|Microbiological test to compare the new material (right) and the wood multilayer (left)|
by Dr Simona Digiuni, PhD - Postdoctoral Researcher at the Department of Industrial Engineering, University of Parma, Italy and Emanuele Bigna, Plant Production Manager and R&D Manager, Ocrim s.p.a, Italy.
When cereals arrive to the milling plant, they carry a series of contaminations that can be divided into three main classes: physical, chemical and biological. The third class of biological contaminations may contain human pathogen microorganisms like E.coli, Salmonella and mycotoxin producing fungi. These organisms are naturally present in the environment where the cereals grow and several factors can increase their concentration leading to a threat to human health.
The first step of the milling process is actually the elimination of these contaminations. The cleaning of cereal prior to milling is therefore an essential step of the flour production. In time, many machines have been developed to remove physical contaminations from cereals like stones and straws or other biological contaminants like insects and seeds from other plants.
However, when it comes to microorganisms, due to their size, it is more difficult to detect and remove them. Moreover, as said before, the amount of microorganisms on the surface of the cereals can differ between batches. This phenomenon can lead to cross contamination effects inside the mill, because it is impossible to clean the plant every time a new lot is used.
How to solve contamination
The problem of microorganism contamination can be approached from different angles. One is to remove them mechanically from the surface by peeling or debranning during the cleaning. Another method is to reduce drastically their number with high temperature, chemicals (e.g. ozone, chlorine) or irradiation at different stages of the milling process.
The third approach is to reduce cross contaminations by avoiding the formation of new source of inoculation in the mill. The R&D team of OCRIM, in collaboration with the University of Parma, has investigated the last one in order to develop an innovative product for the mill.
The 70 years of experience in building and maintaining mills all over the world have shown OCRIM that certain spots in the mill create an optimal environment for mould formation.
Although in theory, the water activity in the milling plant is not optimal for the growth of microorganisms, certain conditions may create ideal microenvironments for their development.
The objective of the R&D team was to counteract the formation of these microenvironments thus block mould formation and bacterial propagation.
In the food industry, the use of materials with antimicrobial characteristics in strategic zones of the plants is largely diffused (e.g. packaging area). Thus, the idea was to transfer this technology to the flour milling industry. This research first identified the plansifters as one of the areas of the mill where microorganisms can develop and contaminate new batches of flour. This contamination can occur for a long period of time, until the growing moulds are physically removed from the machines.
Therefore, OCRIM considered the possibility to build sieves containing an antimicrobial compound that could prevent mould and bacterial formation. A fundamental step of the research was to find the appropriate material to build the sieves that bring together antimicrobial activity and three others main features: compatibility with food usage, durability and mechanical reliability.
OCRIM R&D team succeeded in finding a new composite material certified as food grade that contains an antimicrobial ingredient that can be used in milling plants. This substance is trapped inside the material; therefore, the antimicrobial is not released in the flour during sifting. This has the great advantage that it will not interfere with the rheological and backing characteristics of the flour.
Nonetheless, the antimicrobial is active on the surface of the sieves blocking the development of moulds and bacteria in the plansifter. Moreover, having a component that is incorporated in the material gives the benefit that it does not consume over time and the antimicrobial effect is present and stable for the whole life of the sieves.
The Global Miller
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