Characterization of thermophilic bacilli from a milk powder processing plant

Levels and types of microbial contaminants in different plant-based ingredients used in dairy alternatives

In this study levels and types of microbial contaminants were investigated in 88 different plant-based ingredients including many that are used to manufacture dairy alternatives. Studied ingredients encompassed samples of pulses (pea, faba bean, chickpea, and mung bean), cereals/pseudocereals (oat, rice, amaranth and quinoa) and drupes (coconut, almond and cashew). The microbial analysis included: i) total viable count (TVC), ii) total aerobic mesophilic spore count (TMS), iii) heat resistant aerobic thermophilic spore count (HRTS), iv) anaerobic sulfite reducing Clostridium spore count (SRCS), and v) Bacillus cereus spore count (BCES). Microorganisms isolated from the counting plates with the highest sample dilutions were identified using 16S rRNA and MALDI-TOF MS analyses. Many of the investigated ingredients showed a high proportion of spores as part of their total aerobic mesophilic counts. In 63 % of the samples, the difference between TVC and TMS counts was 1 Log10 unit or less. This was particularly the case for the majority of pea isolates and concentrates, faba bean isolates, oat kernels and flakes, and for single samples of chickpea isolate, almond, amaranth, rice, quinoa, and coconut flours. Concentrations of TVC ranged between <1.0 and 5.3 Log10 CFU/g in different samples, and TMS varied between <1.0 and 4.1 Log10 CFU/g. Levels of HTRS, BCES and SRCS were generally low, typically around or below the LOD of 1.0 Log10 CFU/g. In total, 845 individual bacterial colonies were isolated belonging to 33 different genera. Bacillus licheniformis and B. cereus group strains were most frequently detected among Bacillus isolates, and these species originated primarily from pea and oat samples. Geobacillus stearothermophilus was the main species encountered as part of the HRTS. Among the Clostridium isolates, Clostridum sporogenes/tepidum were predominant species, which were mostly found in pea and almond samples. Strains with potential to cause foodborne infection or intoxication were typed using the PCR-based method for toxin genes detection. In the B. cereus group, 9 % of isolates contained the ces gene, 28 % contained hbl, 42 % cytK, and 69 % were positive for the nhe gene. Absence of the boNT-A and -B genes was confirmed for all isolated C. sporogenes/tepidum strains. Nearly all (98 %) B. licheniformis isolates were positive for the lchAA gene. Insight into the occurrence of microbial contaminants in plant-based ingredients, combined with knowledge of their key inactivation and growth characteristics, can be used for the microbial risk assessment and effective design of plant-based food processing conditions and formulations to ensure food safety and prevent spoilage.

Flow of spore-forming bacteria between suppliers of dairy powders and users in some developing countries: challenges and perspectives

Abstract

Spore-forming bacteria are common contaminants of milk powder and processing lines and a major concern for the dairy industry. This dairy-associated microflora was studied extensively and well characterized in developed countries (exporters of milk powder), compared to developing countries (importers). Thereby, the quality issues affecting dairy powders and derived products are not fully controlled in developing countries. That is the case in Algeria, where recombined or reconstituted pasteurized milk is of low quality, reduced shelf-life, and the related dairies faced recurrent contaminations due to spores and biofilms. The transfer of spore-forming bacteria from exporters of dairy powders to importers in developing countries is an interesting topic, not thoroughly investigated. In addition, milk powder-based products are growing worldwide and their attributes, processes and technologies need to be better understood and controlled. This review analyzes issues affecting milk powder quality, based on few studies from developing countries in comparison with current knowledge, and emphasis on the case in Algeria. It provides information on how spore-forming bacteria and their biofilms affect the quality and shelf-life of recombined pasteurized milk produced in Algeria and compromise hygiene conditions in local dairy plants. Challenges and perspectives for better management of spore transfer from exporters of dairy powders to importers in developing countries are thereby outlined.

