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Evaluation of the distribution and accumulation of species of Alicyclobacillus in the fruit concentrate processing environment

Alicyclobacillus species are thermo-acidophilic bacteria that produce highly resistant endospores able to survive the processing temperatures of fruit concentrate manufacturing, including evaporation and conventional pasteurisation (86 ° 96 °C for ± 2 min). Alicyclobacillus endospores retain their viability in juice concentrates which, under favourable conditions, could germinate and multiply to numbers high enough to cause spoilage and product deterioration through the production of chemical taint compounds. This thesis reports on the distribution of Alicyclobacillus in the fruit concentrate processing environment and the effect of current manufacturing practices on the accumulation of Alicyclobacillus in fruit concentrates. These practices include the recirculation (recycling) of flume water as a means of water conservation, as well as continuous process running times when facilities operate at full capacity. This thesis also reports on the effect of fruit variety and skin type on the occurrence of Alicyclobacillus in fruit concentrates. Alicyclobacillus was monitored at nine processing stages of fruit concentrate manufacturing during the functioning of either a recirculating or a one-pass (not recirculated) flume water system. Significantly higher Alicyclobacillus levels were recovered in fruit mash, single strength juice, concentrate and the final pasteurised product (± 30 °Brix) during the functioning of a re circulating flume system, compared to when a one-pass flume system was functional (P < 0.05). Irrespective of the flume system, high Alicyclobacillus levels were recovered from the concentrate and condensate water (a by-product of juice concentration) from the evaporator, which makes this a point of concern during concentrate manufacturing. Manufacturing practices such as the recirculation of flume water and the recovery of condensate water for fruit washing purposes pose a potential risk of Alicyclobacillus contamination and accumulation in fruit concentrates and the processing environment. The effect of continuous process running times on Alicyclobacillus was monitored in a facility that was operating at full capacity. Sampling occurred every 12 h at four processing stages, during a processing tempo of 1.8 2.0 t h for 108 h. Vegetative cells increased significantly (P < 0.05) in single strength juice and condensate water after 84 h of processing, with 3.15 and 3.85 log10 cfu mL -1 recovered, respectively. Similar accumulation patterns of vegetative cells were observed in concentrate and the final pasteurised product. Endospores in single strength juice, concentrate and the final product were also the highest after 84 h of processing with 1.32, 1.59 and