β-lactoglobulin denaturation, aggregation, and fouling in a plate heat exchanger: Pilot-scale experiments and dimensional analysis

Curcumin and 10-undecenoic acid as natural quorum sensing inhibitors of LuxS/AI-2 of Bacillus subtilis and LasI/LasR of Pseudomonas aeruginosa

The quorum sensing (QS) system is related to cell-to-cell communication as a function of population density, which regulates several physiological functions including biofilm formation and virulence gene expression. QS inhibitors have emerged as a promising strategy to tackle virulence and biofilm development. Among a wide variety of phytochemicals, many of them have been described as QS inhibitors. Driven by their promising clues, this study aimed to identify active phytochemicals against LuxS/autoinducer-2 (AI-2) (as the universal QS system) from Bacillus subtilis and LasI/LasR (as a specific QS system) of Pseudomonas aeruginosa, through in silico analysis followed by in vitro validation. The optimized virtual screening protocols were applied to screen a phytochemical database containing 3479 drug-like compounds. The most promising phytochemicals were curcumin, pioglitazone hydrochloride, and 10-undecenoic acid. In vitro analysis corroborated the QS inhibitory activity of curcumin and 10-undecenoic acid, however, pioglitazone hydrochloride showed no relevant effect. Inhibitory effects on LuxS/AI-2 QS system triggered reduction of 33-77% by curcumin (at 1.25-5 µg/mL) and 36-64% by 10-undecenoic acid (at 12.5-50 µg/mL). Inhibition of LasI/LasR QS system was 21% by curcumin (at 200 µg/mL) and 10-54% by 10-undecenoic acid (at 15.625-250 µg/mL). In conclusion, in silico analysis allowed the identification of curcumin and, for the first time, 10-undecenoic acid (showing low cost, high availability, and low toxicity) as alternatives to counteract bacterial pathogenicity and virulence, avoiding the imposition of selective pressure usually related to classic industrial disinfection and antibiotics therapy.

Molecular Understanding of Fouling Induction and Removal: Effect of the Interface Temperature on Milk Deposits

Molecular details concerning the induction phase of milk fouling on stainless steel at an elevated temperature range were established to better understand the effect of temperature on surface fouling during pasteurization. The liquid-solid interface that replicates an industrial heat exchanger (≤75°C), including four stages (preheating, heating, holding, and cooling), was investigated using both a quartz crystal microbalance (QCM-D) and a customized flow cell. We found that the milk fouling induction process is rate-limited by the synergistic effects of bulk reactions, mass transfer, and surface reactions, all of which are controlled by both liquid and surface temperatures. Surface milk foulant becomes more rigid and compact as it builds up. The presence of protein aggregates in the bulk fluid leads to a fast formation of surface deposit with a reduced Young's modulus. Foulant adhesion and cohesion strength was enhanced as both interfacial temperature and processing time increased, while removal force increased with an increasing deposit thickness. During cleaning, caustic swelling and removal showed semilinear correlations with surface temperature (T_S), where higher T_S reduced swelling and enhanced removal. Our findings evidence that adsorption kinetics, characteristics of the foulant, and the subsequent removal mechanism are greatly dependent on the temperature profile, of which the surface temperature is the most critical one.

Innovative fouling-resistant materials for industrial heat exchangers: a review

Fouling of heat exchangers (HEs) has become a major concern across the industrial sector. Fouling is an omnipresent phenomenon but is particularly prevalent in the dairy, oil, and energy industries. Reduced energy performance that results from fouling represents significant operating loss in terms of both maintenance and impact on product quality and safety. In most industries, cleaning or replacing HEs are currently the only viable solutions for controlling fouling. This review examines the latest advances in the development of innovative materials and coatings for HEs that could mitigate the need for costly and frequent cleaning and potentially extend their operational life. To better understand the correlation between surface properties and fouling occurrence, we begin by providing an overview of the main mechanisms underlying fouling. We then present selected key strategies, which can differ considerably, for developing antifouling surfaces and conclude by discussing the current trends in the search for ideal materials for a range of applications. In our presentation of all these aspects, emphasis is given wherever possible to the potential transfer of these innovative surfaces from the laboratory to the three industries most concerned by HE fouling problems: food, petrochemicals, and energy production.

A critical review on surface modifications mitigating dairy fouling

Thermal treatments performed in food processing industries generate fouling. This fouling deposit impairs heat transfer mechanism by creating a thermal resistance, thus leading to regular shutdown of the processes. Therefore, periodic and harsh cleaning-in-place (CIP) procedures are implemented. This CIP involves the use of chemicals and high amounts of water, thus increasing environmental burden. It has been estimated that 80% of production costs are owed to dairy fouling deposit. Since the 1970s, different types of surface modifications have been performed either to prevent fouling deposition (anti-fouling) or to facilitate removal (fouling-release). This review points out the impacts of surface modification on type A dairy fouling and on cleaning behaviors under batch and continuous flow conditions. Both types of anti-fouling and fouling-release coatings are reported as well as the different techniques used to modify stainless steel surface. Finally, methods for testing and characterising the effectiveness of coatings in mitigating dairy fouling are discussed.

