residues
residues

Dry and cold
Dry and cold
process
process

Simple and effective
Simple and effective

Low cost
Low cost
The future of novel food
The future of novel food
processing
processing
technologies
technologies
The future
The future

More nonthermal applications for larger

More nonthermal applications for larger
consumer groups
consumer groups

Improved systems and reduced

Improved systems and reduced
manufacturing/machinery costs
manufacturing/machinery costs

New pathways to commercialization

New pathways to commercialization
The future
The future

HPTS
HPTS

C. botulinum
C. botulinum
inactivation conditions
inactivation conditions

Roadmap for regulatory approval

Roadmap for regulatory approval

Improved systems
Improved systems
Faster heating/cooling techniques Faster heating/cooling techniques
Maximized heat retention Maximized heat retention

Microbial inactivation/ heat transfer models

Microbial inactivation/ heat transfer models
Process performance parameters Process performance parameters

Innovative shelf stable products

Innovative shelf stable products
Applications: humanitarian, military, outdoors Applications: humanitarian, military, outdoors
The future
The future

Ultrasound, UV
Ultrasound, UV

Nonthermal applications for large consumer

Nonthermal applications for large consumer
groups
groups

Microbial inactivation conditions

Microbial inactivation conditions

Proven advantages with respect to thermal

Proven advantages with respect to thermal
technologies
technologies

Combination with preservatives, heat, HP, HP

Combination with preservatives, heat, HP, HP
-
-
T
T

Larger scale equipment

Larger scale equipment
Moltes
Moltes
Grcies
Grcies
J ORNADES DE LA XARXA DE REFERNCIA
EN TECNOLOGIA DELS ALIMENTS
DE LA GENERALITAT DE CATALUNYA
NUTRICI
I SEGURETAT
ALIMENTRIA
Barcelona
15 i 16 de Novembre de 2007