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Finite element simulation and practical tests on Pulsed Electric Field (PEF) for packaged food pasteurization: inactivating E. coli, C. difficile, Salmonella spp. and mesophilic bacteria

Abstract

In this study we demonstrated the inactivation of E. coli, C. difficile, meshophilic bacteria and Salmonella spp. through Pulsed Electric Field (PEF) technology. First, a simulation using Finite Element Method Magnetics Mathematical Modeling was used to obtain the electric field values to be used in the electro-pasteurization tunnel. Then, practical tests were carried out by using an industrial scale apparatus set with the following parameters: pulse 20 s – 40 s, 40, 80 and 450 kV, radio frequency of 350 kHz and treadmill speed at 10 m/min. The results from practical tests shows a complete elimination of all microrganisms, thus proving that PEF technology significantly contributes to food safety and can be used on an industrial scale.

Keywords:
electrolysis; food security; electro-pasteurization; pulsed electric field; simulation

1 Introduction

During the last decades, many novel techniques of food processing have been developed in response to growing demand for safe and high quality food products. Nowadays, consumers have high expectations regarding the sensory quality, functionality and nutritional value of products. They also attach great importance to the use of environmentally-friendly technologies for food production (Nowosad et al., 2021Nowosad, K., Sujka, M., Pankiewicz, U., & Kowalski, R. (2021). The application of PEF technology in food processing and human nutrition. Journal of Food Science and Technology, 58(2), 397-411. http://dx.doi.org/10.1007/s13197-020-04512-4. PMid:33564198.
http://dx.doi.org/10.1007/s13197-020-045...
).

PEF technology is an effective approach for the preservation and processing of a variety of food products without affecting their quality attributes. PEF technology involves the use of pulses, with high electric fields during only a few micro to milliseconds, with intensities ranging 10-80 kV/cm. The process depends on the number of pulses delivered to the product which is usually held between two electrodes. These electrodes have a specific gap between them, known as treatment gap of the chamber. During PEF processing, the high voltage applied results in the inactivation of microorganisms present in the food sample. The electric field is applied in different forms such as exponentially decaying waves, bipolar waves or oscillatory pulses. The process can also be carried at various temperature ranges such as ambient, sub-ambient and above-ambient. Food is treated with PEF and then stored under refrigerated conditions (Syed et al., 2017Syed, Q. A., Ishaq, A., Rahman, U. U., & Shukat, R. (2017). Pulsed electric field technology in food preservation: a review. Journal of Nutritional Health & Food Engineering, 6(5), 168-172.).

Table 1 summarizes a list of studies on conditions and effects of using PEF in food processing.

Table 1
Studies on conditions and effects of using PEF in food processing.

PEF is also used in meat processing, to increase cell membrane permeability or to form permanent pores in muscle cells. This cellular disintegration can increase the tenderness of low-value tough meat cuts, enhance mass transfer, and improve the efficiency and cost-effectiveness of subsequent unit operations such as sous vide, ageing, curing, drying, fermentation and maturation. The effects of PEF on meat structure and processing can be of great commercial value. The efficiency of PEF treatments depends on process parameters such as electric field strength, pulse frequency, treatment time and specific energy, as well as the intrinsic meat properties, since meat components such as muscle, fat, collagen and bone vary in both electrical and morphological properties. To ensure an effective application of PEF and the production of prime quality meat products, the processing parameters and instrumental design need to be optimised for each application (Karki et al., 2022Karki, R., Oey, I., Bremer, P., & Silcock, P. (2022). Pulsed electric fields application in meat processing. In J. Raso, V. Heinz, I. Alvarez & S. Toepfl (Eds.), Pulsed electric fields technology for the food industry (pp. 399-438). Cham: Springer. http://dx.doi.org/10.1007/978-3-030-70586-2_14.
http://dx.doi.org/10.1007/978-3-030-7058...
).

PEF systems market and it is poised to grow by $ 273.19 mn during 2021-2025, progressing at a Compound Annual Growth Rate (CAGR) of 25.09% (TechNavio, 2021TechNavio. (2021). Global food industry Pulsed Electric Field (PEF) systems market 2021-2025. London: TechNavio.).

In this context, we have investigated (in an industrial scale) the effect of electromagnetic fields added to high voltage modulated radiofrequency and pulsatile plasma to inactivate harmful microorganisms in foods. The advantages are that this technology can be used for both pre-packed and post-packed food and beverages (without use heat or cold) with effective conservation of their organoleptic properties, with low energy expenditure, fast speed capacity, as well as the softening of meat since the binding of actin-myosin is broken by the process.

