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Transcript of Food Engineering Final Paper
1
AN ALTERNATIVE METHOD AND DESIGN TO INACTIVATE BIOLOGICAL CONTAMINANTS IN
MILK BY PULSED ELECTRIC FIELD TREATMENT FOR SMALL-SCALE MILK OPERATIONS
Department of Bioresource Engineering, Macdonald Campus, McGill University, Ste.-Anne-de-Bellevue,
Quebec
C. Jang, I. Han, E. Riskulov, T. Rajchgot, D. Stanger
*16 Pages Before the Appendix
ABSTRACT
Presented is an alternative method and design to conventional heat treatment of milk for a small scale
milk operation. The literature review aimed to understand the limits of standard pasteurization and to
explore better treatment methods. Several treatment methods were researched and analyzed to
ascertain an optimal treatment for milk. The PEF method was found to be optimal on the grounds that it
optimally addressed objective of treating raw milk for a small-scale operation without altering the
desired natural qualities of the product, while at the same time mitigating the associated health risks
and ensuring the safety of consumers. A design section is provided which describes the flow design, PEF
design parameters, and pump design.
CONTENTS
Abstract .................................................................................................................................................................... 1
Contents ................................................................................................................................................................... 1
1. Introduction.......................................................................................................................................................... 2
2.0 an Overview of Raw and Pasteurized Milk .......................................................................................................... 3
Pasteurization Definition ...................................................................................................................................... 4
3.0 Literature Review of Alternative Technologies .................................................................................................... 4
3.1 Batch Pasteurization ....................................................................................................................................... 4
3.2 Microwave Treatment .................................................................................................................................... 5
Introduction ...................................................................................................................................................... 5
Mechanism of Inactivation ................................................................................................................................ 5
Food Safety ....................................................................................................................................................... 5
Food Quality ..................................................................................................................................................... 6
3.3 Pulsed Electric Field (PEF) Processing .............................................................................................................. 6
2
Introduction ...................................................................................................................................................... 6
Mechanism of inactivation ................................................................................................................................ 6
Food Safety ....................................................................................................................................................... 7
Food Quality ..................................................................................................................................................... 8
3.4 High Pressure Processing (HPP) ....................................................................................................................... 8
Introduction ...................................................................................................................................................... 8
Food Safety ..................................................................................................................................................... 10
Food Quality ................................................................................................................................................... 11
3.6 Ultraviolet Processing ................................................................................................................................... 11
Introduction .................................................................................................................................................... 11
Mechanism of Operation ................................................................................................................................ 12
Efficiency ........................................................................................................................................................ 13
Food Safety ..................................................................................................................................................... 13
Food Quality ................................................................................................................................................... 13
4. Design................................................................................................................................................................. 14
Final Design ........................................................................................................................................................ 14
Process ........................................................................................................................................................... 15
Flow Design .................................................................................................................................................... 15
Pump Design ................................................................................................................................................... 16
PEF Design ...................................................................................................................................................... 16
5. Conclusion .......................................................................................................................................................... 16
6. APPENDIX ........................................................................................................................................................... 18
7. Works Cited ........................................................................................................................................................ 20
1. INTRODUCTION
Dairy is and has been a large, if not the primary, source
of nutrition for mammals throughout history. Raw milk
was the principal form of milk before the development
of extensive processing systems in the 1930s (Potter,
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1984). Raw milk and its derivatives are still highly
popular in several European countries, such as France,
with growing popularity in North America due to a
growing “consuming natural and/or local” trend (Claeys
et al., 2012). Raw milk has been linked to several
outbreaks of disease stemming from microbial sources
throughout history, and as a result dairy is
conventionally treated with heat to kill pathogenic
microbes. Despite the inherent health risks associated
with the ingestion of raw milk, it is advocated that raw
milk has superior nutritional value, in addition to other
benefits, when compared to its processed counterpart
(Claeys et al., 2012). Processed milk is milk that has
been altered from its natural (raw) state by heating and
various unit processes. This is, in part, due to
denaturation of beneficial enzymes, a process that
occurs during heat treatment and homogenization
amongst other processes. Some argue that pasteurizing
milk also alters the taste and consistency of the product
(Walstra, 1999). It is therefore important to investigate
methods by which to treat raw milk without altering the
desired natural qualities of the product, while at the
same time mitigating the associate health risks and
ensuring the safety of consumers. Some methods of
treatment, such as vat pasteurization, microwave
treatment, high pressure-processing (HPP), ultraviolet
light treatment (UV treatment) and pulsed electric field
(PEF) treatment are said by some to conserve the
properties of raw milk better than conventional
pasteurization. This paper and accompanying design will
explore these possible alternatives in a small dairy farm
setting by comparing and contrasting the associated
risks and benefits of each treatment.
2.0 AN OVERVIEW OF RAW AND PASTEURIZED
MILK
Milk and dairy products are staples of the North
American diet; consumers consistently demand vast
quantities of high-quality product. In recent years,
pasteurized milk has started to be viewed with some
skepticism from consumers of health food, as well as
gourmet foodies. For these consumers, raw,
unpasteurized milk and its derivatives represent a
healthier, tastier alternative to the market standard.
However, there are inherent risks involved in
consumption of such products; if consumed
unpasteurized, these foods can present a health hazard
due to possible contamination with pathogenic
bacteria. These bacteria can originate even from
clinically healthy animals from which milk is derived or
from environmental contamination occurring during
collection and storage of milk. The decreased frequency
of bovine carriage of certain zoonotic pathogens and
improved milking hygiene have contributed
considerably to decreased contamination of milk but
have not, and cannot, fully eliminate the risk of milk
borne disease (Angulo et al., 2009).
Pathogenic milk bacteria, such as species of E. coli,
Campylobacter, and Salmonella, all present challenges
in milk safety. Milk can be contaminated through
collection and processing in the following ways:
1. Cow feces coming into direct contact with the
milk
2. Infection of the cow's udder (mastitis)
3. Cow diseases (e.g., bovine tuberculosis)
4. Bacteria that live on the skin of cows
5. Environment (e.g., feces, dirt, processing
equipment)
6. Insects, rodents, and other animal vectors
7. Humans, for example, by cross-contamination
from soiled clothing and boots (CDC)
At greatest risk for harmful symptoms of milk borne
illness are infants, young children, pregnant women, the
elderly, and those with compromised immune systems.
