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

Oxygen and air cold plasma for the inactivation of Bacillus cereus in low-water activity soy powder

Cold plasma (CP) technology is a promising alternative to thermal treatments for the microbial decontamination of foods with low-water activity. The aim of this work is study the application of low-pressure CP (0.35 mbar) for the inactivation of Bacillus cereus in a soybean powder matrix using O₂ and synthetic air as ionizing gases. The parameters tested were an input power of 100, 200 and 300 W and an exposure time of 10 to 30 min. The excited reactive species formed were monitored by optical emission spectroscopy, and survival data were analyzed using the Weibull mathematical model. Treatments with both gases were effective in inactivating B. cereus. Air plasma resulted in a maximum 3.71-log reduction in bacterial counts at 300 W and 30 min, while O2 plasma showed the strongest inactivation ability, achieving levels higher than 5 log cycles at 300 W and > 25 min. This is likely due to the strong antimicrobial activity of oxygen-derived radicals together with carbon monoxide as an oxidation by-product. In addition, the Weibull distribution function accurately modeled the inactivation of B. cereus. Cold plasma technology is a promising approach for the decontamination of bacteria in low-water activity foods.

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.

Radiofrequency Inactivation of Salmonella in Black Pepper and Dried Basil Leaves Using In-package Steaming

Radiofrequency (RF) heating has been extensively studied for pasteurizing low-moisture foods. Currently, bulk foods are treated with radiofrequency; potential cross-contamination may occur during packaging of pasteurized products. As an alternative, in-package RF processing was evaluated for Salmonella inactivation on black peppercorns and dried basil leaves and prevention of cross-contamination during storage postprocessing. In-package steaming refers to the process in which the samples were heated in a steam vent package to generate and retain steam during the treatment. This treatment achieved good heating uniformity which could be because of the circulation of steam within the package. One-way steam vent allowed the release of excess steam once a threshold pressure was achieved and later returned to its original position to seal the package, when the RF energy was removed. In-package RF steaming of black peppercorns and dried basil leaves for 135 s and 40 s, respectively, resulted in more than 5 log reduction of Salmonella. The steam vent remained stable posttreatment and properly sealed the package to protect the product from any external contamination. These results indicate that the use of steam vent could effectively pasteurize black peppercorns and dried basil leaves could be beneficial in preventing the potential cross-contamination postprocessing.

Glycogen plays a key role in survival of Salmonella Typhimurium on dry surfaces and in low-moisture foods

Salmonella enterica is known to survive in desiccate environments and is often associated with low-moisture foods (LMFs). In this work, S. Typhimurium ATCC 14028 was found to survive better by achieving the least reductions (3.17 ± 0.20 Log CFU reduction) compared to S. Tennessee ATCC 10722 (3.82 ± 0.13 Log CFU reduction) and S. Newport ATCC 6962 (6.03 ± 0.36 Log CFU reduction) after 30 days on surfaces with a relative humidity of 49% at ambient temperature. A metabolomic analysis revealed that S. Typhimurium was still active in energy metabolism after 24 h in the desiccate environment and glycogen, an energy reserve, was drastically reduced. We followed up on the glycogen levels over 30 days and found indeed a sharp decline on the first day. However, the glycogens detected on day 7 were significantly higher (P < 0.05) and thereafter remained stable above the original levels until day 30. The expression levels of both glycogen anabolism- and catabolism-related genes (csrA, glgA, glgC, glgX) were significantly up-regulated at all tested points (P < 0.05). The glgA and glgC insertion mutants displayed weaker survivability on both dry surfaces and in representative LMFs (flour and milk powder) compared to the wild-type strain. This work highlights the role of glycogen during different periods of desiccation, which may bring novel insight into mitigating Salmonella by disrupting glycogen metabolism.

Effect of oil exposure stages on the heat resistance of Salmonella enterica serovar Enteritidis phage type 30 in peanut flour

The oil in low-moisture foods (LMFs) shows protective effects on bacteria during thermal processing. However, the circumstances under which this protective effect strengthens remain unclear. This study aimed to understand which step of the oil exposure to bacterial cells (inoculation, isothermal inactivation, or recovery and enumeration step) in LMFs can enhance their heat resistance. Peanut flour (PF) and defatted PF (DPF) were selected as the oil-rich and oil-free LMF models. Salmonella enterica Enteritidis Phage Type 30 (S. Enteritidis) was inoculated into four designated PF groups representing different oil exposure stages. It was isothermally treated to obtain heat resistance parameters. At a constant moisture content (a_w,25°C = 0.32 ± 0.02) and controlled a_w,85°C (0.32 ± 0.02), S. Enteritidis exhibited significantly high (p < 0.05) D values in oil-rich sample groups. For instance, the heat resistance values of S. Enteritidis in the PF-DPF and DPF-PF groups were D_80°C of 138.22 ± 7.45 min and 101.89 ± 7.82 min; however, the D_80°C in the DPF-DPF group was 34.54 ± 2.07 min. The oil addition after the thermal treatment also helped injured bacterial recovery in the enumeration. For instance, the D_80°C, D_85°C, and D_90°C values in the DFF-DPF oil groups were 36.86 ± 2.30, 20.65 ± 1.23, and 7.91 ± 0.52 min, respectively, which were higher than those in the DPF-DPF group at 34.54 ± 2.07, 17.87 ± 0.78, and 7.10 ± 0.52 min. We confirmed that the oil protected S. Enteritidis in PF in all three stages: desiccation process, heat treatment, and recovery of bacterial cells in plates.