Highlights

The presence of spore-forming bacteria in milk powder is a serious safety issue.Spores are not well known, characterized and controlled in importers from developing countries.Spores cause recurrent contamination of pasteurized milk and biofilm issues in Algerian dairies.Challenges are how to reduce the flow of spores in milk powder trade.Perspectives on identification targeting predominant spores and improvement of biofilm removal.

Susceptibility of emetic and enterotoxigenic Bacillus cereus grown at high temperature to disinfectants

The prevalence of emetic strains in food products is rare; however, infection with these may be fatal to the vulnerable population. Bacterial control of the emetic Bacillus cereus strains is still unclear. This study aimed to assess the influence of high temperature on the disinfection of emetic and enterotoxigenic B. cereus. Emetic B. cereus strains survived up to 50 °C; the lag time and maximum growth rate were higher at 42 °C than those at 30 °C. Compared to enterotoxigenic B. cereus, all emetic food strains showed higher minimum inhibitory concentrations and minimum bactericidal concentrations for sodium hypochlorite and citric acid. The disinfectant susceptibility of the emetic B. cereus OS-05 strain incubated at a higher temperature did not increase and was maintained at the highest MBC value. In all emetic B. cereus strains, enterotoxin gene expression was upregulated at 42 °C and 45 °C. Increased ces gene expression was also found in emetic B. cereus strains GP-15 and OS-05, with upregulation of 128- and 820-fold at 42 °C. Thus, emetic B. cereus grown at high temperatures may resist common disinfectants of the food industry. The findings may help control B. cereus in food or the food processing industry.

Development of multi-species biofilm formed by thermophilic bacteria on stainless steel immerged in skimmed milk

Thermophilic bacteria, such as Bacillus licheniformis, Geobacillus stearothermophilus, Bacillus Subtilis and Anoxybacillus flavithermus, are detected frequently in milk powder products. Biofilms of those strains act as a major contamination to milk powder manufactures and pose potential risks in food safety. In this study, we explored the developing process of multi-species biofilm formed by the four thermophilic bacteria on stainless steel immerged in skimmed milk. The results showed that the thermophilic strains possessed strong capacities to decompose proteins and lactose in skimmed milk, and the spoilage effects were superimposed from multiple strains. B. licheniformis was the most predominant species in the mixed-species biofilm after 12-h incubation. From 24 h to 48 h, G. stearothermophilus occupied the highest proportion. Within the multi-species biofilm, competitive relation existed between B. licheniformis and G. stearothermophilus, while synergistic impacts were observed between B. licheniformis and A. flavithermus. The interspecies mutual influences on biofilm development provided important evidences for understanding colonization of the predominant thermophilic bacteria during milk powder processing.

Development and validation of an extended predictive model for the effect of pH and water activity on the growth kinetics of Geobacillus stearothermophilus in plant-based milk alternatives

The cardinal model for the effect of temperature on Geobacillus stearothermophilus ATCC 7953 growth developed by Kakagianni, Gougouli, & Koutsoumanis, 2016 was expanded for the effect of pH and water activity (a_w). The effect of pH (range: 5.7-8.5) and a_w (range: 0.985-0.999) on G. stearothermophilus growth rate was studied in tryptone soy broth (TSB) using the Bioscreen C method and further modelled using a Cardinal Model (CM). The estimated values for the cardinal parameters [Formula: see text] , and [Formula: see text] were 5.65 ± 0.14, 6.74 ± 0.03, 8.71 ± 0.03, 0.984 ± 0.007 and 0.998 ± 0.001, respectively. The growth behaviour of G. stearothermophilus was investigated in 7 commercial non-refrigerated plant-based milk alternatives under static conditions (62 °C) and the estimated maximum specific growth rates were used to determine the optimum growth rate for each product. The developed model was validated against observed growth of G. stearothermophilus in the 7 products during storage at non-isothermal conditions (testing 4 different temperature profiles). The validation results showed a good performance of the model with overall Bias factor (B_f) = 1.06 and Accuracy factor (A_f) = 1.12. The developed model can be used as an effective tool by the food industry in predicting spoilage of plant-based milk alternatives during distribution and storage at retail and domestic levels.