As a result of several highly-publicized deaths, Canada
has effectively banned the sale of raw milk. This is in
contrast to the European Union’s regulation and
protection of the raw milk market, as it holds historical
and commercial significance in terms of traditional
European dairy products such as raw milk cheese.
French Roquefort, for example, is required by law to be
produced from raw sheep’s milk; pasteurized milk
cheeses are widely panned in the French market. Thus,
what is the difference between these two schools of
thought? In essence, it appears that Canadian dairy
4
hygiene standards are not up to par with their European
counterparts; in addition, the risk involved in
consumption of dairy products, minimal as it may be
with proper treatment, is not considered acceptable by
North American food regulating agencies.
PASTEURIZATION DEFINITION
Pasteurization is the heat treatment of milk in the
service of killing or denaturing harmful pathogens and
degradative enzymes, thus increasing the shelf life of
milk. There are two main types of pasteurization: The
first is High Temperature Short Time (HTST), which is
the treatment of milk at 72oC for 20 seconds, thus
inactivating pathogenic agents present in the liquid.
This typically allows for a refrigerated shelf life of two to
three weeks. The second type, which is less popular in
North America, is Ultra Heat Treatment (UHT), which is
the treatment of milk for 1-2 seconds at 135 oC, which
combined with sterile processing and aseptic packaging,
can extend the shelf life of milk to 6-9 months
unrefrigerated. Unfortunately, this process caramelizes
some of the lactose sugars present in milk, leading to an
oddly sweet taste that North American consumers
dislike.
3.0 LITERATURE REVIEW OF ALTERNATIVE
TECHNOLOGIES
Alternative methods to HTST and UHT are described in
the following literature review. Our team focused on:
batch pasteurization,
3.1 BATCH PASTEURIZATION
The legal definition of pasteurization is the process of
heating every particle of milk and milk products to the
minimum required temperature (for that specific milk
or milk product), and holding it continuously for the
minimum required time in equipment that is properly
designed and operated (WSDA, 2010). Vat
pasteurization (also referred to as batch pasteurization
by some sources) still involves the heating of raw milk
to meet this objective; however, during this process the
heating occurs at lower temperatures than UHP and
HTST, and over an extended period of time (Gao et al.,
2002). The milk is held at a moderate temperature
(usually between 60 and 70 °C) for half an hour and
then quickly cooled. Milk processed by vat
pasteurization retains a higher percentage of the milks
natural enzymes and beneficial bacteria that would be
denatured or killed at higher temperatures. This is said
to contribute to a stronger flavour and added health
benefits of vat pasteurized milk when compared to
HTST and UHP processed milks (Buffa et al., 2001).
Vat pasteurization involves several unit processes. A
typical system involves a stainless steel vat that has
been fitted with water and steam to the jacket liner,
in which the product is heated. Time and temperature
requirements, methods of operation, properly
designed valves, thermometers to monitor and record
product temperatures and some means of agitation to
assure uniformity in temperature distribution should
also be included in a vat pasteurizer system (WSDA,
2010). During this method all of the components (such
as sugar or sweeteners etc.) are added before
pasteurization. The milk and/or other liquid
ingredients are then heated in the pasteurization vat
for 30 minutes at the specified temperature. The
process is monitored and the results are collected and
recorded. Vat pasteurization was the original method
of pasteurization and is now primarily used in the
dairy industry for preparing milk to be used in the
production of cheese, yogurt, buttermilk and some ice
cream mixes (IDFA, 2009).
The Canadian standards for vat pasteurization of dairy
call for heating of products to temperatures between
60 and 70 °C that are maintained over a half-hour
time period. The following are the generally accepted
pasteurization schedules for dairy products produced
by batch pasteurization in Canada: (1) Milk based
products below 10% milk fat (fluid milk, goat milk,
whey) are to be heated to 63°C for 30 minutes, (2)
Milk based products of 10% milk fat or higher, or
added sugar (fluid cream, cream for butter, chocolate
milk, flavoured milk, etc.) are to heated to 66°C for 30
minutes (CFIA, 2013). Standards for vat or batch
pasteurization are also regulated provincially and may
vary from these national standards. If there is variance
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in the provincial and federal standards, the more strict
standard must be met (CFIA, 2013).
Raw milk is difficult to find in commercial groceries.
This is due to the fact that sale of raw milk for human
consumption is illegal in Canada (Guelph, 2013). In the
United States the sale of raw goat and sheep’s milk is
legal in some states and not others, however it is
technically illegal to produce raw cow’s milk to sell for
human consumption (Fund, 2013). Where raw milk is
available for purchase, consumers will find that the
cost of this product is significantly higher than that of
milk processed through HTST. Vat pasteurization has
higher energy requirements than the notably shorter
process of HTST pasteurization. The lengthier heating
time involved with vat pasteurization has a higher
operating cost than HTST, which is ultimately reflected
in the market price of vat pasteurized products
(Systems, 2013). Therefore many consumers who wish
to reap the benefits of raw milk, without the
associated health risk, must accept the additional cost
when turning to vat pasteurized milk alternative.
3.2 MICROWAVE TREATMENT
INTRODUCTION
Microwave treatment is the intense heat treatment of a
product in a microwave at high frequency. Although it
has the same basic principle as normal pasteurization,
the microwave treated milk can be found to have the
majority of its nutrients to be more intact than in
normal conventional pasteurization. This is due to the
fact that in microwave treatment takes a less amount of
time and the milk is exposed to lower amount of heat.
This reduction in time spent heating up a product
means the loss of much of the vitamins and other
important enzymes are reduced (Özilgen and Özilgen,
1991).
The cost of this process can be assumed to be relatively
low, as there have been research done where
microwave treatment could be done using a
conventional home microwave. A study conducted by
(Sieber et al., 1996) attempted to pasteurize milk using
a conventional microwave. In their experiment, their
milk was able to attain temperatures from 50˚C to 78˚C,
with a microwave using 2450 MHz frequency. They
were able to conclude that this method does not differ
from conventional pasteurization in terms nutritional
loss. However, the uneven temperature distribution by
microwave have shown to have some negative side
effects (Seiber et al., 1995). Unfortunately, the short
lifespan of a microwave raises doubts on whether it is a
good economic alternative for milk pasteurization
(Bansal and Chen, 2006).
