CSIRO: four new technologies for food processing

The CSIRO’s Ciara McDonnell talks about new technologies that are having an impact on the food industry.

When people think of the Commonwealth Scientific and Industrial Research Organisation, or CSIRO as it is affectionately known, most have images of boffins in white coats working in laboratories with Petri dishes, beakers and Bunsen burners busily inventing new gizmos and gadgets for an array of industries. And while this is accurate to a degree, it also is a multi-faceted institution that has more than 5,000 dedicated staff spread around 57 sites throughout the continent.

It has more than 690 patents including the one that encapsulates its most famous invention, wifi, and covers many research spectrums including mining, manufacturing and food. Most recent figures state that it returns about $4.5 billion to the Australian economy annually, and partners with more than 1200 SMEs per year. It’s a very busy place, and one that attracted Irish research scientist Ciara McDonnell to Australia.

McDonnell works at one of the three food sites CSIRO has set up throughout Australia. They’re at Werribee in Melbourne, North Ryde Sydney and Coopers Plains, Queensland, where she is based.

McDonnell spoke at a seminar at the recent FoodTech Expo held in Queensland. She talked about four food technologies that could have a lasting impact on the food industry.

Various Business Units in CSIRO welcome collaboration, and the Agriculture and Food Unit is no different.

“Coopers Plains is home to one of our food pilot plants that we share with the Queensland Department of Agriculture and Fisheries,” she said. “At that pilot plant, CSIRO have an emphasis on meat processing, so we have a suite of conventional pilot scale meat processing equipment. This can enable food processors to conduct trials at reduced batch sizes until the process is ready for scale-up. Then we assist companies with that scale up to ensure the best route to commercialisation.

“When we do any kind of R&D, we do take a multidisciplinary approach. We have a lot of expertise in house and we understand the importance of each aspect – from safety, nutrition, processing, food chemistry and more.’

Future trends are very important in the institution’s work because CSIRO want to conduct research with impact for current and future markets. And what are some of the pressing issues in the food and beverage space at the moment?

“We can certainly say that environment, sustainability, health, clean label and minimal waste are some of the top food trends that we drive towards,” said McDonnell. “CSIRO sees itself as bridging the gap between academic research and commercialisation into industry. We have access to a large suite of innovative processing technologies ranging from pulse electric fields, advanced spray and convection drying, high pressure processing, – the list goes on. In addition, we look after pilot scale conventional processing technologies as well.”

One way of gauging where a technology is at in terms of its development towards commercialisation is the Technology Readiness Level (TRL). This can be 1 or 2, which means it is at the beginning of its research level up to 9 or 10 where it is being commercialised.

High-Pressure Processing
High-pressure processing (HPP), which it is now commercialised for many food applications, was on the CSIRO radar almost 20 years ago. What exactly is HPP?

“HPP can offer an alternative to heat pasteurisation by inactivating microorganisms. A pre-packaged product is placed into a liquid-filled chamber where it gets treated, but there’s no re-opening of the pack, so no recontamination,” said McDonnell. “Pressure is applied instantaneously and uniformly so it is evenly transmitted throughout the product, usually at about 600 megapascals (MPa), or 6,000 bar, for a few minutes. The effectiveness of the process is dependent on the product type and its different properties like pH and water activity.

What makes HPP so attractive is that the high pressure affects non-covalent bonds only. This means that small molecules that give consumers health benefits, micro-nutrients, colour to the product and the flavour molecules, are unaffected. HPP offers a means of maintaining the fresh-like characteristics of the product – better colour, extended shelf life – it fits with the clean label and fewer additives trend that is now part of the food and beverage landscape. Currently, it is estimated that there are more than 2 million tonnes of HPP products produced per year globally. It is estimated that the industry will be worth about $80 billion by 2025. It is broadening into new product sectors, with its main application being shelf-life extension of refrigerated products.

However, McDonnell points out there is a catch. The technology doesn’t inactivate bacterial spores, whereas thermal pasteurisation can.