Influence of the incubation temperature and total dissolved solids concentration on the biofilm and spore formation of dairy isolates of Geobacillus stearothermophilus

Geobacillus species are an important contaminant in the dairy industry and their presence is often considered as an indicator of poor plant hygiene with the potential to cause spoilage. They can form heat resistant spores that adhere to surfaces of processing equipment and germinate to form biofilms. Therefore, strategies aimed towards preventing or controlling biofilm formation in the dairy industry are desirable. In this study we demonstrate that the preferred temperature for biofilm and spore formation among Geobacillus stearothermophilus A1, D1, P3 and ATCC 12980 was 65°C. Increasing the total dissolved milk solids concentration to 20% (w/v) caused an apparent delay in the onset of biofilm and spore formation to detectable concentrations among all the strains at 55°C. Compared to the onset time of the biofilm formation of A1 in 10% (w/v) reconstituted skim milk, addition of milk protein (whey protein and sodium caseinate) caused an apparent delay in the onset of biofilm formation to detectable concentrations by an average of 10 h at 55°C. This study proposes that temperature and total dissolved solids concentration have a cumulative effect on the biofilm and spore formation of G. stearothermophilus A1, D1, P3 and ATCC 12980. In addition, the findings from this study may indicate that preconditioning of stainless-steel surface with adsorbed milk proteins may delay the onset of biofilm and spore formation of thermophilic bacteria during milk powder manufacture.IMPORTANCE The thermophilic bacilli, Geobacillus stearothermophilus is a predominant spoilage bacterium in milk powder manufacturing plants. If their numbers exceed the accepted levels, this may incur financial loses by lowering the price of the end product. Furthermore, they can form heat resistant spores which adhere to processing surfaces and can germinate to form biofilms. Previously conducted research had highlighted the variation in the spore and biofilm formation among three specific strains of G. stearothermophilus isolated from a milk powder manufacturing plant in New Zealand. The significance of our research is demonstrating the effect of two abiotic factors namely temperature and total dissolved solids concentration on the biofilm and spore formation of these three dairy isolates, leading to modifications in the thermal processing steps aimed towards controlling the biofilm and spore formation of G. stearothermophilus in the dairy industry.

Biofilm-Forming Ability and Effect of Sanitation Agents on Biofilm-Control of Thermophile Geobacillus sp. D413 and Geobacillus toebii E134

Geobacillus sp. D413 and Geobacillus toebii E134 are aerobic, non-pathogenic, endospore-forming, obligately thermophilic bacilli. Gram-positive thermophilic bacilli can produce heat-resistant spores. The bacteria are indicator organisms for assessing the manufacturing process’s hygiene and are capable of forming biofilms on surfaces used in industrial sectors. The present study aimed to determine the biofilm-forming properties of Geobacillus isolates and how to eliminate this formation with sanitation agents. According to the results, extracellular DNA (eDNA) was interestingly not affected by the DNase I, RNase A, and proteinase K. However, the genomic DNA (gDNA) was degraded by only DNase I. It seemed that the eDNA had resistance to DNase I when purified. It is considered that the enzymes could not reach the target eDNA. Moreover, the eDNA resistance may result from the conserved folded structure of eDNA after purification. Another assumption is that the eDNA might be protected by other extracellular polymeric substances (EPS) and/or extracellular membrane vesicles (EVs) structures. On the contrary, DNase I reduced unpurified eDNA (mature biofilms). Biofilm formation on surfaces used in industrial areas was investigated in this work: the D413 and E134 isolates adhered to all surfaces. Various sanitation agents could control biofilms of Geobacillus isolates. The best results were provided by nisin for D413 (80%) and α-amylase for E134 (98%). This paper suggests that sanitation agents could be a solution to control biofilm structures of thermophilic bacilli.