MECHANISM OF INACTIVATION
The process of treating milk through microwaves is a
very simple task. In Seiber et al.’s (1995), a traditional
household microwave was used, so it can be assumed
that equipment depending on scale is easy to obtain. In
that process, milk was placed in a vessel and heated in
the microwave at a frequency of 2450 MHz. The high
penetration power of the microwave heats the milk to a
high enough temperature for the harmful bacteria to be
destroyed. At that point, the same basic heat principles
of normal pasteurization is taking place. The enzymes
and proteins lost in normal pasteurization and
microwave treatment is nearly the same, except for the
amount of amino acids and vitamins that were affected
by either treatments (Albert et al., 2009). Overall this
process and equipment needed is incredibly simple, and
the results are very favorable.
FOOD SAFETY
The reason microwave treatment is not used more
widely as a method of pasteurizing milk is due to the
uneven temperature distribution across the sample. The
uneven heat transfer across samples in a microwave
would cause for some bacteria to remain in the milk.
However, if a method for microwave treatment that
evenly distributes heat can be achieved, the quality and
safety of the microwave treated milk would be better
than that of the conventional heat pasteurized milk.
Escherichia coli and Bacillus subtilis, are bacteria that
can be found in raw milk that cause many foodborne
6
diseases. Microwave treatment can inactivate these
cells efficiently at high enough temperatures. In an
experiment (Woo Is, 2000) at 80C, both these cells have
been found to have a fairly good log reduction. When
temperature is raised from 50 to 60C, both E. coli and B.
Subtilis cells have higher log-reductions at 3 and 2
respectively. Therefore, in microwave treatment,
temperatures higher than 60C causes less efficient in
inactivating these bacteria. At higher temperatures, E.
coli is seen to be more efficiently inactivated, but at
lower temperatures, from 40 to 50C, B. Subtilis
inactivates better with a log-reduction of 3.66 while E.
coli has 3.23-log reduction. It was found that when
temperature increases between 40 to 60C, B. Subtilis, is
more sensitive. Therefore it can be concluded that, in
microwave treatment, bacterial inactivation depends on
the increases of temperature and different temperature
ranges. (Woo, 2000).
FOOD QUALITY
The quality change of milk after microwave treatment
was determined to be minimal according to the
experiment done by Seiber et al. Majority of the
vitamins, proteins and enzymes found in raw milk, were
left relatively untouched and shelf life was found to
have increased. A survey was also carried out to test the
flavor and texture of the microwaved milk, and around
half claimed the quality to be equivalent to that of
normally heated milk (Seiber et al., 1995). In another
experiment performed by Cs Albert et al in 2009, it was
found that the amount of enzymes and proteins lost in
microwave heated milk were much lower than that of
milk pasteurized by conventional methods. The
difference found in amino acids and vitamins losses
were even larger. Microwave treated milk were found
to have a much higher concentration of vitamins and
amino acids than that of normal heat convention
(Albert et al, 2009).
3.3 PULSED ELECTRIC FIELD (PEF) PROCESSING
INTRODUCTION
In a study, (Qin et al., 1995) describes Pulsed Electric
Field (PEF) processing as a method which utilizes quick
successive applications of voltage upon food placed
between two electrodes. Often PEF systems include a
high-voltage power source, capacitors to store energy, a
resistor to limit the current (Ortega-Rivas, 2010). A
charging current limiting resistor, a switch which
discharges energy from the capacitor across the food,
and a treatment chamber. In other systems, other
accessories are used. In continuous systems, a pump
transports the food to and through the treatment
chamber. Additionally, a cooling systems, such as a heat
exchanger, or water bath, might be necessary to reduce
the heating effect of the PEF treatment (Figure 1 and 2).
Generally, two waveforms are utilized in PEF treatment:
exponential and square. Square has been shown to be
more effective in inactivation and in efficiency, but
requires a more advanced circuit assembly. The circuit
designs for exponential and square are shown in Figure
3.
MECHANISM OF INACTIVATION
Membrane breakdown occurs when the
transmembrane potential exceeds a critical voltage (Ec)
of 1 V in most cells (Martín-Belloso and Soliva-Fortuny,
2010). For example, this potential corresponds to an
external electric field of about 10 kV/cm for Escherichia
coli (Castro et al., 1993).
Electrical breakdown theory regards the cell membrane
as a capacitor filled with dielectric material. There is a
natural build up of 10-mV transmembrane potential
(Zimmermann, 1986). Applying an external electrical
field of 1V induces a stronger polarization of the
membrane, a larger transmembrane potential, resulting
in a reduction of the membrane thickness. When Ec is
exceeded the membrane breaks down occurs. The
breakdown causes the formation of membrane pores.
These pores allow the electrical discharge to travel from
the medium into the cytoplasm and expedite the the
membrane decomposition. If the amount and size of
pores is large enough compared to the cell’s surface
area, than the membrane will break down irreversibly,
7
as the membrane can not reseal the pore openings.
When the field is removed, electroporation occurs,
during which the proteins in the phospholipid bilayer
temporarily destabilized from the application of PEF.
The altered proteins in the membrane effectively
changes the cell becomes semi permeable to small
molecules, leading to the cell to swell and eventually
rupture.
Advantage with this technology is the rapid inactivation
rate (quasi-instantaneous) which can have large
potential on production scale. Limitations include
design of generator sufficient enough to provide
enough field strength and power at a reasonable capital
cost. Components such as cooling systems and anti-
bubble formation units are subjected to additional
maintenance costs. Furthermore, high energy
intensities are required for microbial inactivation in
liquid foods. Consequently, higher energy and upkeep
costs can limit PEF implementation (Martín-Belloso and
Soliva-Fortuny, 2010). Estimated investment cost can be
2-3 million US for production rate of 5t/hr.
FOOD SAFETY
In general, PEF reaches high levels of microorganismal
inactivation. Maximum inactivation of 9log10 reduction
was achieved on E. coli by Qin et al. in 1995. However,
inactivation depends on the microorganism, treatment
media, processing atmosphere, and equipment
(Sampedro et al., 2005). PEF seems to be weaker
against gram negative bacteria than gram positive ones
(Ortega-Rivas, 2010). A study (Dutreux et al., 2000)
concluded that conductivity was the most important
parameter in inactivating microorganisms with PEF
(Sampedro et al., 2005): Gupta and Murray observed
that bacteria were better protected against PEF when
milk fat content was higher, and that critical treatment
time (tc) was lowest for low fat milk. Qin et al., in 1994
concluded similarly with regards to spores of the
Bacillus genus. This conclusion seems to indicate that
PEF is more apt to be applied to low fat rather than high
fat milk.