2 Materials and methods

2.1 Finite element simulation

The Finite Element Method Magnetics (FEMM) software version 4.2 was used in for the simulation of electric fields in the post-filling electro-pasteurization tunnel. The cross-sectional view is shown in Figure 1, where it is possible to observe the construction and arrangement of the electrodes (304 stainless steel) and dielectric barriers (20 mm acrylic).

Figure 1
Sectional view of the post-filling electro-pasteurization tunnel. Having as dimensions: width: 646 mm, Height: 400 mm; Electrodes (50 mm x 400 mm).

To simulate the electric field in the software, equations for verification of parameters were used in according to Ganea (2017)Ganea, I. (2017). Influence of the solid dielectric over the electric field from the ozone cell gap with double dielectric barrier. IOP Conference Series: Materials Science and Engineering, 200, 012058. http://dx.doi.org/10.1088/1757-899X/200/1/012058.. These equations are used in sizing cells for ozone production using parallel planes. The equation, however, considers some points: the electric field is uniform inside the cell; the electric field strength value outside the cell is zero; the electric charge density is constant and uniform over the entire surface of the electrodes; the dimensions of the electrodes are much larger compared to the distance between them, in according to the Equation 1 presented below:

E = ε 2 × U / ε 1 × d 2 + ε 2 × d 1 (1)

Where:

E - electric field strength in the effective area,

Ɛ1 – air permittivity,

Ɛ2 - permittivity of the dielectric material,

d1 - distance between dielectrics,

d2 - total thickness of the dielectrics.

The simulations were carried out using the Finite Element Method Magnetics (FEMM) software 4.2, considering an electrical voltage of 120 kVolts and a change in the distance between the dielectric barriers of 5 cm, 10 cm, 15 cm and 20 cm, respectively. The permittivity of the materials considered were: air = 1/polypropylene = 2.2 and acrylic = 3.4. From simulations it was possible to calculate the pasteurization electric fields in practical tests.

Figure 2 presents graphically the modeling from FEMM software, regarding the electric field intensity, flux density, and equipotential electric field lines for the simulations performed:

Figure 2
Graphical simulation 1: DDP = 120 kV/Distance = 5 cm. Image A1 shows Electric field strength (V = 120 kV/d = 5 cm); Image A2 - Electric field flux density (V = 120 kV/d = 5 cm); Image A3 - Equipotential electric field lines (V = 120 kV/d = 5 cm). Simulation 2: DDP = 120 kV/Distance = 10 cm. Image B1 - Electric field strength (V = 120 kV/d = 10 cm); Image B2 - Electric field flux density (V = 120 kV/d = 10 cm); Image B3 - Equipotential electric field lines (V = 120 kV/d = 10cm). Simulation 3: DDP = 120 kV/Distance = 15 cm. Image C1 - Electric field strength (V = 120 kV/d = 15 cm); Image C2 - Electric field flux density (V = 120 kV/d = 15 cm); Image C3 - Equipotential electric field lines (V = 120 kV/d = 15 cm). Simulation 4: DDP = 120 kV/Distance = 20 cm. Image D1 - Electric field strength (V = 120 kV/d = 20 cm); Image D2 - Electric field flux density (V = 120 kV/d = 20 cm); Image D3 - Equipotential electric field lines (V = 120 kV/d = 20 cm).

2.2 Electro-pasteurization essay

For each microorganism tested (including E. coli, C. difficile and mesophilic bacteria) 1.0 x 106 CFU/mL was diluted in protein broth transferred to 100 mL of sterile saline solution and was inoculated in plastic packages containing milk (samples 1-16) and meat samples (17-30). In tests we used E. coli + C. difficile spores and mesophilic bacteria for milk samples, and Salmonella spp. for meat samples (packed sausages). For results reliability 10 samples were tested for each bacteria in the electro-pasteurization process essay. For the quantitative counting of bacteria the tests were carried out in accordance with the ISO-15213: (International Organization for Standardization, 2003International Organization for Standardization – ISO. (2003). ISO 15213:2003: microbiology of food and animal feeding stuffs – horizontal method for the enumeration of sulfite-reducing bacteria growing under anaerobic conditions. Geneva: ISO.) and AOAC-OMA 991.14. 20th ed. 2016, and for the qualitative determination of Salmonella spp. using by the Presence/Absence (P-A) test based on ISO 6579-1:2017 (International Organization for Standardization, 2017International Organization for Standardization – ISO. (2017). ISO 6579-1:2017: microbiology of the food chain – horizontal method for the detection, enumeration and serotyping of Salmonella – part 1: detection of Salmonella spp. Geneva: ISO.) being validated by the certified Microbiological Laboratory - Eireli EPP, Florianópolis - SC, Brazil.

