Superheated steam effectively inactivates diverse microbial targets despite mediating effects from food matrices in...

Sanitation in dry food processing environments is challenging due to the exclusion of water. Superheated steam (SHS) is a novel sanitation technique that utilizes high temperature steam to inactivate microorganisms. The high sensible heat of SHS prevents condensation on surfaces. Here we evaluated SHS thermal inactivation of various vegetative and spore forming bacteria and fungi and determined the effect of food matrix composition on SHS efficacy. Capillary tubes with vegetative cells (Salmonella, E. coli O157:H7, Listeria monocytogenes, or Enterococcus faecium), Aspergillus fischeri ascospores, or B. cereus spores (100 μL) were SHS treated at 135 ± 1 °C for 1 or 2 s. After 1 s, SHS achieved a reduction of 10.91 ± 0.63 log₁₀ CFU/mL for vegetative cells, 2.09 ± 0.58 log₁₀ ascospores/mL for A. fischeri, and 0.21 ± 0.10 log₁₀ spores/mL for B. cereus. SHS treatment achieved significant reductions in vegetative cells and fungal ascospores (p < 0.05), however B. cereus spores were not significantly reduced after 2 s and were determined to be the most resistant of the cell types evaluated. Consequently, peanut butter compositions (peanut powder, oil, and water) and milk powder (whole and nonfat) inoculated with B. cereus spores on aluminum foil coupons (2 × 3 × 0.5 cm) were tested. The D_161°C values for B. cereus spores ranged from 46.53 ± 4.48 s (6 % fat, 55 % moisture, a_w: 0.927) to 79.21 ± 14.87 s (43 % fat, 10 % moisture, a_w: 0.771) for various peanut butter compositions. Whole milk powder had higher D_161°C (34.38 ± 20.90 s) than nonfat milk powder (24.73 ± 6.78 s). SHS (135 ± 1 °C) rapidly (1 s) inactivated most common vegetative bacterial cells; however B. cereus spores were more heat resistant. B. cereus spore inactivation was significantly affected by product composition (p < 0.05). Compared to the log-linear model (R² 0.81-0.97), the Weibull model had better fit (R² 0.94-0.99). Finally, the ease of peanut butter removal from surfaces increased while the ease of non-fat dry milk removal decreased with the increasing SHS treatment duration. However, allergen residues were detectable on surfaces regardless of SHS treatment. The findings from this study can inform the development of pilot-scale research on SHS.