College of Health Sciences

Department of Environmental Health Sciences

Food Microbiology 0506513
Fall semester/ 2022-2023

Hurdle Technology in Foods Preservation

 

Prepared by:

Raghad Khaled Mohd. Zeer 22105059

Table of contents:

Introduction---------------------------------------------------------------------------------------------------------------1

Body:

The concept of hurdle approach ---------------------------------------------------------------------------------------1

Effects of hurdle technology -------------------------------------------------------------------------------------------3

Mechanisms of food preservation by Hurdle Technology----------------------------------------------------------

Types of hurdles in food------------------------------------------------------------------------------------------------8

Application of hurdle technology in preservation food-------------------------------------------------------------9

Conclusion---------------------------------------------------------------------------------------------------------------

13

References---------------------------------------------------------------------------------------------------------------14
To guarantee global food safety from farm to fork, researchers are continually developing new

microbial control technologies. The level of microbial contamination in a food product is

determined by the microbial load and virulence of the spoilage-causing microorganisms,

including bacteria, fungus, yeasts, viruses, and protozoa. Certain pathogenic bacteria can harm

customers' health by causing food poisoning and other foodborne illnesses. Hurdle technology is

a comprehensive approach to basic food preservation methods that results in safe, stable, and

nutritious foods.  For decades, a variety of traditional food processing techniques have been used

to resolve problems linked to food safety. However, some decontamination methods alter the

organoleptic and nutritional qualities of food products, resulting in unfavorable changes. This

situation forces food producers, product developments, and quality assurances to create the

hurdle technology that uses "minimum" processing technology and combines these mild

procedures to offer an alternative to traditional technology and generate safe and nutritious food

items.

 The concept of Hurdle technology:

In the past, generic terms like heating, drying, salting, acidifying, fermenting, etc. were used to

describe techniques used to preserve foods. The preservation treatments could be quantified in

terms of F, aw, pH, Eh, etc. once the principles behind these measurements, i.e., how to quantify

heating by F values, drying by water activity, acidifying by pH and titratable acidity, measuring

the redox state (Eh), etc., became recognized. The crucial limits for the development, survival,

and demise of important microorganisms in relation to these values have since been the subject
of extensive research. and such information has served as the foundation for numerous

developments in food preservation methods. However, it soon became obvious that in most

foods, a combination of preservative variables, rather than just one, determines the

microbiological stability and safety. (L. Leistner et al., 2002). Leistner is credited with coining

the phrase "hurdle technology" after years of productive work with his teammates at the Federal

Centre for Meat Research in Germany to identify the preservative factors which were called

hurdles and control them. By the use a variety of technologies and methods, hurdle technology

ensures the safety of foods by eliminating or controlling the growth of pathogens, making the

food safe for consumption, and extending its shelf life. High temperatures during processing, low

temperatures during storage, increasing acidity, decreasing water activity or redox potential, or

the presence of preservatives are all hurdles in the food system. The intensity of the hurdles can

be adjusted individually to meet consumer preferences in an economical way without

compromising product safety, depending on the type of pathogens and how risky they are.

Hurdle technology has the goal not just to know why a particular food is safe and stable, but to

enhance the microbial quality of the food by an optimization and intelligent modification of the

hurdles present. a further step was to focus on food design not just on microbial safety and

stability but also on the sensory and nutritional quality of a foodstuff, i.e., on total quality (A.

Gordon, 2017). For example, most meat products use the hurdle technique. Developing a meat

product that is both shelf-stable and consumer-acceptable requires a multidisciplinary approach

from experts. Low-dose radiation combined with other decontamination techniques helps to

eradicate microbes without degrading sensory quality since the dose of ionizing radiation needed

to inactivate pathogenic bacteria in meat products induces unfavorable alterations in sensory

qualities. (B. Aaliya et al., 2021)

  Effect of hurdle technology

The technology's primary goal is to combine different preservation methods in a way that

prevents the growth of spoilage microorganisms and the overall deterioration of the food

product. Figure 1 shows nine examples of the hurdle effect.