In tests, 1 sample was contaminated with each microorganism being left as initial reference, with perfect conditions of vitality to test the bacterial spread. The PEF apparatus is protected under World Intellectual Property Organization – WIPO (Duvoisin, 2017Duvoisin, C. A. (2017). WO2018090110 - sistema e método para neutralização de agrotóxocos ou agente similares contidos em alimentos e configuração construtiva para sua implementação. Geneva: World Intellectual Property Organization. Retrieved from https://patentscope.wipo.int/search/pt/detail.jsf?docId=WO2018090110
https://patentscope.wipo.int/search/pt/d...
) and follows the same principles of eletrons trap described by Duvoisin et al. (2020)Duvoisin, C. A., Souza, J. P. F. A., Pscheidt, A., Baretta, D., Horst, D. J., Vieira, R. A., Mourão, C. A. Jr., & Secchi, M. (2020). System electro-neutralizer of agrochemicals contained in food and water samples through electrons trap. Food Science and Technology, 40(2), 315-325. http://dx.doi.org/10.1590/fst.42318.
http://dx.doi.org/10.1590/fst.42318...
. With the purpose of microbiologically testing this electro-pasteurizer technique/equipment, we carried out 40 tests using packed milk and meat. Figure 3 shows the microbiological essay of packaged foods.

Figure 3
Legend: A) packing contaminated samples; B) sausage samples before and after test; C) electro-pasteurization tunnel; D) plasma beam over the sample during essay.

The electrical discharges were placed on a rolling treadmill with speed advance set at 10 m/min. Stainless steel 316L electrodes (round to avoid undesirable sparks) with width of 40 cm and were placed between 15 cm, the pulse was applied each 20-40 s. The frequency of pulsed electrical fields was 20 to 350 kilo/Hertz using double polarity electrodes with the possibility of inversion if needed. All samples were packed using plastic polyethylene with 5 layers to hold vacuum (standard packaging for vacuum).

The equipment size is 3 x 2 x 3 m, has a control panel and Faraday cage due high voltages ranging 8 - 450 kV. 40 tests were carried out as follows: 2 times of entry + passage + exit in the sterilizing/pasteurizing machine using 20 s and 40 s, these time periods are justified because these speeds are significant and commercially viable on an industrial scale. Worth mentioning that as we are working with an extremely resistant bacterium C. difficile, a result of bacterial quantitative reduction would be enough to justify an efficient electro-pasteurization process. Figure 4 shows in details the industrial-scale PEF apparatus built.

Figure 4
PEF industrial-scale apparatus showing: A) chamber with automated control panel; B) isolated treadmill for pasteurization of packed foods; C) eletrical font; D) coil with ceramic insulation on the treadmill.

3 Results and discussion

3.1 Electric field simulations

The comparison between the values calculated using the Ganea (2017)Ganea, I. (2017). Influence of the solid dielectric over the electric field from the ozone cell gap with double dielectric barrier. IOP Conference Series: Materials Science and Engineering, 200, 012058. http://dx.doi.org/10.1088/1757-899X/200/1/012058. method and those simulated using the FEMM 4.2 software is shown in Table 2.

Table 2
Pulsed electric field simulations used in this study.

Table 3 presents the microbiology results obtained from the electro-pasteurization process, the results of the microbiological inactivation are the average result from 10 samples each (p < 0.05).

Table 3
Results of electro-pasteurization process in this study.

For C. difficile + E. coli contaminated meat samples, after pasteurization by PEF the microbiological count showed values < 0.1 CFU/mL thereby indicating absence. In relation to Salmonella spp. and mesophilic bacteria, the treatments of 10 X electrolysis + UV + 450 kVolts, radiofrequency of 350 kHz and treadmill speed of 10m/min, also showed the total absence of microorganisms.