Survival persistence of the 3 common Salmonella enterica serotypes isolated from broilers' in different matrices

Broiler meat is the predominant source of Salmonella as a foodborne pathogen. Several control strategies have focused on the reduction of Salmonella spp. levels at different production stages. However, the persistence of Salmonella between consecutive flocks is still of great concern. This study was designed to understand the cause of reinfection in broiler flocks due to survival of Salmonella in feeding lines of related matrices. Salmonella (S.) Enteritidis, S. Infantis, and S. Typhimurium isolated from broiler farms in North-West Germany were used. Four types of matrices (phosphate buffer saline (PBS), dietary plant fat, fat with feed mixture, and feed) were applied to evaluate Salmonella survival (with the initial dose about 8.0 log10 CFU/mL) during a simulation of 4 production cycles. To evaluate the growth and survival status of Salmonella ISO 6579-1:2017 were performed (quantitatively by plate count method (PCM) and most probable number method (MPN)) and qualitatively) at 5 defined time points (-7, 0, 4, 7, and 35 d). In all matrices and for the 3 serovars, the Salmonella count decreased at the end of the fourth cycle in comparison to the beginning of the experimental infection, and was still cultivated except for fat matrix. The PBS matrices showed the highest survival level of Salmonella and did not decline drastically by the end of the fourth cycle (5.93 ± 0.00, 5.87 ± 0.02, 5.73 ± 0.05 log10 CFU/mL, respectively). However, the fat matrices showed the lowest survival level for the 3 isolates at d 35 since the first cycle (0 log10 CFU/mL using PCM). Regarding the fat-feed mixture, and feed matrices, there was a fluctuation in the survival rate of Salmonella (all serovars) within each cycle. For the qualitative method, the 3 serovars persisted in all matrices until the end of the fourth cycle except for fat matrices. The present study highlights the ability of Salmonella to survive for a long time in different temperatures and matrices despite efficient cleaning and disinfection processes in the feeding lines, which may influence reinfection with Salmonella in poultry houses.

Food safety and food security through predictive microbiology tools: a short review

This article discusses the issues of food safety and food security as a matter of global health. Foodborne illness and deaths caused by pathogens in food continue to be a worldwide problem, with a reported 600 million cases per year, leading to around 420,000 deaths in 2010. Predictive microbiology can play a crucial role in ensuring safe food through mathematical modelling to estimate microbial growth and behaviour. Food security is described as the social and economical means of accessing safe and nutritious food that meets people's dietary preferences and requirements for an active and healthy life. The article also examines various factors that influence food security, including economic, environmental, technological, and geopolitical challenges globally. The concept of food safety is described as a science-based process or action that prevents food from containing substances that could harm human health. Food safety receives limited attention from policymakers and consumers in low- and middle-income countries, where food safety issues are most prevalent. The article also highlights the importance of detecting contaminants and pathogens in food to prevent foodborne illnesses and reduce food waste. Food and Agriculture Organization (FAO), an institution belonging to World Health Organization (WHO) presented calls to action to solve some of the emerging problems in food safety, as it should be a concern of all people to be involved in the pursue of safer food. The guarantee of safe food pertaining to microbiological contamination, as there are different types of active microorganisms in foods, could be obtained using predictive microbiology tools, which study and analyse different microorganisms' behaviour through mathematical models. Studies published by several authors show the application of primary, secondary, or tertiary models of predictive microbiology used for different food products.

Practice and Progress: Updates on Outbreaks, Advances in Research, and Processing Technologies for Low-moisture Food Safety

Large, renowned outbreaks associated with low-moisture foods (LMFs) bring to light some of the potential, inherent risks that accompany foods with long shelf lives if pathogen contamination occurs. Subsequently, in 2013, Beuchat et al. (2013) noted the increased concern regarding these foods, specifically noting examples of persistence and resistance of pathogens in low-water activity foods (LWAFs), prevalence of pathogens in LWAF processing environments, and sources of and preventive measures for contamination of LWAFs. For the last decade, the body of knowledge related to LMF safety has exponentially expanded. This growing field and interest in LMF safety have led researchers to delve into survival and persistence studies, revealing that some foodborne pathogens can survive in LWAFs for months to years. Research has also uncovered many complications of working with foodborne pathogens in desiccated states, such as inoculation methods and molecular mechanisms that can impact pathogen survival and persistence. Moreover, outbreaks, recalls, and developments in LMF safety research have created a cascading feedback loop of pushing the field forward, which has also led to increased attention on how industry can improve LMF safety and raise safety standards. Scientists across academia, government agencies, and industry have partnered to develop and evaluate innovate thermal and nonthermal technologies to use on LMFs, which are described in the presented review. The objective of this review was to describe aspects of the extensive progress made by researchers and industry members in LMF safety, including lessons-learned about outbreaks and recalls, expansion of knowledge base about pathogens that contaminate LMFs, and mitigation strategies currently employed or in development to reduce food safety risks associated with LMFs.