Example No.1: A food is shown with six hurdles: high processing temperature (F), low storage

temperature (t), low water activity (aw), acidity (pH), redox potential (Eh) in the product, and

preservatives (pres.). In this instance, the microorganisms present are unable to get through these

barriers, making the food microbiologically stable and safe. Looking at this situation, all the

hurdles appear to have the same height or level of intensity, which is unusual. As a result, this

situation can only be hypothetical.

Example No.2: A food includes aw and preservatives as the main hurdles. Other obstacles that

are less significant include redox potential, pH, and storage temperature (t) (Eh). This product's

microbiological stability is supported by hurdles of various intensity. Therefore, the five

obstacles listed above are adequate to stop the spread and thriving of the typical types of

microorganisms that typically make up the product's microflora.

The third example demonstrates a product that has only a few microorganisms present at the

beginning then few or only low number of hurdles and at low intensity are sufficient for the

product's microbiological stability. The aseptic preparation of perishable foods (such as high

moisture foods) uses this approach after minimizing the initial load of microorganisms by the

steam blanching.

Example No. 4, on the other hand, is the result of poor hygienic settings, where too many

undesirable microorganisms are present at the beginning. In this situation, it's possible that the
product's inherent hurdles won't be enough to avoid spoiling or the multiplication of food-

poisoning microorganisms.

Example 5 illustrates a food high in nutrients (N) and vitamins (V). The trampoline effect is a

term used to describe how quickly germs can multiply because of the inherent properties of food.

The bacteria present may not be able to overcome the hurdles in this product, though, if they are

enhanced. The behavior of organisms that have undergone sub-lethal injury is described in

Example 6. This occurs when the food has been pretreated by heat, which results in the lack of

vitality of vegetative cells. This makes it conceivable for few or low hurdles to have an

inhibitory effect. Additionally, some foods are stabilized throughout processing by a sequence of

hurdles. These hurdles are crucial at various phases of the fermentation or ripening process to

produce a stable final product (e.g., in the production of yoghurt).

Example No.7 illustrates an example of the preservative hurdles in canned cured meat products

that may decrease over time because once the nitrite is depleted, dormant spores may grow and

spoil the food or increase the risk of food poisoning. Stability is achieved in some foods during

processing through a time-dependent sequence of hurdles that are important at different stages,

particularly in fermentation or ripening processes, and lead to stable final products. (S.

Nassarawa et al.,2019).
 

Mechanisms of food preservation by Hurdle Technology

The physiology and growth of microorganisms in food are affected by hurdle technology. There

are four major mechanisms by which hurdle technology influences microorganism growth in

foods:

1. Homeostasis

‘‘Homeostasis is the tendency to uniformity and stability in the internal status of organisms.’’ (T.

Tsironi et al., 2020) In food preservation, the homeostasis of microorganisms is a critical

phenomenon that requires close attention, because if the homeostasis of these microorganisms is

disrupted by preservative factors (hurdles) in foods, they are unable to multiply, i.e., they remain

in the lag-phase or even die, before homeostasis is re - established. Microorganisms, on the other

hand, can go through a variety of important homeostatic reactions. As a result, combining

multiple factors is the most effective way to disrupt homeostatic mechanisms (hurdles). Because
maintaining a disturbed homeostasis requires energy, restricting the energy supply prevents

microbial cells from maintaining their homeostasis and may have a synergistic antimicrobial

impact. For instance, the microorganisms that live in a food with a changing pH try to keep their

internal pH within extremely specific ranges. (O. Erkmen et al.,2016)

