José de Assis Fonseca Faria

Food Safety Systems in a Small Dairy Factory: Implementation, Major Challenges, and Assessment of Systems' Performances

The present study describes the implementation of a food safety system in a dairy processing plant located in the State of São Paulo, Brazil, and the challenges found during the process. In addition, microbiological indicators have been used to assess systems implementation performance. The steps involved in the implementation of a food safety system included a diagnosis of the prerequisites, implementation of the good manufacturing practices (GMPs), sanitation standard operating procedures (SSOPs), training of the food handlers, and hazard analysis and critical control point (HACCP). In the initial diagnosis, conformity with 70.7% (n=106) of the items analyzed was observed. A total of 12 critical control points (CCPs) were identified: (1) reception of the raw milk, (2) storage of the raw milk, (3 and 4) reception of the ingredients and packaging, (5) milk pasteurization, (6 and 7) fermentation and cooling, (8) addition of ingredients, (9) filling, (10) storage of the finished product, (11) dispatching of the product, and (12) sanitization of the equipment. After implementation of the food safety system, a significant reduction in the yeast and mold count was observed (p<0.05). The main difficulties encountered for the implementation of food safety system were related to the implementation of actions established in the flow chart and to the need for constant training/adherence of the workers to the system. Despite this, the implementation of the food safety system was shown to be challenging, but feasible to be reached by small-scale food industries.

Probiotic yogurts manufactured with increased glucose oxidase levels: Postacidification, proteolytic patterns, survival of probiotic microorganisms, production of organic acid and aroma compounds

We investigated the effect of increased glucose oxidase concentration as a technological option to decrease oxidative stress during the processing of probiotic yogurts. Probiotic yogurts were produced with increased concentrations of glucose oxidase (0, 250, 500, 750, or 1,000 mg/kg) and submitted to physicochemical and microbiological analysis at 1, 15, and 30 d of refrigerated storage. Higher concentrations of glucose oxidase (750 and 1,000 mg/kg) and a longer storage time were found to have an influence on the characteristics of the probiotic yogurt, contributing to more extensive postacidification, an increase in the dissolved oxygen level, and higher proteolysis. In addition, increased production of aroma compounds (diacetyl and acetaldehyde) and organic acids (mainly lactic acid) and a decrease in the probiotic bacteria count were reported. The use of glucose oxidase was a feasible option to minimize oxidative stress in probiotic yogurts. However, supplementation with excessive amounts of the enzyme may be ineffective, because insufficient substrate (glucose) is present for its action. Consumer tests should be performed to evaluate changes in the sensory attributes of the probiotic yogurts with increased supplementation of glucose oxidase. In addition, packaging systems with different permeability to oxygen should be evaluated.

Manufacture of low-sodium Minas fresh cheese: Effect of the partial replacement of sodium chloride with potassium chloride

We investigated the effect of sodium reduction by partial substitution of sodium chloride (NaCl) with potassium chloride (KCl) on the manufacture of Minas fresh cheese during 21 d of refrigerated storage. Four treatments of low-sodium Minas fresh cheese were manufactured, with partial replacement of NaCl by KCl at 0, 25, 50, and 75% (wt/wt), respectively. The cheeses showed differences in the content of moisture, ash, protein, salt, and lipid contents, as well as on the extent of proteolysis and hardness throughout the storage period. However, no difference was observed among treatments within each storage day tested. The partial substitution of NaCl by KCl decreased up to 51.8% the sodium concentration of the cheeses produced. The consumer test indicated that it is possible to manufacture a low-sodium Minas fresh cheese that is acceptable to consumers by partial substitution of NaCl by KCl at 25% (wt/wt) in the salting step.

Reduced fat and sugar vanilla ice creams: Sensory profiling and external preference mapping

The aims of this study were (1) to map sensory attributes of vanilla ice cream with reduced fat and sugar, and (2) to determine drivers of liking by applying external preference mapping and reveal the relationship between descriptive attributes and hedonic judgments using the partial least squares method. Descriptive sensory profiles (n=11) and consumer test (n=117) of 6 samples of vanilla ice cream (3 traditional and 3 with reduced fat and sugar) were determined. The attributes brightness and sweet aftertaste for sample and creaminess (appearance and texture) and sweet aroma contributed positively to the acceptance of ice cream samples. The attributes aeration, powdered milk aroma and flavor, and white chocolate aroma and flavor contributed positively to the acceptance of the ice creams. The attributes hydrogenated fat aroma and flavor were responsible for the lower acceptance of samples. The reduction in fat and sugar did not necessarily cause a decrease in acceptance. The most important factors were selection of the appropriate sweetener system and the use of good quality raw material.