Peanut Butter Food Safety Concerns—Prevalence, Mitigation and Control of Salmonella spp., and Aflatoxins in Peanut Butter

Peanut butter has a very large and continuously increasing global market. The food safety risks associated with its consumption are also likely to have impacts on a correspondingly large global population. In terms of prevalence and potential magnitude of impact, contamination by Salmonella spp., and aflatoxins, are the major food safety risks associated with peanut butter consumption. The inherent nature of the Salmonella spp., coupled with the unique chemical composition and structure of peanut butter, present serious technical challenges when inactivating Salmonella spp. in contaminated peanut butter. Thermal treatment, microwave, radiofrequency, irradiation, and high-pressure processing all are of limited efficacy in inactivating Salmonella spp. in contaminated peanut butter. The removal of aflatoxins in contaminated peanut butter is equally problematic and for all practical purposes almost impossible at the moment. Adopting good manufacturing hygiene practices from farm to table and avoiding the processing of contaminated peanuts are probably some of the few practically viable strategies for minimising these peanut butter food safety risks. The purpose of this review is to highlight the nature of food safety risks associated with peanut butter and to discuss the effectiveness of the initiatives that are aimed at minimising these risks.

Salmonella spp. in low water activity food: Occurrence, survival mechanisms, and thermoresistance

The occurrence of disease outbreaks involving low-water-activity (a_w ) foods has gained increased prominence due in part to the fact that reducing free water in these foods is normally a measure that controls the growth and multiplication of pathogenic microorganisms. Salmonella, one of the main bacteria involved in these outbreaks, represents a major public health problem worldwide and in Brazil, which highlights the importance of good manufacturing and handling practices for food quality. The virulence of this pathogen, associated with its high ability to persist in the environment, makes Salmonella one of the main challenges for the food industry. The objectives of this article are to present the general characteristics, virulence, thermoresistance, control, and relevance of Salmonella in foodborne diseases, and describe the so-called low-water-activity foods and the salmonellosis outbreaks involving them.

Bioinspired fabrication of bifunctional antibody-enzyme co-assembled nanocomposites for chemiluminescence immunoassays of E. coli O157:H7

Immunoassays based on enzyme-labeled antibodies have been widely used in the food safety field. However, the production process of enzyme-labeled antibodies is complicated and the low storage stability limits their application. Herein, antibody-horseradish peroxidase (HRP) co-assembled nanocomposites (AHC NCs) with outstanding advantages such as enhanced stability, lower cost, and substrate affinity were successfully prepared via a one-pot green method. Then the AHC NCs were employed as an alternative to traditional enzyme-labeled antibodies to develop a chemiluminescence enzyme immunoassay (CLEIA) toward Escherichia coli (E. coli) O157:H7. Under optimal conditions, E. coli O157:H7 can be detected in a linear range from 1 × 10³ CFU mL^-1 to 5 × 10⁶ CFU mL^-1, while the limit of detection (LOD) is as low as 2.2 × 10² CFU mL^-1 (3σ). A series of repeatability studies showed reproducible results with a coefficient of variation of less than 7%. In addition, the proposed CLEIA was successfully applied to the analysis of spiked samples (tap water) and gave quantitative recoveries from 93.72% to 100.72%. This work demonstrates that the developed CLEIA can be applied as a universal platform for specific detection of diversified analytes.

Recent developments in low-moisture foods: microbial validation studies of thermal pasteurization processes

Outbreaks associated with low-moisture foods (e.g., wheat flour, nuts, and cereals) have urged the development of novel technologies and re-validation of legacy pasteurization process. For various thermal pasteurization processes, they share same scientific facts (e.g., bacterial heat resistance increased at reduced water activity) and guidelines. However, they also face specific challenges because of their different heat transfer mechanisms, processing conditions, or associated low-moisture foods' formulations. In this article, we first introduced the general structural for validating a thermal process and the shared basic information that would support our understanding of the key elements of each thermal process. Then, we reviewed the current progress of validation studies of 7 individual heating technologies (drying roasting, radiofrequency-assisted pasteurization, superheated steam, etc.) and the combined treatments (e.g., infrared and hot air). Last, we discussed knowledge gaps that require more scientific data in the future studies. We aimed to provide a process-centric view point of thermal pasteurization studies of low-moisture foods. The information could provide detailed protocol for process developers, operators, and managers to enhance low-moisture foods safety.