2. Metabolic exhaustion

The auto sterilization of food is the focus of this aspect of hurdle technology. Foods may become

auto sterilized as a result of microbes becoming metabolically exhausted from hurdles. It has

been noted that during storage, especially at room temperature, the spore counts in food products

treated using hurdle technology decrease. The microbes in the hurdle-treated stable products

expend all their energy maintaining homeostasis, which exhausts them metabolically. Food

products are subsequently auto sterilized and are protected from pathogens and spoilers during

storage as a result. Thus, it is safer to store the microbiologically stable product at ambient room

temperatures. (O. Erkmen et al.,2016)

3. Stress reactions

Microorganisms under stress can tolerate further pressures effectively (cross tolerance). The

implementation of hurdle technology in food preservation may be complicated by the different

stress responses of microorganisms. Since some bacteria may become more resistant or more

virulent under stress reactions, such as synthesis of protective stress shock proteins

(PSSPs). Several stresses, including heat, pH, water activity, ethanol, oxidative compounds, and

nutrient deprivation, cause the synthesis of protective stress shock proteins. The different ways

that bacteria react to stress could make it difficult to preserve food and make it difficult to use

hurdle technology. The simultaneous exposure to several stresses will necessitate the energy-
intensive synthesis of several, or at least much more, defensive stress shock proteins, which may

lead to the metabolic exhaustion of the microorganisms. (O. Erkmen et al.,2016)

4. Multi target preservation of food

The most effective method of food preservation is multitarget preservation. Individual hurdle in a

food may not have an additive effect on microbial stability, but a combination of factors might

have. If the hurdles in a food hit different targets (e.g., cell membrane, DNA, and enzyme

systems) within the microbial cell at the same time, a synergistic effect could be achieved. PSSP

synthesis can be avoided through multitarget food preservation. When microorganisms are

subjected to multiple stresses at the same time, their energy levels fall dramatically. This could

lead to metabolic exhaustion in the microorganisms. Different hurdles' multitarget actions

enhance each hurdle's antimicrobial effect. It is more effective to use multiple small-intensity

preservative factors (hurdles) than one large-intensity preservative factor, for this reason hurdle

technology allows for the use of individual lower-intensity hurdles to improve product quality.

(O. Erkmen et al.,2016)

 Types of Hurdles in food

Physical, physiochemical, and microbial hurdles are briefly outlined as they are used for the

preservation of a variety of foods.

1. Physical hurdles consist of:

•High Temperature: Sterilization, Pasteurization and Blanching

• Low temperature: Chilling and Freezing
• Irradiation: ultraviolet and ionizing radiation
• Electromagnetic energy (Microwave energy, Radio frequency energy, oscillating magnetic field
pulses and High electric field pulses)
• Photodynamic inactivation
• Modified atmospheric packaging (Gas packaging, Vacuum packaging, Moderate vacuum and
active packaging)
• Packaging film (Plastic, multilayer, active coating and edible coating)
• Aseptic packaging
• food microstructure
• High-pressure processing (HPP)

2. Physiochemical hurdles consist of:

• Preservatives: Salt, nitrate, nitrite, sulphate, phosphate, ethanol, chelators, lactate, acetate,
propylene glycol, smoke, phenols, surface treating agents, lysozyme.
• Low water activity (aw)
• Low pH & redox potential (Eh)
• Gases: Oxygen, ozone, carbon dioxide
• Organic acids: Lactic acid, acetic acid, ascorbic acid,
• Maillard reaction products
• Spices & Herbs (S. Nassarawa et al., 2019)

3. Microbial hurdles consist of:

•Antibiotics
•bacteriocins
•competitive flora
•protective cultures (S. Mukhopadhyay et al.,2014)

 Application of hurdle technology in preservation food.