Stability of sliced mozzarella cheese in modified-atmosphere packaging

Twelve slices of mozzarella cheese (about 174 g) were packaged in expanded polystyrene trays placed in gas-barrier bags under three different atmospheres (100% N2, 100% CO2, and 50% CO2/50% N2). A gas headspace-to-cheese ratio of 2.5 liters/kg of cheese was initially set in the modified-atmosphere packages. Simulating conventional Brazilian packaging, some trays were wrapped in PVC stretched film. Periodically, the product stored at 7 ± 1°C was evaluated as to its sensorial quality, microbiological condition, and physical and chemical characteristics. The head-space volume and gas composition of modified-atmosphere packages were evaluated, The mozzarella cheese did not show any physical or chemical alteration in all packaging treatments. These characteristics were not factors which limited shelf life in air or in modified atmospheres. The critical parameter was sensory degradation. The shelf life of sliced mozzarella in conventional air pack was 13 days. N2 atmospheres had only a minor effect on shelf life compared with air. Samples under N2 were satisfactory up to 16 days. A significant shelf life increase was verified under CO2 atmospheres compared with air, as follows: 63 days (a 385% increase) and 45 days (a 246% increase) for product under 100% CO2 and 50% CO2/50% N2, respectively. The bacteriostatic and fungistatic effects of CO2 were verified. The growth of psychrotrophic bacteria, molds, and yeasts was slower under CO2 atmospheres. Mold and yeast development was inhibited under 100% CO2 (2 liters of CO2 per kg of cheese).

Development of probiotic dairy beverages: Rheological properties and application of mathematical models in sensory evaluation

Strawberry-flavored probiotic dairy beverages (2% vol/vol Lactobacillus acidophilus) were produced using 0, 20, 35, 50, 65, and 80% (vol/vol) whey in their formulations. Mathematical models (survival analysis, minimal significant difference, and mean global acceptance) were used to identify the optimal (sensorially) whey concentration in probiotic beverages. Fifty-five consumers evaluated acceptance of the beverages using hybrid 9-point hedonic scales. In addition, Lb. acidophilus were enumerated and pH was determined. Rheological behavior is an important characteristic for the processing and sensory acceptance of dairy beverages, varying with the presence of additives, fermentation process (time, bacterial strain), and whey concentrations used. All beverages presented minimal counts of 8 log cfu/mL of Lb. acidophilus, and pH ranged from 4.09 to 4.14. Increasing the whey content increased the fragility of the gel structure, probably because of the replacement of casein by whey proteins, once the concentrations of other ingredients in formulation were fixed. Whey content had a significant effect on acceptance of the probiotic dairy beverages; beverages with whey contents greater than 65% resulted in lower acceptance by consumers. The model of mean global acceptance presented 2 solutions with high sensory scores: beverages with 12 and 65% whey, the latter being of interest because it allows greater use of the whey by-product. The Weibull distribution presented a prediction of whey concentration of 49%, with higher sensory acceptance. The methodologies used in this research were shown to be useful in determining the constituents of food formulations, especially for whey-based probiotic beverages.

Characterization of Brazilian lager and brown ale beers based on color, phenolic compounds, and antioxidant activity using chemometrics.

BACKGROUND Epidemiological studies have shown that beer has positive effects on inhibiting atherosclerosis, decreasing the content of serum low-density lipoprotein cholesterol and triglycerides, by acting as in vivo free radical scavenger. In this research, the antioxidant activity of commercial Brazilian beers (n = 29) was determined by the oxygen radical absorbance capacity (ORAC) and 1,1-diphenyl-2-picrylhydrazyl (DPPH(·) ) assays and results were analyzed by chemometrics. RESULTS The brown ale samples (n = 11) presented higher (P < 0.05) flavonoids (124.01 mg L(-1) ), total phenolics (362.22 mg L(-1) ), non-flavonoid phenolics (238.21 mg L(-1) ), lightness (69.48), redness (35.75), yellowness (55.71), color intensity (66.86), hue angle (59.14), color saturation (0.9620), DPPH(·) values (30.96% inhibition), and ORAC values (3, 659.36 µmol Trolox equivalents L(-1) ), compared to lager samples (n = 18). Brown ale beers presented higher antioxidant properties (P < 0.05) measured by ORAC (1.93 times higher) and DPPH (1.65 times higher) compared to lager beer. ORAC values correlated well with the content of flavonoids (r = 0.47; P = 0.01), total phenolic compounds (r = 0.44; P < 0.01) and DPPH (r = 0.67; P < 0.01). DPPH values also correlated well to the content of flavonoids (r = 0.69; P < 0.01), total phenolic compounds (r = 0.60; P < 0.01), and non-flavonoid compounds (r = 0.46; P = 0.01). CONCLUSION The results suggest that brown ale beers, and less significantly lager beers, could be sources of bioactive compounds with suitable free radical scavenging properties.