Tracking the Dairy Microbiota from Farm Bulk Tank to Skimmed Milk Powder

Microorganisms from the environment can enter the dairy supply chain at multiple stages, including production, milk collection, and processing, with potential implications for quality and safety. The ability to track these microorganisms can be greatly enhanced by the use of high-throughput DNA sequencing (HTS). Here HTS, both 16S rRNA gene amplicon and shotgun metagenomic sequencing were applied to investigate the microbiomes of fresh mid- and late-lactation milk collected from farm bulk tanks, collection tankers, milk silos, skimmed milk silos, a cream silo, and powder samples to investigate the microbial changes throughout a skim milk powder manufacturing process. 16S rRNA gene analysis established that the microbiota of raw milks from farm bulk tanks and in collection tankers were very diverse but that psychrotrophic genera associated with spoilage, Pseudomonas and Acinetobacter, were present in all samples. Upon storage within the whole-milk silo at the processing facility, the species Pseudomonas fluorescens and Acinetobacter baumannii became dominant. The skimmed milk powder generated during the mid-lactation period had a microbial composition that was very different from that of raw milk; specifically, two thermophilic genera, Thermus and Geobacillus, were enriched. In contrast, the microbiota of skimmed milk powder generated from late-lactation milk more closely resembled that of the raw milk and was dominated by spoilage-associated psychrotrophic bacteria. This study demonstrates that the dairy microbiota can differ significantly across different sampling days. More specifically, HTS can be used to trace microbial species from raw milks through processing to final powdered products.IMPORTANCE Microorganisms can enter and persist in dairy at several stages of the processing chain. Detection of microorganisms within dairy food processing is currently a time-consuming and often inaccurate process. This study provides evidence that high-throughput sequencing can be used as an effective tool to accurately identify microorganisms along the processing chain. In addition, it demonstrates that the populations of microbes change from raw milk to the end product. Routine implementation of high-throughput sequencing would elucidate the factors that influence population dynamics. This will enable a manufacturer to adopt control measures specific to each stage of processing and respond in an effective manner, which would ultimately lead to increased food safety and quality.

The effect of phosphate on the heat resistance of spores of dairy isolates of Geobacillus stearothermophilus

In this study, we show that phosphate decreases the spore heat resistance by accelerating the rate of loss of cations from spores. Heat resistance of spores of Geobacillus stearothermophilus A1, D1, P3 and ATCC 12980 were determined in distilled water containing varying concentrations (0.1, 1 and 2% w/v) of di‑sodium phosphate. The average decimal reduction times (D value) for strains A1, D1, P3 and ATCC 12980 in distilled water were 5.8, 6.8, 5.7 and 9 min at 110 °C respectively. On the addition of 0.1, 1 and 2% w/v of di‑sodium phosphate, the average D₁₁₀ values of all the strains in distilled water were lowered by 50, 61 and 70% respectively. Addition of 0.05% w/v of Na-EDTA to distilled water resulted in lowering of the average D₁₁₀ value of all the strains by 55%. Heat resistance of spores of A1, D1, P3 and ATCC 12980 was found to be associated with the Dipicolinic Acid (DPA) content whose concentrations were 0.25, 0.30, 0.27 and 1.6 pg per spore respectively. Analysis by atomic absorption spectroscopy revealed that the phosphate present in the heating medium causes excess release of calcium from spores with 2% w/v phosphate being highly effective, thus confirming the chelating effect of phosphate. This study provides insight into the heat resistance and the increased heat sensitivity of spores of G. stearothermophilus A1, D1 and P3 in the presence of phosphate, which can be used in the design of Cleaning in Place (CIP) systems involving phosphate based cleaning agents to combat biofilms and spores in the dairy industry.

