Process analytical technology for cheese manufacture

Metrological traceability in process analytical technologies and point-of-need technologies for food safety and quality control: not a straightforward issue

Traditional techniques for food analysis are based on off-line laboratory methods that are expensive and time-consuming and often require qualified personnel. Despite the high standards of accuracy and metrological traceability, these well-established methods do not facilitate real-time process monitoring and timely on-site decision-making as required for food safety and quality control. The future of food testing includes rapid, cost-effective, portable, and simple methods for both qualitative screening and quantification of food contaminants, as well as continuous, real-time measurement in production lines. Process automatization through process analytical technologies (PAT) is an increasing trend in the food industry as a way to achieve improved product quality, safety, and consistency, reduced production cycle times, minimal product waste or reworks, and the possibility for real-time product release. Novel methods of analysis for point-of-need (PON) screening could greatly improve food testing by allowing non-experts, such as consumers, to test in situ food products using portable instruments, smartphones, or even visual naked-eye inspections, or farmers and small producers to monitor products in the field. This requires the attention of the research community and devices manufacturers to ensure reliability of measurement results from PAT strategy and PON tests through the demonstration and critical evaluation of performance characteristics. The fitness for purpose of methods in real-life conditions is a priority that should not be overlooked in order to maintain an effective and harmonized food safety policy.

Invited review: A comprehensive review of visible and near-infrared spectroscopy for predicting the chemical composition of cheese

Substantial research has been carried out on rapid, nondestructive, and inexpensive techniques for predicting cheese composition using spectroscopy in the visible and near-infrared radiation range. Moreover, in recent years, new portable and handheld spectrometers have been used to predict chemical composition from spectra captured directly on the cheese surface in dairies, storage facilities, and food plants, removing the need to collect, transport, and process cheese samples. For this review, we selected 71 papers (mainly dealing with prediction of the chemical composition of cheese) and summarized their results, focusing our attention on the major sources of variation in prediction accuracy related to cheese variability, spectrometer and spectra characteristics, and chemometrics techniques. The average coefficient of determination obtained from the validation samples ranged from 86 to 90% for predicting the moisture, fat, and protein contents of cheese, but was lower for predicting NaCl content and cheese pH (79 and 56%, respectively). There was wide variability with respect to all traits in the results of the various studies (standard deviation: 9-30%). This review draws attention to the need for more robust equations for predicting cheese composition in different situations; the calibration data set should consist of representative cheese samples to avoid bias due to an overly specific field of application and ensure the results are not biased for a particular category of cheese. Different spectrometers have different accuracies, which do not seem to depend on the spectrum extension. Furthermore, specific areas of the spectrum-the visible, infrared-A, or infrared-B range-may yield similar results to broad-range spectra; this is because several signals related to cheese composition are distributed along the spectrum. Small, portable instruments have been shown to be viable alternatives to large bench-top instruments. Last, chemometrics (spectra pre-treatment and prediction models) play an important role, especially with regard to difficult-to-predict traits. A proper, fully independent, validation strategy is essential to avoid overoptimistic results.

A FT-NIR Process Analytical Technology Approach for Milk Renneting Control

The study proposes a process analytical technology (PAT) approach for the control of milk coagulation through near infrared spectroscopy (NIRS), computing multivariate statistical process control (MSPC) charts, based on principal component analysis (PCA). Reconstituted skimmed milk and commercial pasteurized skimmed milk were mixed at two different ratios (60:40 and 40:60). Each mix ratio was prepared in six replicates and used for coagulation trials, monitored by fundamental rheology, as a reference method, and NIRS by inserting a probe directly in the coagulation vat and collecting spectra at two different acquisition times, i.e., 60 s or 10 s. Furthermore, three failure coagulation trials were performed, deliberately changing temperature or rennet and CaCl₂ concentration. The comparison with fundamental rheology results confirmed the effectiveness of NIRS to monitor milk renneting. The reduced spectral acquisition time (10 s) showed data highly correlated (r > 0.99) to those acquired with longer acquisition time. The developed decision trees, based on PC1 scores and T² MSPC charts, confirmed the suitability of the proposed approach for the prediction of coagulation times and for the detection of possible failures. In conclusion, the work provides a robust but simple PAT approach to assist cheesemakers in monitoring the coagulation step in real-time.