“So for those foods – low acid food, mainly with a pH greater than 4.6 – it will not work at reducing spore-forming bacteria” said McDonnell. “Any manufacturer that is interested in making products where spore control is required would have to limit the shelf-life, add preservatives, or the alternative is to heat the product, which could result in reduced flavour and nutritional value.”

McDonnell’s colleagues then started to experiment with a combination of heat and pressure, or, high pressure thermal processing (HPTP). They simultaneously applied moderate heat and pressure, and reduced the spore load with less overall thermal load than would typically be required to pasteurise or sterilise a product. What they found was that if they applied HPTP at 550 MPa for one minute at 87.5°C, they could achieve the same inactivation of Clostridium botulinum spores as a thermal-only process of 10 minutes at 90°C. They refer to this phenomena as HPTP synergy.

“You have less thermal load, so you are maintaining the nutritional molecules value, while achieving a significant increase in Clostridium botulinum inactivation” said McDonnell.

But there was another catch. As mentioned, the CSIRO sees itself as bridging the gap between research and commercialisation. And it knows that companies that have invested in HPP, have units without heating ability, and this limits the scope of products it could potentially process; in fact, there are no HPP machines available at commercial scale that have heating capability.

“In order to commercialise the HPTP, we need some processing adaptation,” said McDonnell. “CSIRO developed an insulated HPP canister that, after a pre-heating step, can be inserted into a conventional (cold) HPP unit to deliver a HPTP process. This is something that is going to be licensed by CSIRO and it will allow HPP units to be adapted with a simple drop-in solution.”

Ultrasound
Another technology finding its feet within the food industry is ultrasound processing. It has commercial applications in several processes in the food sector including emulsion breaking and separation, mixing, , homogenising and degassing products.

How does it work? Ultrasound pressures can be created in gas or liquid media  at frequencies in the range of 20 to 100 kHz with traditional transducer devices. As the soundwave travels, it oscillates above and below atmospheric pressure. When this occurs in a liquid, any microscopic gas bubble, which can be dissolved gas as well as water vapour, present in that medium will go through the cycles where it expands and contracts until it reaches an unstable size. It then goes through a final cycle, this causes the bubble to implode on itself. This is known as cavitation. It is not visible to the eye, but it is a very destructive microscopic mechanism. There are other effects caused by ultrasound, such as microstreaming, caused by the sound waves as well as the cavitation, that can be used for a range of applications. During the last decade CSIRO has created applications with frequencies from 400 kHz to 2 MHz, where smaller and larger amount of bubbles are created. In such cases, very mild cavitation occurs, if any, as bubbles do not reach their unstable state and transition back into compression.

CSIRO has filed a patent application based on the innovative application of ultrasound to dry foods far more gently with less energy consumption for sustainable manufacture of premium food products & ingredients.

The ultrasound-assisted drying technology has been shown to be highly effective in intensifying low temperature drying (from 40°C to below freezing) of various food materials (e.g., fruits, coffee, and meat products) resulting in up to 57 per cent reduction in drying time (i.e., corresponds to 54 per cent reduction in energy consumption) with better product quality by minimising thermal degradation.

The technology can be applied to enhance the drying processes of other heat sensitive non-food materials (e.g., bio-pharmaceuticals, medicinal crop, petfoods, etc.), providing further commercialisation opportunities across a broader sector. The patent also covers a novel use of the system in pretreatment processes for improved drying efficiency.

CSIRO is currently partnering with equipment manufacturers to develop and build a pre-commercial pilot prototype of the system to help prove its scalability and commercial viability.