Hurdle Technology is a novel concept with several applications in the preservation of various

food products. Before using hurdle technology, different types of foods must be differentiated. In

this assignment, foods will be classified as low-moisture foods (LMFs), intermediate-moisture

foods (IMFs), and high-moisture foods (HMFs) since they apply hurdles differently.
1. low-moisture foods (LMFs): Water activity in low-moisture foods (LMFs) is equal or less

than 0.85 at 25 °C (aw,25Co). Most bacteria cannot grow in this environment in order to

cause illness, spoil food, or produce toxins. However, just because bacteria can't multiply at

low temperatures aw,25Co, doesn't mean they can't survive in LMFs. When consumed,

pathogenic bacteria like Salmonella enterica, Listeria monocytogenes, and Cronobacter can

survive in LMFs for months or even years. (S. Liu, et al., 2022) Cereals, spices, nuts, and

food powders are some examples of such food ingredients or products, which may also be

dried. Dry foods are contaminated with microorganisms that can cause disease, spoilage, or

both. Recent years saw the identification of major lethal outbreaks of pathogenic

microorganisms in food powders. For example, the presence of C. sakazakii in infant

formula, Enterococcus in dairy powder, and B. cereus in spice and rice powders presented

serious health and safety risks to newborns, young children, and adults. At first, fumigation

was believed to be an effective technique for getting rid of bacteria in food powders. But

when food products are treated with fumigation, mutagenic and carcinogenic residues are left

behind. In order to disinfect low-moisture meals, possible thermal and non-thermal solutions

were therefore introduced. Regarding that stress-resistant bacteria can survive on food

powders, combining two or more technologies helps low moisture foods have significantly

greater microbial stability. Applying two physical barriers to inactivate Salmonella in dry

almonds and grated/powered almonds is an example of introducing hurdle technology.

Salmonella inactivation on dried almonds and grated/powered almonds has been studied

using a combination of superheated steam (SHS) and infrared heat treatments. It was

discovered that the mixture offered benefits such a high heat transmission rate and quicker

drying rate. It was discovered that heat treatment on grated/powered almonds followed by
 infrared treatment for 70 s was able to reduce the Salmonella population by 5.73 log CFU/g

(In comparison to 1.56 log CFU/g and 2.83 log CFU/g under SHS and IR, respectively when

applied individually), and no survivors were discovered in the enrichment medium. The

microbiological parameter and quality indicators suggest that SHS treatment followed by

infrared exposure is successful in removing the population of pathogens on almonds without

significantly altering their general quality. (E.J. Rifna et al., 2019)

2. Intermediate-moisture foods (IMFs) or Semi-dried foods (SDFs): IMF or SDF typically have

a weight

moisture content of 20% to 50%. IMF foods are often regarded as microbiologically stable at

room temperature and have an aw of 0.65 to 0.90. IMF typically preserves the initial qualities

(color, texture, and flavor) of fresh food goods. The distinct qualities that draw customers to IMF

are its high nutritional content, ready-to-eat (RTE) status, and conceptional microbiological

safety. The food business must provide IMF with qualities like those of fresh foods but with a

prolonged shelf life to meet consumer demand. Drying is a crucial stage in the reduction of water

in IMF. Due to its low cost and ease of usage, hot air drying is one of the most popular drying

techniques. However, hot air drying has a number of disadvantages, including inefficient energy

use, prolonged drying times, and frequently poor product quality. The hurdle technology

combines the low levels of two or more preservation hurdles, resulting in little damage to food

product quality. Various researchers used hurdle technology to preserve various food products

instead of traditional preservation methods that use a single physical or chemical hurdle applied

at a relatively high level that contributes to noticeable changes in sensory qualities of the

preserved food. Avocado puree is an example of an intermediate moisture food that can be stored

for four months at 4 °C or 22 °C using hurdle methods. Sorbic acid significantly affected
microbiological stability, and 300 mg/kg sorbic acid was sufficient to inhibit microorganism

growth. Avocado puree can also be preserved without the addition of sorbic acid by using a

vacuum package and storing it at 4 °C. Maltose can slightly extend the shelf life of samples by

lowering their aw. However, using sugar alone to achieve the required level of preservation is

likely to have an impact on the sensory properties. Hurdle technology was also used in the

preservation of spiced mutton and spiced chicken products with intermediate moisture (IM) (aw