A study performed by (Sensoy et al., 1997) found that
inactivation increased when the conductivity of the
product decreased, as there was an increase of osmotic
forces induced pressure on the membrane, making it
more sensitive to pulses. Later, the researchers
increased the field intensity from 25 to 40 kV/cm,
treatment time from 25 μs to 100 μs, and temperature
from 10°C to 50°C. Under these conditions, the
inactivation increased, following a logarithmic trend.
They developed a new inactivation kinetic model,
combining the effect of time and field intensity or
temperature of the product. Several authors have
suggested the use of alternative technologies combined
with PEF treatment such as addition of nisin or minor
thermal processing to achieve optimal inactivation
(Sampedro et al., 2005). Other authors found a
beneficial synergy between thermal and PEF treatments
(Ortega-Rivas, 2010). It was suggested that the
significant increase of PEF inactivation efficacy at 55°C
may be due to the phase transition of the cell
membrane at this temperature. The membrane
transitions from a gel-like consistency to a crystalline
liquid one, making the bacterial cells more susceptible
to PEF (Jayaram et al., 1992).
(Dutreux et al., 2000) achieved 4.7 to 5.7 log10
reductions of Escherichia coli ATCC 11775 in pasteurized
skim milk in 10 pulses. Nearly complete inactivation was
achieved after 35 pulses. Mañas et al. (2001) studied
inactivation of Escherichia coli NTCC 9001 inoculated in
sterile dairy cream and achieved a 5 log10 reduction with
a treatment time of 261 μs (Sampedro et al., 2005).
Gupta and Murray, in 1988, achieved 4.5 log reductions
in milk inoculated with Pseudomonas frag and later, in
1996, studied inactivation of Pseudomonas fluorescens
in UHT milk (Sampedro et al., 2005). They established Ec
(critical field intensity) and the tc (critical treatment
time), which they found to be 22.4 kV/cm and 19.8 μs
respectively for 4 log reductions (Sampedro et al.,
2005).
While studying inactivation in the Salmonella genus,
Dunn and Pearlman, in 1987, obtained 4 log reductions
8
when used Salmonella dublin (3800 CFU/mL) in
pasteurized, homogenized milk (Sampedro et al., 2005).
While studying inactivation of the Listeria genus, Dunn,
1995 used L. innocua in treated raw whole milk, at
process temperature above 55°C and achieved over 6
log reductions (Sampedro et al., 2005).
Gongora-Nieto et al. (2003) reported the problematic
effect bubbles present in the treatment chamber,
finding that field strength experiences a significant drop
along the boundary regions of the bubbles, causing food
safety problems (Martín-Belloso and Soliva-Fortuny,
2010). In the treatment of milk, this issue could be to
ensuring a laminar flow. The Available Net Positive
Suction Head (NPSHA) must exceed Required Net
Positive Suction Head (NPSHR) or else cavitation will
occur resulting in bubble formation. Our team’s design
would guarantee this relationship to reduce bubble
formation.
FOOD QUALITY
Pulsed electric fields have little or very insignificant
impacts on sensory, textural and nutritional qualities of
raw milk. Maintaining quality with as little impact as
possible has been shown to be ineffective at high ends
of field strengths. A study conducted by Michalac et al.
(1999) demonstrated that there existed no variation in
color, pH, moisture and particle size of raw milk
subjected to field strength of 35kV/cm and pulse time
and width of 90 and 3 microseconds, respectively,
before and after treatment. In cheese production, PEF
attracts large attention due to the retention of sensory
and textural attributes similar to that of raw milk. In a
study by (Sepulveda-Ahumada et al., 2000), further
comparative evaluation of textural parameters such as
hardness springiness, adhesiveness and sensory
qualities in Cheddar cheese was conducted. This study
supported the enhanced aroma and textural qualities of
PEF treated milk in comparison to thermal processed
milk. In another study by Qin et al (1995),
physicochemical and sensory attributes were evaluated
and conducted in comparison to conventional thermal
pasteurization which resulted in little or insignificant
changes of given attributes for 2% fat milk (40kV/cm)
for an extended shelf life of 2 weeks at 4C. Shelf life was
later evaluated by Fernandez-Molina (1999) for PEF
treatment (30-50kV/cm) and PEF in addition to heat
process (80 C, 6s), which concluded shelf-life time of
over 14 days and 22 days respectively, at refrigerated
conditions (Sampedro et al., 2005).
Furthermore, Dunn and Pearlman (1987) observed in
PEF pasteurized and homogenized milk that, after
storage for 8 d at 7 to 9°C, no significant changes were
evaluated in nutritional attributes including “enzyme
activity, fat integrity, starter growth, rennet clotting
yield, cheese production, calcium distribution, casein
structure, and protein integrity” in raw milk treated
with PEF at lower field strength ranges (Sampedro et al.,
2005). In contrast, fat particles seem to protect the
microorganisms against electric pulses (Ortega-Rivas,
2010). Additionally, certain enzymes are found to be
more resistant to PEF, such as protease, and further
exhibit larger resistances in batch processes compared
to continuous flow (Bendicho et al., 2002). Substantial
amounts of energy are required to inactivate particular
enzymes which greatly limits the application of PEF on
raw milk (Ortega-Rivas, 2010). Inactivation of enzymes
further varies with field parameters (strength/pulse
number), type of enzyme (size/shape) and media.
Therefore, the retention of organoleptic characteristics
similar to raw milk would further enhance the qualities
and process making of cheese, butter, and ice-cream.
No destruction of vitamins, such as riboflavin and
thiamine, were observed by Bendicho et al. (1999) at
field strengths of 16-33 kV/cm. However, slight
destruction was observed at pulse numbers greater
than 100 (Sampedro et al., 2005).