CSIRO has also patented a process that enables oil recovery during both aqueous based edible oil extraction processes and oil refining by application of high frequencies beyond 400 kHz, also known as megasonics. The megasonic equipment is now commercially used in the palm oil industry to recover 200,000 litres extra crude oil per annum in a traditional palm oil plant or an additional 1 per cent oil loss reduction (saving about USD 500,000 per annum). The process consists of passing pre-macerated oil palm fruit through the megasonic unit to enable oil removal from the vegetable biomass, thereby enhancing oil recovery after the centrifugation step. The technology has also been proven to aid the olive oil process. A megasonic treated olive paste can provide an additional 4 per cent oil recovery at 3 tonnes of olive paste per hour, with a payback time of 3 years in a middle sized olive oil plant. Another use of the technology is in avoiding oil losses during the refining process by treating the emulsified oil with megasonic waves before gum removal. The technology has enabled reducing up to half of the oil trapped in gums, obtained as a refining process by-product.

Pulsed Electric Fields
Another innovative processing application is pulsed electric fields (PEF) processing, which is based on placing the food between two oppositely charged electrodes.

“If you imagine a bacterial cell filled with charged ions – positive and negative – and we apply very short pulses of very high voltage so we don’t generate heat. Typically, we apply several thousands volts for a few microseconds – this results in the ions moving towards the oppositely charged electrode until they permeate the cell membrane of the bacterial cell,” said McDonnell. “Just like HPP, it is a way of targeting those micro-organisms without affecting any molecules that contribute to flavour, colour and nutritional value of a product.”

The technology is high on the TRL scale as it has already been commercialised for fruit juice use. It can extend shelf-life significantly for preservative-free juices, while preserving nutrients. In addition, it has helped companies achieve up to 6% increase in extraction yield.

‘’We’ve looked at other applications, like non-thermal milk pasteurisation and improving the texture and quality of meat.”

Shockwave
Shockwave technology is the most novel of all those discussed by McDonnell because it is at proof-of-concept stage. It is the CSIRO’s newest investment, with the government entity having acquired a second commercial prototype, the first outside of Europe.

The idea of shockwave technology first came for meat applications around 1997 when scientists decided to put pre-packaged meat under water and detonate explosives to see if they could  tenderise meat.

“When I spoke about HPP I was talking about static application of hundreds of megapascals,” said McDonnell. “With shockwave technology, high pressures are applied for a shorter time – micro seconds. In previous studies, 100gms of explosives, placed underwater, were used to tenderise meat. Scientists thought, ‘this is great, but how can we commercialise something with explosives?’ For that reason the speed at which the idea progressed has been slow because, as you imagine with explosives, there were a lot of safety concerns.”

In 2001, dielectric discharge came into being, which helped recreate the shockwave. The technology uses two electrodes to generate a similar effect to the explosives. The scientists put voltage through the electrodes and the resulting arc causes very high pressure under water.

“We have acquired a commercial prototype from Germany, which can allow for continuous processing by a conveyor system. We can place a product on it, allowing it to go into the water tank, exposing it to shockwaves and come out at the other side,” said McDonnell. “At the moment, we have a lot of concepts to prove with the technology.

“We think it might cause tissue disintegration so we could accelerate the tenderisation of meat. The first application we are studying it for is meat processing through an Australian Meat Processor Corporation-funded project.”

McDonnell said that when it came to modelling and pressure, the scientists aimed to understand shockwave distribution in the treatment chamber and to identify the area of maximum impact.

“We used the information from the modelling and conducted trials with meat. We had a tenderisation effect which was measured objectively using a Warner Bratzler shear test, where the peak force required to cut through treated meat samples is recorded,” she said. “And now we are working towards optimising this effect.”

McDonnell is hopeful that a lot of these technologies will come to fruition. Some will take longer than others to be realised, but that is the nature of science and discovery.

“There is a future for some of these novel technologies as they provide an opportunity for clean labelling, either by changing the food structure or inactivating microbes,” she said. “Certain applications have already been commercialised and there are good opportunities for all these technologies to be taken up by the food industry. Who knows what else is to come from TRL 1 when new ideas are generated at research? They all certainly fit with the trends we are aware of, and they could help with regard with things like having less waste. It could allow us to have more food for increased food demand. Also, with globalisation we need extended shelf life to reach new markets so it will really help us on the supply chain and yield, as well as having healthier products and more efficient and sustainable processes.”