Bactéries sporulées et biofilms : un problème récurrent dans les lignes de production de lait reconstitué ou recombiné pasteurisé

In the dairy industry, bacterial contaminants persist on equipment surfaces due to spore and biofilm formation. These are involved in cross-contamination problems that affect the quality of processed products and limit their life. The pasteurization process, in which milk is submitted to moderate heat treatment, is inefficient against bacterial spores. The most prevalent sporulated bacteria belong to Bacillus and related genera. The situation is more complicated in countries where pasteurized milk is derived from imported milk powder originally contaminated by bacterial spores. Studies have shown biofilm formation on dairy equipment by mesophilic strains from the group Bacillus cereus and thermophilic strains from the genus Geobacillus. These biofilms are resistant to cleaning procedures and are sources of chronic contamination of pasteurized milk. This review analyzes the dairy situation in Algeria exposed to sporulated flora and derived biofilm problems, with the aim of proposing efficient solutions in the light of current knowledge. [Journal translation].

Peculiarities and biotechnological potential of environmental adaptation by Geobacillus species

The genus Geobacillus comprises thermophilic bacilli capable of endospore formation. The members of this genus provide thermostable proteins and can be used in whole cell applications at elevated temperatures; therefore, these organisms are of biotechnological importance. While these applications have been described in previous reviews, the present paper highlights the environmental adaptations and genome diversifications of Geobacillus spp. and their applications in evolutionary-protein engineering. Despite their obligate thermophilic properties, Geobacillus spp. are widely distributed in nature. Because several isolates demonstrate remarkable properties for cell reproduction in their respective niches, they seem to exist not only as endospores but also as vegetative cells in diverse environments. This suggests their excellence in environmental adaptation via genome diversification; in fact, evidence suggests that Geobacillus spp. were derived from Bacillus spp. while diversifying their genomes via horizontal gene transfer. Moreover, when subjected to an environmental stressor, Geobacillus spp. diversify their genomes using inductive mutations and transposable elements to produce derivative cells that are adaptive to the stressor. Notably, inductive mutations in Geobacillus spp. occur more rapidly and frequently than the stress-induced mutagenesis observed in other microorganisms. Owing to this, Geobacillus spp. can efficiently generate mutant genes coding for thermostable enzyme variants from the thermolabile enzyme genes under appropriate selection pressures. This phenomenon provides a new approach to generate thermostable enzymes, termed as thermoadaptation-directed enzyme evolution, thereby expanding the biotechnological potentials of Geobacillus spp. In this review, we have discussed this approach using successful examples and major challenges yet to be addressed.

Insights into the Geobacillus stearothermophilus species based on phylogenomic principles

BACKGROUND

The genus Geobacillus comprises bacteria that are Gram positive, thermophilic spore-formers, which are found in a variety of environments from hot-springs, cool soils, to food manufacturing plants, including dairy manufacturing plants. Despite considerable interest in the use of Geobacillus spp. for biotechnological applications, the taxonomy of this genus is unclear, in part because of differences in DNA-DNA hybridization (DDH) similarity values between studies. In addition, it is also difficult to use phenotypic characteristics to define a bacterial species. For example, G. stearothermophilus was traditionally defined as a species that does not utilise lactose, but the ability of dairy strains of G. stearothermophilus to use lactose has now been well established.

RESULTS

This study compared the genome sequences of 63 Geobacillus isolates and showed that based on two different genomic approaches (core genome comparisons and average nucleotide identity) the Geobacillus genus could be divided into sixteen taxa for those Geobacillus strains that have genome sequences available thus far. In addition, using Geobacillus stearothermophilus as an example, we show that inclusion of the accessory genome, as well as phenotypic characteristics, is not suitable for defining this species. For example, this is the first study to provide evidence of dairy adaptation in G. stearothermophilus - a phenotypic feature not typically considered standard in this species - by identifying the presence of a putative lac operon in four dairy strains.