3.4 HIGH PRESSURE PROCESSING (HPP)
INTRODUCTION
High pressure processing (HPP) in milk is the application
of high hydrostatic pressure (HHP) on medium and
consists of three essential components: pressure vessel,
delivery system, process fluid. Pressure vessel must be
9
properly designed to withstand high magnitudes of
pressure and fatigue. Furthermore, delivery systems can
consist of continuous or batch processing. Factors
impacting bacterial inactivation include: the type of
microorganism, food composition, pH, and water
activity (Nguyen and Balasubramaniam, 2011). Gram-
positive organisms are more resistant than gram-
negatives. Water activity also has a major influence on
the microbial inactivation rate.
Examples of high-pressure pasteurized products
available in the United States, Europe, and Japan
include smoothies, guacamole, deli meat slices, ready to
eat (RTE) food ready-meal components, poultry,
oysters, ham, fruit juices, and salsa (Dunne, 2005).
From Le Chatelier's principle, which states the
equilibrium of system shifting towards the smallest
volume, pressure will be the reaction force that results
in decrease of volume (microorganism). It is possible to
alter the mechanism of cell and further inactivate it
provided that sufficient energy is applied to the system.
In pressure process, mass is an independent variable
and is not altered by the objects shape or size because
pressure forces are equally distributed on the medium.
PACKAGING
Semicontinuous systems are used for liquid products,
which are then aseptically packaged after treatment
(Nguyen and Balasubramaniam, 2011). Flexible or
semirigid packaging (packaging with at least one flexible
interface) is well suited for batch processing. As the high
moisture foods compress by 15-20% during pressure
treatment of 600 MPa, HPP packaging must be able to
accommodate the reduction in size and return to the
original volume without losing its seal. For this reason,
cans are not suited for HPP.
WATER
Water has also emerged as a the optimal pressure
producing fluid due to its “availability, nontoxicity, and
low cost” (Nguyen and Balasubramaniam, 2011).
Furthermore, water produces a greater energy buffer,
improving the safety and efficacy of the processing.
OPERATION
Pressure levels necessary for effective inactivation
depend on types of microorganisms constituting in milk.
Increase of pressure affects the temperature
equilibrium, and likely pH levels (slightly) and viscous
properties of medium in the system at high levels of
pressure. Inactivation kinetics are altered when heat is
introduced to the medium. Pressure heat treatment can
be synergistic and antagonistic in inactivating for safety
of product and quality of food. Proper modeling for
conservation of mass and energy is often required to
keep the uniformity of pressure treatment. Designing
an effective HPP system requires proper design of
equipments (vessel, delivery system, safety
mechanisms) Often, it is required to minimize pressure
come-up, holding and decompression time (1 cycle) in
order to increase productivity and potentially save costs
in required energy delivered.
PRESSURE PASTEURIZATION
Pressure pasteurization treatment typically fall within
the pressure range of 600 MPa (87,000 psi) and
temperature range around room temperature for a
specified treatment time (Chef-tel, 1995; Farkas and
Hoover, 2000; Anon 2006). High-pressure pasteurization
have successfully inactivated pathogenic and spoilage
bacteria, yeasts, and molds, but produced limited
inactivation against spores and enzymes.
OSCILLATORY PRESSURE TREATMENT OR PRESSURE
PULSING
(Meyeret al., 2000) found that applying two or more
pressure pulses (referred to as “pressure pulsing” or
“oscillatory pressure treatment”) at an equivalent
holding time is more effective at inactivation. Pressure
pulsing can be used for both pasteurization and
sterilization (Nguyen and Balasubramaniam, 2011).
However, the measure of improved inactivation due to
10
pulsed pressure treatment must be compared to the
“design capabilities of the pressure unit, the added
compression costs, added wear on the pressure unit,
possible detrimental effects on the sensory quality of
the product, and the additional time required for
cycling.”
Oscillatory high pressure systems can be applied for
enhanced inactivation results. For instance, use of
dynamic high pressure (DHP) batch system has been
shown to be very effective in destruction of Listeria
monocytogenes, Escherichia coli and Salmonella enteric
(Vachon et al., 2002). Listeria monocytogenes is a gram-
positive, non-spore forming facultatively anaerobic
bacteria. Listeria monocytogenes can grow in a pH
range of 4.1–9.6 and a temperature range of 0–45 °C
(Chen and Hoover, 2003). Its ability to grow in
refrigerated temperatures and anaerobic conditions
makes it a food safety threat, especially since it can
cause serious illnesses and death (Jay, 1996; Ryser and
Marth, 1999).
PRESSURE ASSISTED THERMAL TREATMENT
Naturally, higher operating pressure levels are more
effective in the inactivation of microorganisms.
However, it is shown that similar effectiveness can be
achieved by treating milk at higher pressure-shorter
time, and at lower pressure-longer time (Mussa and
Ramaswamy, 1997) (also refer to Figure 4).
COST
Capital costs of high pressure equipment increase
exponentially with a linear increase in operating
pressures. Therfore, it is economically viable to utilize
low pressure processing in conjunction with other
processing methods to obtain the desired inactivation,
and, at the same time, maintain the sensory and
nutrient characteristics of the processing (Chen and
Hoover, 2003).
FOOD SAFETY
Dogan assumed that pressure inactivation of
microorganisms followed the first-order rate kinetics
(Dogan and Erkmen, 2004):
(1)
(2)
(Chen and Hoover, 2003)
Where,
N = number of surviving microorganisms after a
pressure treatment for time t (min),N0 = initial number
of microorganisms, and k = inactivation rate constant
(min−1).
At higher pressures of 600 and 700 MPa, D values
obtained compared well with those for thermal
inactivation of Listeria (Dogan and Erkmen, 2004). HPP
treatment of L. monocytogenes in milk was not as
effective as was in borth and fruit juices. Dogan and
Erkman (2004) claimed that fat and protein content in
whole milk buffered the bacteria to HPP. As in UV
treatment, perhaps we should use HPP for low fat milk
if it is chosen as method for our final design.
HPP has the potential to commercially sterilize heat
sensitive products such as milk, soups, tea and others
using pressure assisted thermal processing (PATP).
Commercial sterilization is the inactivation of all
pathogens to render them incapable of growth and
reproduction under non refrigerated conditions. Spores
and prions are known to be very resistant even under
high temperature (Nguyen and Balasubramaniam,
2011). Furthermore, the application of pressure pulsing
much like UV or PEF pulsing have been shown to be
more effective than non-pulsed pressurizing at
equivalent holding times The rate of microbial
destruction was much more rapid than enzyme
inactivation or color and viscosity changes (Mussa and
Ramaswamy, 1997). Studies have reported that PATP
reduces the process time of thermal inactivation
thereby preserving food quality, especially texture,
color and flavor.
