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Applied and Environmental Microbiology, June 2000, p. 2605-2612, Vol. 66, No. 6
0099-2240/00/$04.00+0
Copyright © 2000, American Society for Microbiology. All rights reserved.
Comparative Survival Rates of Human-Derived Probiotic
Lactobacillus paracasei and L. salivarius
Strains during Heat Treatment and Spray Drying
G. E.
Gardiner,1
E.
O'Sullivan,2
J.
Kelly,1
M. A. E.
Auty,1
G. F.
Fitzgerald,2
J. K.
Collins,2
R. P.
Ross,1,* and
C.
Stanton1
Teagasc, