Pilot-scale crossflow-microfiltration and pasteurization to remove spores of Bacillus anthracis (Sterne) from milk

Application of Membrane Filtration to Cold Sterilization of Drinks and Establishment of Aseptic Workshop

Aseptic packaging of high quality beverage is necessary and its cold-pasteurization or sterilization is vital. Studies on application of ultrafiltration or microfiltration membrane to cold- pasteurization or sterilization for the aseptic packaging of beverages have been reviewed. Designing and manufacturing ultrafiltration or microfiltration membrane systems for cold-pasteurization or sterilization of beverage are based on the understanding of size of microorganisms and theoretical achievement of filtration. It is concluded that adaptability of membrane filtration, especially its combination with other safe cold method, to cold- pasteurization and sterilization for the aseptic packaging of beverages should be assured without a shadow of doubt in future.

Non-thermal Processing Technologies for Dairy Products: Their Effect on Safety and Quality Characteristics

Thermal treatment has always been the processing method of choice for food treatment in order to make it safe for consumption and to extend its shelf life. Over the past years non-thermal processing technologies are gaining momentum and they have been utilized especially as technological advancements have made upscaling and continuous treatment possible. Additionally, non-thermal treatments are usually environmentally friendly and energy-efficient, hence sustainable. On the other hand, challenges exist; initial cost of some non-thermal processes is high, the microbial inactivation needs to be continuously assessed and verified, application to both to solid and liquid foods is not always available, some organoleptic characteristics might be affected. The combination of thermal and non-thermal processing methods that will produce safe foods with minimal effect on nutrients and quality characteristics, while improving the environmental/energy fingerprint might be more plausible.

The Use of Membrane Filtration to Increase Native Whey Proteins in Infant Formula

The introduction of membrane filtration during infant milk formula (IMF) processing represents an innovative approach to increasing native protein content compared to standard IMF. The objective of this study was to compare IMF powder produced using a standard process and IMF produced from raw bovine skim milk with added whey protein isolate using a split-stream process incorporating a ceramic 1.4 μm filter followed by a polyvinylidene difluoride polymeric 0.2 μm filter. Retentates from 0.2 μm microfiltration (MF) were blended with fat, lactose, and minerals and subsequently high-temperature treated (125 °C × 5 s). The heat-treated retentate was merged with the permeate from the 0.2 μm MF, homogenised, and spray-dried (referred to as membrane-filtered IMF or MEM-IMF). A control IMF was also produced using standard treatment (referred to as high-temperature IMF or HT-IMF) without membrane filtration. Both IMF products were characterised by high-performance liquid chromatography, particle size, and enzyme activity assays. MEM-IMF powder had significantly higher amounts of native (1.1 g per 100 g powder) and monomeric (1.48 g per 100 g powder) whey proteins when compared to 0.18 and 0.46 g per 100 g powder in HT-IMF, respectively. MEM-IMF also exhibited a lower degree of protein aggregation compared to HT-IMF. Comparison of microbial and Maillard by-products markers demonstrated that a safe IMF product could be produced at scale, although levels of the Maillard by-product marker, carboxymethyl-lysine, were not significantly reduced in MEM-IMF. This study demonstrates how membrane filtration can be used to retain native proteins during IMF manufacture.

Modeling and Optimization of Gas Sparging-Assisted Bacterial Cultivation Broth Microfiltration by Response Surface Methodology and Genetic Algorithm

Production of highly efficient biomass-based microbial biopesticides significantly depends on downstream processing in terms of obtaining as high concentration of viable cells as possible. Microfiltration is one of the recommended operations for microbial biomass separation, but its main limitation is permeate flux decrease due to the membrane fouling. The effect of air sparging as a hydrodynamic technique for improvement of permeate flux during microfiltration of Bacillus velezensis cultivation broth was investigated. Modeling of the microfiltration was performed using the response surface methodology, while desirability function approach and genetic algorithm were applied for optimization, i.e., maximization of permeate flux and minimization of specific energy consumption. The results have revealed antagonistic relationship between the investigated dependent variables. The optimized values of superficial feed velocity and transmembrane pressure were close to the mean values of the investigated value ranges (0.68 bar and 0.96 m/s, respectively), while the optimized value of superficial air velocity had a more narrow distribution around 0.25 m/s. The results of this study have revealed a significant improvement of microfiltration performance by applying air sparging, thus this flux improvement method should be further investigated in downstream processing of different bacterial cultivation broths.

A Human Milk-Based Protein Concentrate Developed for Preterm Infants Retains Bioactive Proteins and Supports Growth of Weanling Rats

BACKGROUND

Bovine milk-based protein modulars are currently available to nutrient-enrich enteral feedings; however, they have limitations for use in very-low-birth-weight infants.

OBJECTIVES

Our objectives were to develop a human milk-based protein (HMP) concentrate and to conduct a preclinical assessment of the HMP concentrate in weanling rats.

METHODS

An HMP concentrate was produced from donor milk using pressure-driven membrane filtration processes and high hydrostatic pressure processing. Protein and lactoferrin concentrations and lysozyme activity were determined by Kjeldahl, HPLC, and turbidimetric assay, respectively. Male Sprague Dawley rats 24 d old (n = 30) were randomly assigned to 1 of 3 isocaloric AIN-93G diets for 4 wk containing 100% casein (control) or with 50% of the casein replaced with the HMP concentrate (treatment) or a bovine whey protein isolate (treatment). Body weight, food intake, fat mass, plasma amino acid profiles, and organ weights were measured. Data were analyzed using linear regression models.

RESULTS

Raw donor milk contained (mean ± SD) 101 ± 6 g protein/kg and 5 ± 1 g lactoferrin/kg of milk solids. Postprocessing, protein and lactoferrin concentrations were 589 ± 3 g/kg and 29 ± 10 g/kg, respectively. Lysozyme activity was initially 209 ± 4 U/kg and increased to 959 ± 39 U/kg in the HMP concentrate. There were no statistically significant differences in body weight, food intake, fat mass, or plasma amino acid profiles between rats fed diets containing the HMP concentrate and the control diet. Full cecum weights were higher in rats fed the HMP concentrate than in those fed control diets (mean difference: 5.59 g; 95% CI: 4.50, 6.68 g; P < 0.0001), likely reflecting the concentration of human milk oligosaccharides. No differences were found for other organ weights.

CONCLUSIONS

The HMP concentrate retained important bioactive proteins and supported normal rat growth in the preclinical assessment.

Semi-industrial production of a minimally processed infant formula powder using membrane filtration

Infant formula (IF) is submitted to several heat treatments during production, which can lead to denaturation or aggregation of proteins and promote Maillard reaction. The objective of this study was to investigate innovative minimal processing routes for the production of first-age IF powder, thus ensuring microbial safety with minimal level of protein denaturation. Three nutritionally complete IF powders were produced at a semi-industrial scale based on ingredients obtained by fresh bovine milk microfiltration (0.8 and 0.1-µm pore size membranes). Low-temperature vacuum evaporation (50°C) and spray-drying (inlet and outlet temperatures of 160 and 70°C, respectively) were conducted to produce the T- formula with no additional heat treatment. The T+ formula was produced with a moderate heat treatment (75°C for 2 min) applied before spray-drying, whereas the T+++ formula received successive heat treatments (72°C for 30 s on the milk; 90°C for 2-3 s before evaporation; 85°C for 2 min before spray-drying), thus mimicking commercial powdered IF. Protein denaturation and Maillard reaction products were followed throughout the production steps and the physicochemical properties of the powders were characterized. The 3 IF powders presented satisfactory physical properties in terms of a_w, free fat content, glass transition temperature, and solubility index, as well as satisfactory bacteriological quality with a total flora <10³ cfu/g and an absence of pathogens when a high level of bacteriological quality of the ingredients was ensured. Protein denaturation occurred mostly during the heat treatments of T+ and T+++ and was limited during the spray-drying process. The IF powder produced without heat treatment (T-) presented a protein denaturation extent (6 ± 4%) significantly lower than that in T+++ (58 ± 0%), but not significantly different from that in T+ (10 ± 4%). Although T- tended to contain less Maillard reaction products than T+ and T+++, the Maillard reaction products did not significantly discriminate the infant formulas in the frame of this work. The present study demonstrated the feasibility of producing at a semi-industrial scale an infant formula being bacteriologically safe and containing a high content of native proteins. Application of a moderate heat treatment before spray-drying could further guarantee the microbiological quality of the IF powders while maintaining a low protein denaturation extent. This study opens up new avenues for the production of minimally processed IF powders.

Clarification of 1,3-Propanediol Fermentation Broths by Using a Ceramic Fine UF Membrane

This work examined the use of a ceramic fine ultrafiltration (UF) membrane for the pre-treatment of 1,3-propanodiol (1,3-PD) fermentation broths. It has been demonstrated that the membrane used provides obtaining a high-quality, sterile permeate, which can be sequentially separated by other processes such as nanofiltration (NF) and membrane distillation (MD). Special attention was paid to the impact of the operational parameters on the membrane performance. The series of UF experiments under transmembrane pressure (TMP) from 0.1 to 0.4 MPa and feed flow rate (Q) from 200 to 400 dm3/h were performed. Moreover, the impact of the feed pH, in the range from 5 to 10, on the flux was investigated. It has been demonstrated that for fine UF, increasing the TMP is beneficial, and TMP equal to 0.4 MPa and Q of 400 dm3/h ensure the highest flux and its long-term stability. It has been shown that in terms of process efficiency, the most favorable pH of the broths is equal to 9.4. An effective and simple method of membrane cleaning was presented. Finally, the resistance-in-series model was applied to describe resistances that cause flux decline. Results obtained in this study can assist in improving the cost-effectiveness of the UF process of 1,3-PD fermentation broths.

Cross-Flow Microfiltration of Glycerol Fermentation Broths with Citrobacter freundii

This paper reports the study of the cross-flow microfiltration (MF) of glycerol fermentation broths with Citrobacter freundii bacteria. A single channel tubular ceramic membrane with a nominal pore size of 0.14 µm was used. It has been demonstrated that the MF ceramic membrane has been successfully applied to bacteria cell removal and to effectively eliminate colloidal particles from glycerol fermentation broths. However, due to fouling, the significant reduction of the MF performance has been demonstrated. In order to investigate the impact of transmembrane pressure (TMP) and feed flow rate (Q) on MF performance, 24 experiments have been performed. The highest steady state permeate flux (138.97 dm3/m2h) was achieved for 0.12 MPa and 1000 dm3/h. Fouling analysis has been studied based on the resistance-in series model. It has been found that the percentage of irreversible fouling resistance during the MF increases with increasing TMP and Q. The permeate flux regeneration has been achieved by membrane cleaning with 3 wt % NaOH and 3 wt % H3PO4 at 45 °C. The results of this study are expected to be useful in industrially employing the MF process as the first step of glycerol fermentation broth purification.

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].

Multi-Layer Filters: Adsorption and Filtration Mechanisms for Improved Separation

Filters made of cellulose fiber and perlite particles were prepared using a wet laying papermaking technique. Polyamide-amine-epichlorohydrin (PAE) was added to provide wet strength. Filters were prepared at two different total basis weights of 200 and 400 grams per square meter (gsm). Single and multi-layered filters were structured for each total basis weights. The effect of total basis weights and multi-layered structure on methylene blue adsorption and silicon dioxide (SiO₂) particle filtration was investigated. Methylene blue adsorption was performed in two modes: constant pressure and constant flow rate. In both operation modes, the adsorption capacity of multi-layered filters was significantly higher (16–100%) than for single-layer filters at the same overall weight. The effect of layer separation was also characterized using polypropylene separators and tested under constant flow rate operation. Separators provided more effective methylene blue adsorption by generating a well-distributed flow. Filtration performance was quantified with 0.5 μm silicon dioxide particles under constant pressure conditions; this is to mimic bacteria rejection. Filtration capability of SiO₂ particles was reduced slightly (12%) with decreasing individual filter layer thickness regardless of the multi-layered structure. Filtering polyethylene glycol (PEG) molecules with two different molecular weights was performed; however, no rejection was recorded. The filter internal pore structure was visualized by 3D-X ray computed tomography and the void fraction was quantified. 400 gsm single layer presented areas of low fiber density forming pores, while the pore volume decreased for thinner filter layers.

Spoilage of Microfiltered and Pasteurized Extended Shelf Life Milk Is Mainly Induced by Psychrotolerant Spore-Forming Bacteria that often Originate from Recontamination

Premature spoilage and varying product quality due to microbial contamination still constitute major problems in the production of microfiltered and pasteurized extended shelf life (ESL) milk. Spoilage-associated bacteria may enter the product either as part of the raw milk microbiota or as recontaminants in the dairy plant. To identify spoilage-inducing bacteria and their routes of entry, we analyzed end products for their predominant microbiota as well as the prevalence and biodiversity of psychrotolerant spores in bulk tank milk. Process analyses were performed to determine the removal of psychrotolerant spores at each production step. To detect transmission and recontamination events, strain typing was conducted with isolates obtained from all process stages. Microbial counts in 287 ESL milk packages at the end of shelf life were highly diverse ranging from <1 to 7.9 log cfu/mL. In total, 15% of samples were spoiled. High G+C Gram-positive bacteria were the most abundant taxonomic group, but were responsible for only 31% of spoilage. In contrast, psychrotolerant spores were isolated from 55% of spoiled packages. In 90% of samples with pure cultures of Bacillus cereus sensu lato and Paenibacillus spp., counts exceeded 6 log cfu/mL. In bulk tank milk, the concentration of psychrotolerant spores was low, accounting for merely 0.5 ± 0.8 MPN/mL. Paenibacillus amylolyticus/xylanexedens was by far the most dominant species in bulk tank milk (48% of all isolates), but was never detected in ESL milk, pointing to efficient removal during manufacturing. Six large-scale process analyses confirmed a high removal rate for psychrotolerant spores (reduction by nearly 4 log-units). B. cereus sensu lato, on the contrary, was frequently found in spoiled end products, but was rarely detected in bulk tank milk. Due to low counts in bulk tank samples and efficient spore removal during production, we suggest that shelf life is influenced only to a minor extent by raw-milk-associated factors. In contrast, recontamination with spores, particularly from the B. cereus complex, seems to occur. To enhance milk quality throughout the entire shelf life, improved plant sanitation and disinfection that target the elimination of spores are necessary.

Computer simulation of energy use, greenhouse gas emissions, and costs for alternative methods of processing fluid milk

Computer simulation is a useful tool for benchmarking electrical and fuel energy consumption and water use in a fluid milk plant. In this study, a computer simulation model of the fluid milk process based on high temperature, short time (HTST) pasteurization was extended to include models for processes for shelf-stable milk and extended shelf-life milk that may help prevent the loss or waste of milk that leads to increases in the greenhouse gas (GHG) emissions for fluid milk. The models were for UHT processing, crossflow microfiltration (MF) without HTST pasteurization, crossflow MF followed by HTST pasteurization (MF/HTST), crossflow MF/HTST with partial homogenization, and pulsed electric field (PEF) processing, and were incorporated into the existing model for the fluid milk process. Simulation trials were conducted assuming a production rate for the plants of 113.6 million liters of milk per year to produce only whole milk (3.25%) and 40% cream. Results showed that GHG emissions in the form of process-related CO₂ emissions, defined as CO₂ equivalents (e)/kg of raw milk processed (RMP), and specific energy consumptions (SEC) for electricity and natural gas use for the HTST process alone were 37.6g of CO₂e/kg of RMP, 0.14 MJ/kg of RMP, and 0.13 MJ/kg of RMP, respectively. Emissions of CO2 and SEC for electricity and natural gas use were highest for the PEF process, with values of 99.1g of CO₂e/kg of RMP, 0.44 MJ/kg of RMP, and 0.10 MJ/kg of RMP, respectively, and lowest for the UHT process at 31.4 g of CO₂e/kg of RMP, 0.10 MJ/kg of RMP, and 0.17 MJ/kg of RMP. Estimated unit production costs associated with the various processes were lowest for the HTST process and MF/HTST with partial homogenization at $0.507/L and highest for the UHT process at $0.60/L. The increase in shelf life associated with the UHT and MF processes may eliminate some of the supply chain product and consumer losses and waste of milk and compensate for the small increases in GHG emissions or total SEC noted for these processes compared with HTST pasteurization alone. The water use calculated for the HTST and PEF processes were both 0.245 kg of water/kg of RMP. The highest water use was associated with the MF/HTST process, which required 0.333 kg of water/kg of RMP, with the additional water required for membrane cleaning. The simulation model is a benchmarking framework for current plant operations and a tool for evaluating the costs of process upgrades and new technologies that improve energy efficiency and water savings.

Uso de microfiltração para melhoria da qualidade e extensão da vida de prateleira de leite pasteurizado

A microfiltração é uma das tecnologias utilizadas para melhorar a qualidade do leite fluido. O objetivo dessa revisão é abordar o uso da microfiltração do leite para estender sua vida de prateleira. A importância da qualidade do leite cru (microorganismos contaminantes e enzimas naturais do leite, provenientes das células somáticas ou do crescimento dos microrganismos psicrotróficos) e as condições de estocagem do leite cru (refrigeração), que são decisivas para a qualidade e vida de prateleira do leite pasteurizado, também serão discutidas. São mencionados os progressos já obtidos e em desenvolvimento da tecnologia de microfiltração para a extensão da vida de prateleira do leite pasteurizado e a importância da microfiltração para manter as características nutricionais do leite. Ainda serão descritos os problemas associados com incrustações da membrana que afetam o seu desempenho.