11
Several studies have shown the effectiveness of
temperature assisted pressure processing (Chen and
Hoover, 2003). Temperature assisted pressure process
inactivation of L. monocytogenes was obtained at four
temperatures (22, 40, 45 and 50 °C) and two pressure
levels (400 and 500 MPa) in UHT whole milk. “A 5-min
treatment of 500 MPa at 50 °C resulted in a more than
8-log10 reduction of L. monocytogenes, while at 22 °C a
35-min treatment was needed to obtain the same level
of inactivation.” CHEN Temperature greatly impacted
the level of inactivation in pressure treatment of L.
monocytogenes. As temperature increased, inactivation
did as well. A 12-min treatment of 400 MPa at 50 °C
resulted in an roughly 7-log10 reduction of L.
monocytogenes in UHT whole milk, while at 22 °C more
than 120 min was needed to obtain the same
inactivation level. A 5-min treatment of 500 MPa at 50
°C resulted in a more than 8-log10 reduction of L.
monocytogenes in UHT whole milk, while at 22 °C a 35-
min treatment was needed to obtain the same level of
inactivation. In both pressure levels in this study,
increasing the temperature levels from 40 to 45 °C or
from 45 to 50 °C decreased the time to reach the same
level of inactivation by more than half. Chen found that
the log-logistic and Weibull models provide the most
accurate models for inactivation.Patterson and
Kilpatrick (1998) found that applying high pressure and
mild heat was more effective in inactivating Escherichia
coli O157:H7 and Staphylococcus aureus than either
treatment alone. A 5-min treatment of 500 MPa at 50
°C obtained a 6.0-log10 reduction of S. aureus in UHT
milk, while less than a <1.0-log10 reduction was
achieved with either treatment alone. Ponce, Pla,
Capellas, Guamis and Mor-Mur (1998) and Ponce, Pla,
Sendra, Guamis and Mor-Mur (1999) studied the effect
of temperature on the pressure inactivation of
Salmonella enterica serovar Enteritidis and E. coli. They
found that 50 °C to be the most effective temperature
in inactivation of the two gram-negative bacteria among
four temperature levels studied (−15, 2, 20 and 50 °C)
(also refer to Figure 5 and 6).
FOOD QUALITY
For milk and other liquid foods, the effect of adiabatic
heating can alter the sensory and nutritional changes if
pressure is not strictly controlled or high pressure
inputs are delivered to the system. At high pressure
levels (above 700 MPa), denaturation of proteins, lipids
and starches can potentially occur from additional
thermal stress. However, the effect of pressure alone
has no sensory changes preserving food freshness
because HPP has no effects on conformation of
macromolecules (does not break covalent bonds)
(Nguyen and Balasubramaniam, 2011) Furthermore,
viscosity affects the resultant texture of cheese. At high
pressures where proteins begin to denature, particular
enzymes in milk begin to coagulate thereby changing its
viscous effects (Mussa and Ramaswamy, 1997).
Nonetheless, HHP processing did not substantially
change the viscosity of milk (Mussa and Ramaswamy,
1997). High lipidic milk (3.5% fat milk) can accelerate
the heating due to its increase heat of compression
(Nguyen and Balasubramaniam, 2011). Additionally, it
can be advantageous in achieving temperature to
refrigeration level more effectively due to accelerated
heating rate and heat loss to the medium during
pressure come-down phase. Color and smell of the milk
was not affected by HHP processing to a large extent
(Mussa and Ramaswamy, 1997). Overall, HPP
processing is known to retain most of sensory and
nutritional values of milk, thereby retaining most of milk
freshness, by effectively inactivating pathogens through
the control of heat-pressure parameters for fresh and
quality cheese production.
3.6 ULTRAVIOLET PROCESSING
INTRODUCTION
Pulsed UV is a recent technology which offers an
alternative to inactivating pathogens in fruit juices,
apple cider, syrup, water and milk. It has been
successfuly applied to disinfecting surfaces of fresh
fruits and lettuces (Lu et al., 2011). The quick succession
of UV pulses of Pulsed UV outperforms the inactivation
effect of continuous UV. Pulsed UV treatment differs
from unpulsed UV. Pulsed UV requires a very simple set
12
up, a xenon inert gas lamp is placed to apply the UV
rays to the product (from lecture slides). In study
(Reinemann et al., 2006), germicidal UV lamp (UV-C
range) of 30 watts (1.4KJ/L) at standard-254 nm field
strength was used. (Rossitto et al., 2012)’s technology
used continuous turbulent flow and low-power UV
reactor at 254 nm at 1.5KJ/L to attain a maximum of 3-
log reductions. (Lu et al.) pumped raw milk through a
helical tubing set up around a pulsed UV lamp (Figure
7). This set up illustrates the ability for lamps to be
shaped to fit any application.
Ultraviolet processing is comprised of two methods:
conventional method and pulsed ultraviolet (PUV)
method. Conventional method uses regular mercury
lamp (range 100-400 nm) as a flashhead source for
inactivation whereas pulsed UV uses Xenon flash head.
In pulsed more, energy is stored and released from a
capacitor in form of pulses. Ultraviolet range from 200-
280 (UV-C) is germicidal. Other components of a typical
UV system includes a control module, which controls
the exposure variables, and high voltage supply, capable
to generate high pulsed optical energy. It can also
include additional components such as blower or
cooling unit that removes any volatile gases, such as
ozone, that can be detrimental to environment. PUV
can generate wideband generation in broad spectrum
range (100-1100 nm) which makes it more favorable
over continuous conventional ultraviolet processing. For
this particular processing, we will be focusing more on
PUV technology, its advantages and its disadvantages
(from lecture slides.
Factors affecting the efficaciousness of PUV have been
identified to include: UV wavelength,intensity and dose
rate, thickness of the radiation path, andflow
turbulence (Rossitto et al., 2012).
MECHANISM OF OPERATION
Mercury UV treatment has its complications in terms of
long exposure time on food medium which results in
heat generation, loss of energy and can reduce product
quality due to surface browning. On the other hand,
PUV sends high potential bursts of pulses in short
amount of expsure time and at low energy costs. Unlike
conventional method, it can achieve sterility because it
destroys the double and primary bonds in the DNA and
RNA bonds thereby inactivating microorganisms by
rendering their cell repair mechanism incapable of
development and reproduction. It is hypothesized that
thermal stress from UV leads to rupture of cell
membrane. However, the disadvantage of certain
pathogens having to remain resistant to UV radiation,
where only DNA sequencing is disrupted, can lead to
abnormal cellular development. Microorganisms can
potentially form pyrimidine dimers which can result in
damages, and due to repair mechanism of cell, it can
lead to cell mutation. As a society, we like to see the
food we eat is high quality and remains pathogen-free
and especially “mutated” pathogen free remaining safe
to eat (from lecture notes).
Low cost, efficient and low maintenance are main
advantages which consequently brings to better
product profit for small scale farm production of dairy
products. Product is potentially minimally processed, it
is non-thermal thereby retaining sensory and nutritional
attributes. It can be used to effectively disinfect
surfaces of products and solids in particular (fruits,
veggies, frozen meats, etc) and can be used as sanitizers
in public areas. Furthermore, This particular application
has very good advantages in water treatment for
potable water used as tertiary treatment method to
sterilize water. Good thing about PUV treatment is that
it follows a similar inactivation rate, first order kinetics,
as thermal inactivation so both effects can be hurdled
together for enhanced log reductions. Main
disadvantages include the insufficient log reduction
capacity of most pathogens for milk (12-D). This further
extends the limitation of UV processing due to low
productivity. In order to increase productivity, high
capital costs must be invested, making it more suitable
for small scale production. For non transparent liquids,
it is difficult or almost impractical to treat. For instance
in milk, calcium, fat/protein, and other constituents that
interfere with MO inactivation). Furthermore, shoulder
and tail effects occur in the inactivation curve of first
order kinetics. Shoulder effect is due to delayed
inactivation of cell injury (takes time to damage DNA).
13
Tail effect is the result of shielding of external particles
(foodstuffs) which ends up protecting pathogens. This
can be potentially eliminated by mechanical mixture so
that all surfaces come in contact with UV radiation. PUV
has several applications in cold treatment of raw milk
(Reinemann et al., 2006), reduction of thermally
resistant bacteria, inactivation in refrigerated milk in
long term storage. Additionally, PUV can reduce
pathogenic populations and improve milk quality in
areas which lack a supply of reliable and cheap energy.
EFFICIENCY
(Lu et al., 2011)’s PUV apparatus potentially may not
only “improve the safety and extend the shelf life of
milk”, but also has simpler processing procedures and
require less energy and space than does conventional
thermal pasteurization. G. Lu’s apparatus ran at a
processing rate of.194.2 kJ/kg. Krishnamurthy specified
that PUV is applicale for small-scale milk processing
operations (Krishnamurthy et al., 2007).
FOOD SAFETY
On a small scale cheese processing facility, it is possible
to achieve commercial sterility using UV treatment.
Small scale facilities have low production levels and
produced normally in batches for effectiveness.
Drawback of UV treatment of milk, but a potential
advantage for small scale production, is the small depth
of milk medium required for efficient inactivation
(Ngadi et al., 2003). However, in terms of safety or
public concern using PUV processing is the potential to
modify microbiological activity in the food medium. UV
exposure can lead to formation of dimers in
microorganisms from DNA damage. These damages can
result in mutations by impairing the replication of cell
mechanism and gene transcription sequencing. This
would normally lead to cell death. However, cells have
evolved evolutionary mechanism for repairing DNA
damage which allows survival of a mutated cell.
G. Lu et al. (2011) found that PUV could be used a viable
alternative for thermal pasteurization as PUV achieved
a greater than 6 log10 reduction in many cultures of milk
bacteria. . Krishnamurthy, applied PUV on
Staphylococcus aureus reducing the microorganism
which experienced complete inactivation in two cases
(7.23 and 7.26 log10 reductions). Matak et al. (2005)
achieved a 5log10 reduction in viable numbers of Listeria
monocytogenes with a low PUV dose of 15.8 ± 1·6 mJ
cm-1 (Donaghy et al., 2009). However, Donaghy et al.
(2009) found inactivating Mycobacterium avium ssp.
paratuberculosis (Map) with PUV difficult. At UV dose
rate of 1000 mJ ml-1 log10 reductions were all less than
2.5. “Map shows similar UV resistance to spore-forming
micro-organisms and is much more resistant than the
major microflora associated with milk.” Map, under
certain conditions, will survive pasteurization, making it
important to find viable secondary treatment. If PUV
unsuccessfully inactivates Map, another method must
be considered. Solids content in milk presents PUV a
second treatment challenge as it limits the penetration
of UV light into the liquid (Rossitto et al., 2012).
FOOD QUALITY
In terms of product quality, most studies carried out in
the last decade demonstrated significant effects on
sensory and nutritional values of UV treated milk. Off-
odours, foul taste, and nutritional imbalances were
observed.
A particular study by Rossitto et al. (2012) was carried
out to evaluate safety and quality changes of UV
treated milk. This study was based on a continuous
production system and was carried out to analyze
treatment for bovine milk destined for further
processing (cheesemaking, fermentation, etc). The
results showed a significant change in odour and
especially in taste, attaining 3-log reduction between
control and applied dose of 1.76 KJ/L. For doses below
0.88 KJ/L, there were little or no significant changes in
the quality of taste or aroma. Lactic acid levels following
waiting period remained unchanged compared to
control or non-treated milk.) Chemical imbalance at
dose of 1.76 KJ/L showed decrease change in fat,
protein, and lactose concentrations in 2% and 3.5% fat
milk. This can be explained by denaturation of enzymes
14
and breakdown of amino acids present in milk.
Additionally, oxidation of proteins occurred at high UV
doses affecting the proteolysis reaction contributing in
cheese making. UV light can also degrade vitamins by
photodegradation (especially A, C, and B2) (Demirci et
al., 2011; Scheidegger et al., 2010).