Processing optimization of probiotic yogurt containing glucose oxidase using response surface methodology

Exposure to oxygen may induce a lack of functionality of probiotic dairy foods because the anaerobic metabolism of probiotic bacteria compromises during storage the maintenance of their viability to provide benefits to consumer health. Glucose oxidase can constitute a potential alternative to increase the survival of probiotic bacteria in yogurt because it consumes the oxygen permeating to the inside of the pot during storage, thus making it possible to avoid the use of chemical additives. This research aimed to optimize the processing of probiotic yogurt supplemented with glucose oxidase using response surface methodology and to determine the levels of glucose and glucose oxidase that minimize the concentration of dissolved oxygen and maximize the Bifidobacterium longum count by the desirability function. Response surface methodology mathematical models adequately described the process, with adjusted determination coefficients of 83% for the oxygen and 94% for the B. longum. Linear and quadratic effects of the glucose oxidase were reported for the oxygen model, whereas for the B. longum count model an influence of the glucose oxidase at the linear level was observed followed by the quadratic influence of glucose and quadratic effect of glucose oxidase. The desirability function indicated that 62.32 ppm of glucose oxidase and 4.35 ppm of glucose was the best combination of these components for optimization of probiotic yogurt processing. An additional validation experiment was performed and results showed acceptable error between the predicted and experimental results.

Effect of the inoculation level of Lactobacillus acidophilus in probiotic cheese on the physicochemical features and sensory performance compared with commercial cheeses.

The complex metabolism of probiotic bacteria requires several technological options to guarantee the functionally of probiotic dairy foods during the shelf life. This research aimed to evaluate the effect of the supplementation of increasing amounts of Lactobacillus acidophilus (0, 0.4, or 0.8 g/L of milk) on the physicochemical parameters and sensory acceptance of Minas fresh cheese. In addition, the sensory acceptance of probiotic cheeses was assessed using a consumer test and compared with commercial cheeses (conventional and probiotic). High counts (9.11 to 9.42 log cfu/g) of L. acidophilus were observed throughout the shelf life, which contributed to the maintenance of its probiotic status and resulted in lower pH values and greater production of organic acids. The probiotic cheeses presented lower scores for appearance, aroma, and texture compared with conventional cheeses. Internal preference mapping explained almost 60% of the total variation of the data and showed a large number of consumers concentrated near the conventional cheeses, demonstrating greater preference for these samples. The findings indicated that some negative sensory effects could occur when high level of supplementation with L. acidophilus is used in probiotic cheese processing.

The influence of sweeteners in probiotic Petit Suisse cheese in concentrations equivalent to that of sucrose

As in the case of probiotic functional foods in recent years, demand has increased notably for light or diet foods with added sweeteners. However, little is known about the effect of different sweeteners on the microorganisms present. Thus, the objective of the current study was to establish the ideal sucrose concentration and equivalent concentrations of different sweeteners and to determine, by microbiological analyses, the influence of these compounds on the viability of the starter and probiotic cultures used in the production of strawberry-flavored Petit Suisse cheese during its shelf life. The ideal sucrose concentration was determined using the just-about-right (JAR) scale, and the equivalent concentrations of the sweeteners were subsequently determined by the magnitude estimation method. Microbiological analyses were also carried out to check the viability of the cultures during the products shelf life. The results showed that the compounds Neotame (NutraSweet, Chicago, IL) and stevia presented, respectively, the greatest and least sweetening power of the sweeteners tested. None of the sweeteners used in this study exerted a negative effect on the viability of the starter or probiotic cultures, and thus we were able to obtain a probiotic, functional food with reduced calorie content.