0.8). In this case, hot air drying, or grilling was used to reduce the aw of the samples to 0.80. The

package was then vacuumed and eradiated at 0-10 kGy. The shelf life of the samples increased

as the irradiation dose increased. The shelf life of samples subjected to 10 kGy irradiation was

extended by about 7 months without sensory changes when compared to samples not subjected

to irradiation processing. (L. Qiu et al., 2019)

3. High-moisture foods (HMFs): HMFs are fresh-like items with minimal processing. HMFs are

chilled

or frozen and have an aw above 0.90. Low temperature maintenance costs money and uses a lot

of energy. HMFs' stability and safety may be compromised by storage conditions that are too hot

or too cold. Therefore, in addition to the low temperature, HMFs must also apply additional

hurdles related to heating, pH, Eh, aw, preservatives, and competitive flora. Fish, meat, and meat

products are increasingly being processed using hurdle technology, because meat and fish are

extremely perishable foods having aw above 0.90 and prone to microbial contamination. (O.

Erkmen et al., 2016) Since fish is a very perishable food, low temperature storage is typically

recommended because high temperature preservation methods cause unfavorable quality

changes. So, to prevent microbial growth and maintain quality, fish and shellfish are immediately

refrigerated or frozen after harvest. Fish can be preserved traditionally by freezing, canning,
salting, or marinating. Even though these techniques are efficient, the seafood processing

industry still needs new processing technologies for surface cleaning. In general, the combination

of minimal processing methods (applying hurdle technology) led to more effective microbial

inactivation and shelf-life extension than individual approaches in fish and fish products. These

methods included low-temperature treatment, pH and aw alteration, application of

antimicrobials, HPP, etc. Meat is an extremely perishable food, just like fish. To guarantee the

microbiological stability and safety of fresh and processed meat products, food preservation

procedures are essential. Thermal processing, chilled storage, vacuum packaging, and the

addition of nitrites and other preservatives are all steps in the traditional processing of meat

products. However, these hurdles do not appear to be effective against pathogens like L.

monocytogenes due to their widespread. In addition, the products that have been chemically

treated fall short due to significant residual deposition. Meat cuts cannot be subjected to

pasteurizing procedures because the cut muscle surfaces discolor when heated to the proper

pasteurization temperatures. To get rid of potentially hazardous residuals and prevent adverse

quality changes after high-temperature treatment, non-thermal methods were preferred. By

exposing meat surfaces to HPP, UV light, X-rays, and -rays, bacteria can be destroyed. Several

meat products use hurdle technology. Building a meat product that is both shelf-stable and

consumer-acceptable requires a multidisciplinary approach from experts. since the dose of

ionizing radiation needed to inactivate pathogenic bacteria in meat products induces unfavorable

alterations in sensory qualities. Low-dose radiation combined with other decontamination

techniques helps to eradicate microbes without degrading sensory quality. To maximize

antibacterial activity, non-thermal technology combinations with vacuum packing or MAP are
also used. It has been clearly demonstrated that meat products processed using hurdle technology

had enhanced microbiological stability with little impact on quality. (B. Aaliya et al.,2021)

The vast majority of preserved foods consumed in various countries rely on a combination of

preservative factors for their stability and microbiological safety. "Hurdles" and "hurdle

technologies" have become meaningful and widely recognized descriptors of these factors and

their application. Because of the gentle process used, food remains stable and safe, with high

sensory and nutritive value. It has no effect on the integrity of food pieces and can be used in

both large and small-scale industries. Apart from the advantages, this technology has certain

disadvantages like high cost, high level of preservatives required, and high amount of

antimicrobial additives. Although hurdle strategies in the food industry have been investigated,

more research is needed to determine the optimal combinations of different treatments to reduce

the intensities of single unit processes and improve overall food properties.

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