CONCLUSIONS

The traditional polyphasic approach of combining both genotypic and phenotypic characteristics to define a bacterial species could not be used for G. stearothermophilus where many phenotypic characteristics vary within this taxon. Further evidence of this discordant use of phenotypic traits was provided by analysis of the accessory genome, where the dairy strains contained a putative lac operon. Based on the findings from this study, we recommend that novel bacterial species should be defined using a core genome approach.

The Prevalence and Control of Bacillus and Related Spore-Forming Bacteria in the Dairy Industry

Milk produced in udder cells is sterile but due to its high nutrient content, it can be a good growth substrate for contaminating bacteria. The quality of milk is monitored via somatic cell counts and total bacterial counts, with prescribed regulatory limits to ensure quality and safety. Bacterial contaminants can cause disease, or spoilage of milk and its secondary products. Aerobic spore-forming bacteria, such as those from the genera Sporosarcina, Paenisporosarcina, Brevibacillus, Paenibacillus, Geobacillus and Bacillus, are a particular concern in this regard as they are able to survive industrial pasteurization and form biofilms within pipes and stainless steel equipment. These single or multiple-species biofilms become a reservoir of spoilage microorganisms and a cycle of contamination can be initiated. Indeed, previous studies have highlighted that these microorganisms are highly prevalent in dead ends, corners, cracks, crevices, gaskets, valves and the joints of stainless steel equipment used in the dairy manufacturing plants. Hence, adequate monitoring and control measures are essential to prevent spoilage and ensure consumer safety. Common controlling approaches include specific cleaning-in-place processes, chemical and biological biocides and other novel methods. In this review, we highlight the problems caused by these microorganisms, and discuss issues relating to their prevalence, monitoring thereof and control with respect to the dairy industry.

Draft Genome Sequences of Three Strains of Geobacillus stearothermophilus Isolated from a Milk Powder Manufacturing Plant

Three strains of Geobacillus stearothermophilus (designated A1, P3, and D1) were isolated from a New Zealand milk powder manufacturing plant. Here, we describe their draft genome sequences. This information provided the first genomic insights into the nature of G. stearothermophilus strains present in the milk powder manufacturing environment.

Changes in Sodium, Calcium, and Magnesium Ion Concentrations That Inhibit Geobacillus Biofilms Have No Effect on Anoxybacillus flavithermus Biofilms

This study investigated the effects of varied sodium, calcium, and magnesium concentrations in specialty milk formulations on biofilm formation by Geobacillus spp. and Anoxybacillus flavithermus. The numbers of attached viable cells (log CFU per square centimeter) after 6 to 18 h of biofilm formation by three dairy-derived strains of Geobacillus and three dairy-derived strains of A. flavithermus were compared in two commercial milk formulations. Milk formulation B had relatively high sodium and low calcium and magnesium concentrations compared with those of milk formulation A, but the two formulations had comparable fat, protein, and lactose concentrations. Biofilm formation by the three Geobacillus isolates was up to 4 log CFU cm(-2) lower in milk formulation B than in milk formulation A after 6 to 18 h, and the difference was often significant (P ≤ 0.05). However, no significant differences (P ≤ 0.05) were found when biofilm formations by the three A. flavithermus isolates were compared in milk formulations A and B. Supplementation of milk formulation A with 100 mM NaCl significantly decreased (P ≤ 0.05) Geobacillus biofilm formation after 6 to 10 h. Furthermore, supplementation of milk formulation B with 2 mM CaCl2 or 2 mM MgCl2 significantly increased (P ≤ 0.05) Geobacillus biofilm formation after 10 to 18 h. It was concluded that relatively high free Na(+) and low free Ca(2+) and Mg(2+) concentrations in milk formulations are collectively required to inhibit biofilm formation by Geobacillus spp., whereas biofilm formation by A. flavithermus is not impacted by typical cation concentration differences of milk formulations.