In the 40 samples, a total inactivation of each microorganism occured, evidencing this technology as a rapid method for pasteurization of foods and beverages. Regarding the 10 samples of mesophilic bacteria, after PEF we also achieved total absense in concentration of this microorganism in practical testes.

Through the scientific evidence of previous works, as well as the results present here, it is clear that this technology can be applied to the large scale food industry, with promising perspectives to the progress of food security, since plasma pasteurization offers a faster, less toxic and versatile alternative to conventional methods.

The literature demonstrates that PEF can be used in food processing either in a singular, pure way or also as a summation method to the trivial systems already used in a classical way for the treatment of pasteurization of food itself. The great advantage of PEF is that this system does not use heat for food processing and thus conserving its organoleptic properties, as well as the process of death of microorganisms generated by PEF are quickly and thus PEF has been a great promise for the contemporary food industry (Nowosad et al., 2021Nowosad, K., Sujka, M., Pankiewicz, U., & Kowalski, R. (2021). The application of PEF technology in food processing and human nutrition. Journal of Food Science and Technology, 58(2), 397-411. http://dx.doi.org/10.1007/s13197-020-04512-4. PMid:33564198.
http://dx.doi.org/10.1007/s13197-020-045...
).

By using PEF, a targeted cell disruption of membranes of biological cells and microorganisms takes place. The principle of the innovative technology is so-called electroporation, with which the product is subjected to electric pulses by applying a voltage. Cell disruption of biological materials encourages the mass transport of water, however also of valuable substances (pigments) out of the cells. In the potato processing industry, advantages result from implementation of this technology with regard to processing and product quality. The induced structural modification enables energy savings, less raw product waste and the ability to develop new products. In the area of drying as well, energy savings can be achieved, just as an improved structural preservation and a more intensive flavour of various fruit and vegetable products. The cell disruption achieved with PEF enables a rapid discharge of water from the cells. In addition, valuable substances, such as cell sap, fatty acids, amino acids or pigments can also be more easily extracted.

Moreover, this is used in juice production, in particular to supporting the pressing process for the extraction of ingredients from microalgae and in wine production (Deutsche Landwirtschafts-Gesellschaft, 2018Deutsche Landwirtschafts-Gesellschaft – DLG. (2018). Use of Pulse Electric Fields (PED) in the food industry. Deutsche Landwirtschafts-Gesellschaft, 1-12. DLG Expert report 5/2018. Retrieved from https://www.dlg.org/fileadmin/downloads/lebensmittel/themen/publikationen/expertenwissen/lebensmitteltechnologie/e_2018_5_Expertenwissen_PEF.pdf
https://www.dlg.org/fileadmin/downloads/...
).

Using 450 kvolts, high frequency and alternate current during short periods of time, demonstrated effectiveness to sterilize harmful microorganisms in hermetically packaged foods and beverages.

4 Conclusion

From the simulations carried out, it was possible to obtain the values used as main parameters in the practical electro-pasteurization tests.

The PEF procedure used was: pulses 20 s – 40 s, using 40, 80 and 450 kV, and radio frequency of 350 kHz and 10 m/min treadmill speed. The electrical pulses (20 to 350 kilohertz) were discharged using double polarity 316L electrodes connected to the source, with the possibility of inversion as needed, the constant advancement of the treadmill was 10 m/min.

The results from tests shows a reduction from 1.0 x 106 CFU/mL to < 1.0 CFU/mL resulting in a complete elimination of all microrganisms tested including E. coli, C. difficile, meshophilic bacteria and Salmonella spp.

Excellent results were obtained with designed dimensions, having packed samples. This electro-pasteurization technology significantly contributes to food safety, beneficial for both pre-filling and post-filling liquid and solid foods.

In future work we intend to study the role of this technology in the denaturation of food proteins.

Acknowledgements

The authors would like to thank the Microbiological Laboratory - Eireli EPP and also the Post-Graduate Program in Chemical Engineering from Federal University of São Paulo – UNIFESP for the postdoctoral interships.

  • Practical Application: The practical application of this technology allows the pasteurization of beverages and packaged foods, sterilizing them and increasing their shelf life without the need to add salt or preservatives.
  • Availability of data and material

    The data used to support the findings of this study are available from the corresponding author upon request.
  • Funding

    No funding was obtained for this work.

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Publication Dates

  • Publication in this collection
    19 Sept 2022
  • Date of issue
    2022

History

  • Received
    13 Dec 2021
  • Accepted
    11 Aug 2022
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