A Review on the General Cheese Processing Technology, Flavor Biochemical Pathways and the Influence of Yeasts in Cheese

Cheese has a long history and this naturally fermented dairy product contains a range of distinctive flavors. Microorganisms in variety cheeses are an essential component and play important roles during both cheese production and ripening. However, cheeses from different countries are still handmade, the processing technology is diverse, the microbial community structure is complex and the cheese flavor fluctuates greatly. Therefore, studying the general processing technology and relationship between microbial structure and flavor formation in cheese is the key to solving the unstable quality and standardized production of cheese flavor on basis of maintaining the flavor of cheese. This paper reviews the research progress on the general processing technology and key control points of natural cheese, the biochemical pathways for production of flavor compounds in cheeses, the diversity and the role of yeasts in cheese. Combined with the development of modern detection technology, the evolution of microbial structure, population evolution and flavor correlation in cheese from different countries was analyzed, which is of great significance for the search for core functional yeast microorganisms and the industrialization prospect of traditional fermented cheese.

Enhancing Micronutrients Bioavailability through Fermentation of Plant-Based Foods: A Concise Review

Plant-based foods are rich sources of vitamins and essential micronutrients. For the proper functioning of the human body and their crucial role, trace minerals (iron, zinc, magnesium, manganese, etc.) are required in appropriate amounts. Cereals and pulses are the chief sources of these trace minerals. Despite these minerals, adequate consumption of plant foods cannot fulfill the human body’s total nutrient requirement. Plant foods also contain ample amounts of anti-nutritional factors such as phytate, tannins, phenols, oxalates, etc. These factors can compromise the bioavailability of several essential micronutrients in plant foods. However, literature reports show that fermentation and related processing methods can improve nutrient and mineral bioavailability of plant foods. In this review, studies related to fermentation methods that can be used to improve micronutrient bioavailability in plant foods are discussed.

Fiberoptic-Coupled Spectrofluorometer with Array Detection as a Process Analytical Chemistry Tool for Continuous Flow Monitoring of Fluoroquinolone Antibiotics

Nowadays, there is an increasing need for sensitive real-time measurements of various analytes and monitoring of industrial products and environmental processes. Herein, we describe a fluorescence spectrometer in continuous flow mode in which the sample is fed to the flow cell using a peristaltic pump. The excitation beam is introduced to the sample chamber by an optical fiber. The fluorescence emitted upon excitation is collected at the right angle using another optical fiber and then transmitted to the fluorescence spectrometer which utilizes an array detector. The array detection, as a key factor in process analytical chemistry, made the fluorescence spectrometer suited for multiwavelength detection of the fluorescence spectrum of the analytes. After optimization of the experimental parameters, the system has been successfully employed for sensitive determination of four fluoroquinolone antibiotics such as ciprofloxacin, ofloxacin, levofloxacin, and moxifloxacin. The linear dynamic ranges of four fluoroquinolones were between 0.25 and 20 μg·mL-1, and the detection limit of the method for ciprofloxacin, ofloxacin, levofloxacin, and moxifloxacin were 81, 36, 35, and 93 ng·mL-1, respectively. Finally, the proposed system is carried out for determination of fluoroquinolones in some pharmaceutical formulations.

Fermentation for tailoring the technological and health related functionality of food products

Fermented foods are experiencing a resurgence due to the consumers' growing interest in foods that are natural and health promoting. Microbial fermentation is a biotechnological process which transforms food raw materials into palatable, nutritious and healthy food products. Fermentation imparts unique aroma, flavor and texture to food, improves digestibility, degrades anti-nutritional factors, toxins and allergens, converts phytochemicals such as polyphenols into more bioactive and bioavailable forms, and enriches the nutritional quality of food. Fermentation also modifies the physical functional properties of food materials, rendering them differentiated ingredients for use in formulated foods. The science of fermentation and the technological and health functionality of fermented foods is reviewed considering the growing interest worldwide in fermented foods and beverages and the huge potential of the technology for reducing food loss and improving nutritional food security.

Control and Monitoring of Milk Renneting Using FT-NIR Spectroscopy as a Process Analytical Technology Tool

Failures in milk coagulation during cheese manufacturing can lead to decreased yield, anomalous behaviour of cheese during storage, significant impact on cheese quality and process wastes. This study proposes a Process Analytical Technology approach based on FT-NIR spectroscopy for milk renneting control during cheese manufacturing. Multivariate Curve Resolution optimized by Alternating Least Squares (MCR-ALS) was used for data analysis and development of Multivariate Statistical Process Control (MSPC) charts. Fifteen renneting batches were set up varying temperature (30, 35, 40 °C), milk pH (6.3, 6.5, 6.7), and fat content (0.1, 2.55, 5 g/100 mL). Three failure batches were also considered. The MCR-ALS models well described the coagulation processes (explained variance ≥99.93%; lack of fit <0.63%; standard deviation of the residuals <0.0067). The three identified MCR-ALS profiles described the main renneting phases. Different shapes and timing of concentration profiles were related to changes in temperature, milk pH, and fat content. The innovative implementation of MSPC charts based on T² and Q statistics allowed the detection of coagulation failures from the initial phases of the process.