In another comparative study, conducted by Reinemann
et al. (2006) was carried out to evaluate the sensory
quality changes between HTST and UV treated milk. At
3-log reductions, milk was observed to have changes in
flavour. Results showed that excessive doses (1.4 KJ/L)
had effect on flavor being unclean with a “flat” off-
flavor. At this dose, 92% of panelists had a preference
for HTST than UV treated mlk. Whereas, at a dose of
0.47 KJ/L, sensory qualities of UV treated milk were
favored over HTST throughout the 14 day shelf-life.
Little difference was found between 1-log and 2-log
reduction of UV treated milk for storage time of 21
days. Hence, higher inactivation values can be reached
at the cost of sensory qualities of milk, which might not
be ideal for customer or production purposes.
4. DESIGN
To determine the best technology, a Pugh chart is presented:
Table 1
Criteria Weight Technology
HTST Batch Pasteurization HPP PEF PUV Microwave
Inactivation Potential 3 0 -2 3 2 1 -2
Nutritional Retention (ie. enzyme, vitamin) 3 0 2 2 2 1 0
Sensory retention (taste, smell, color) 3 0 2 3 3 -2 0
Shelf Life 1 0 -3 3 2 1 0
Cost 2 0 -2 -3 2 3 1
Production Scale-Flexible 2 0 3 -3 2 3 2
Treatment time 2 0 -3 -2 3 3 1
Total Score
0 -1 11 37 19 2
The inactivation potential, nutritional and sensory
retention were given the highest weights in the Pugh
chart to emphasize the objective of treating raw milk
without altering the desired natural qualities of the
product, while at the same time mitigating the
associated health risks and ensuring the safety of
consumers. Technologies that received a weight of 3 for
shelf life would produce a shelf-stable product.
Efficiency, capital cost and operational costs were all
accounted for when considering the weight of cost and
production scale-flexibility. These parameters were
given a weight of two because the objective of the
design works within the context small-scale, farm
operations.
When evaluating different technologies in Pugh chart,
Pulsed Electric Field was deemed superior with a score
of 37. PEF best fit the aforementioned criteria for a
small scale farming operation, and thus is technological
basis of the following design.
FINAL DESIGN
The typical small-scale dairy farm is comprised of 30
cows or less (Bagg, 2013). The typical cow produces 30
litres per day, on a two-times-a-day milking schedule
(Onario, 2013). This means that 900 litres of milk would
be produced per day, assuming that all cows were
milked. The flow rate of the system will be assumed to
be 254 litres per hour based on available pipe
diameters. Based on experimental viscosities from
University of Copenhagen the viscosity was assumed to
15
be roughly 1.55 mP*s for warmed raw milk entering the
system (Hougaard et al., 2009).
PROCESS
Milk is initially contained inside a stainless steel holding
tank (450 m^3) to allow initial bubbles to rise to
surface. As mentioned, bubbles present in the PEF
treatment chamber can adversely affect the effective
inactivation as well as lead to equipment failure from
accelerated corrosion. A centrifugal pump with an open
impeller is used to deliver controlled laminar flow at a
mean velocity of 0.1 m/s of raw milk. The treatment
chamber has a volume of 25.7 mL, utilizing a bipolar
square wave of 35 kV/cm The treatment chamber is
specified further in the design section. Using batch
treatment, it is possible to effectively process the
necessary daily flow rate using the proposed PEF
chamber design. Figure 8 below represents the
proposed general process design for a particular PEF
system for the given conditions applied.
Figure 8
Process flow diagram involved in the design.
FLOW DESIGN
The design requires that flows remain laminar.
Turbulent flows might produce bubbles which Gongora-
Nieto et al. (2003a) indicates significantly reduces the
field strength of PEF along the boundaries of the
bubbles.
(3)
Where,
), 1030
Determining the Reynold’s number for raw milk with
full fat. After holding tank has released milk,
the flow rate calculated for laminar flow is:
(4)
16
PUMP DESIGN
The Net Positive Suction Head (NPSH) is used to determine the selection of an appropriate pump for the particular laminar flow system. Bubbles should not be formed at suction and discharge. It is expressed as follows:
(5)
Where,
NPSH = Net Positive Suction Head (m)
= pressure at atmospheric sea level (101.3
kPa)
p = density of raw milk (kg/m^3)
g = gravitational constant (9.81 m/s^2)
u = mean velocity through pipe (m/s)
Pv = suction vapour pressure of raw milk at
impeller (kPa)
Givens
p = 1030kg/m^3 (JEK, 2009)
u = 0.1 m/s
Pv = 2.4 kPa (Obtained value from literature review)
NPSHA must be higher than NPSHR which can be obtained from pump manufacturers as requested and must be appropriately chosen to avoid cavitation.
PEF DESIGN
Our team found the pulse duration and energy density
needed for our PEF system.
(6)
Where,
(Mohamed and Eissa, 2012) offered standard
capacitance and resistance values for PEF:
0.12 uF for the capacitor and resister 6 MΩ.
Thus,
(7)
Where,
(Floury et al., 2006) found that to reduce E. coli by 5 log
reductions a square wave form, 64 pulses, 36 kv/cm, 2
μs per pulse, and entire treatment time was 90 μs was
necessary.
(Huang and Wang, 2009) used a gap between the electrode and volume of chamber as 0.95 cm and 25.7 ml.
That per batch, is 8.7 kJ.
5. CONCLUSION
Our team successfully addressed the objective to find a treatment option for a small-scale milk operation which
inactivates most pathogenic bacteria without significantly altering the beneficial nutritional properties of the product.
17
Based on an extensive literature review and Pugh Chart evaluation, our team found Pulsed Electric Field to best address
the problem statement. The design presented can be further expanded to further specify the design parameters and
propel the project into the prototyping phase design cycle.
Acknowledgments: Our team would like to that Professor Michael Ngadi for his sound counsel on this project
and for the comprehensive material from his course in Food Safety Engineering. DA
18
6. APPENDIX
Figure 1
Schematic diagram of PEF operation
(Martín-Belloso and Soliva-Fortuny, 2010)
Figure 2
PEF System
(from lecture notes)
Figure 3
Simplified circuitry for the generation of exponential decay and square wave pulses.
(Martin-Beloso nd Soliviva-Fortuny, 2010)
19
Figure 4
Temperature Assisted Pressure Treatment
(Nguyen and Balasubramaniam, 2011)
Figure 5
Figure 6
20
Figure 7
Experimental Set displaying versatile shaping of PUV.
(Lu et al., 2011)
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