Calcium Chelation by Phosphate Ions and Its Influence on Fouling Mechanisms of Whey Protein Solutions in a Plate Heat Exchanger

Fouling of plate heat exchangers (PHEs) is a recurring problem when pasteurizing whey protein solutions. As Ca²⁺ is involved in denaturation/aggregation mechanisms of whey proteins, the use of calcium chelators seems to be a way to reduce the fouling of PHEs. Unfortunately, in depth studies investigating the changes of the whey protein fouling mechanism in the presence of calcium chelators are scarce. To improve our knowledge, reconstituted whey protein isolate (WPI) solutions were prepared with increasing amounts of phosphate, expressed in phosphorus (P). The fouling experiments were performed on a pilot-scale PHE, while monitoring the evolution of the pressure drop and heat transfer coefficient. The final deposit mass distribution and structure of the fouling layers were investigated, as well as the whey protein denaturation kinetics. Results suggest the existence of two different fouling mechanisms taking place, depending on the added P concentration in WPI solutions. For added P concentrations lower or equal to 20 mg/L, a spongy fouling layer consists of unfolded protein strands bound by available Ca²⁺. When the added P concentration is higher than 20 mg/L, a heterogeneously distributed fouling layer formed of calcium phosphate clusters covered by proteins in an arborescence structure is observed.

Development and Validation of CFD Models of Thermal Treatment on Milk Whey Proteins Dispersion In Batch and Continuous Process Condition

The objective of this study was to develop and experimentally validate CFD models of thermal treatments on whey protein dispersions both in batch and continuous conditions, considering several processing times (2 to 9.92 min), shear rates (191 to 519 s−1) and temperatures (70, 80 and 85 °C). Regarding thermo-rheological properties of WP dispersions, the viscosity peak (raising up at 66 °C) decreased as the shear rate increased. Two different CFD models were developed to simulate the thermal process: results showed a good fitting between experimental and simulated data (RMSE <1.7 °C for batch model and mean temperature difference of 0.93 °C for the continuous one). Based on the developed models, cook values of both processes were calculated and slowest heating points were exactly located; by means of these data, equations to estimate the cook value in processing conditions within experimental range were obtained, overcoming the need of experimental tests or in-silico simulations.

Antifouling amphiphilic silicone coatings for dairy fouling mitigation on stainless steel

Pasteurization of dairy products is plagued by fouling, which induces significant economic, environmental and microbiological safety concerns. Herein, an amphiphilic silicone coating was evaluated for its efficacy against fouling by a model dairy fluid in a pilot pasteurizer and against foodborne bacterial adhesion. The coating was formed by modifying an RTV silicone with a PEO-silane amphiphile comprised of a PEO segment and flexible siloxane tether ([(EtO)₃Si-(CH₂)₂-oligodimethylsiloxane_m-block-(OCH₂CH₂)_n-OCH₃]). Contact angle analysis of the coating revealed that the PEO segments were able to migrate to the aqueous interface. The PEO-modified silicone coating applied to pretreated stainless steel was exceptionally resistant to fouling. After five cycles of pasteurization, these coated substrata were subjected to a standard clean-in-place process and exhibited a minor reduction in fouling resistance in subsequent tests. However, the lack of fouling prior to cleaning indicates that harsh cleaning is not necessary. PEO-modified silicone coatings also showed exceptional resistance to adhesion by foodborne pathogenic bacteria.

Antifouling Biomimetic Liquid-Infused Stainless Steel: Application to Dairy Industrial Processing

Fouling is a widespread and costly issue, faced by all food-processing industries. Particularly, in the dairy sector, where thermal treatments are mandatory to ensure product safety, heat-induced fouling represents up to 80% of the total production costs. Significant environmental impacts, due the massive consumption of water and energy, are also to deplore. Fouling control solutions are thus desperately needed, as they would lead to substantial financial gains as well as tremendous progress toward eco-responsible processes. This work aims at presenting a novel and very promising dairy fouling-mitigation strategy, inspired by nature, and to test its antifouling performances in real industrial conditions. Slippery liquid-infused surfaces were successfully designed directly on food grade stainless steel, via femtosecond laser ablation, followed by fluorosilanization and impregnation with an inert perfluorinated oil. Resulting hydrophobic surfaces (water contact angle of 112°) exhibited an extremely slippery nature (contact angle hysteresis of 0.6°). Outstanding fouling-release performances were obtained for these liquid-infused surfaces as absolutely no trace of dairy deposit was found after 90 min of pasteurization test in pilot-scale equipment followed by a short water rinse.

Predicting the distribution of whey protein fouling in a plate heat exchanger using the kinetic parameters of the thermal denaturation reaction of β-lactoglobulin and the bulk temperature profiles

Fouling of plate heat exchangers (PHE) is a severe problem in the dairy industry, notably because the relationship between the build-up of protein fouling deposits and the chemical reactions taking place in the fouling solution has not yet been fully elucidated. Experiments were conducted at pilot scale in a corrugated PHE, and fouling deposits were generated using a model β-lactoglobulin (β-LG) fouling solution for which the β-LG thermal denaturation reaction constants had been previously determined experimentally. Then 18 different bulk temperature profiles within the PHE were imposed. Analysis of the fouling runs shows that the dry deposit mass per channel versus the ratio R=k_unf/k_agg (with k_unf and k_agg representing, respectively, the unfolding and aggregation rate constants computed from both the identification of the β-LG thermal denaturation process and knowledge of the imposed bulk temperature profile into the PHE channel) is able to gather reasonably well the experimental fouling mass data into a unique master curve. This type of representation of the results clearly shows that the heat-induced reactions (unfolding and aggregation) of the various β-LG molecular species in the bulk fluid are essential to capture the trend of the fouling mass distribution inside a PHE. This investigation also illustrates unambiguously that the release of the unfolded β-LG (also called β-LG molten globule) within the bulk fluid (and the absence of its consumption in the form of aggregates) is a key phenomenon that controls the extent of protein fouling as well as its location inside the PHE.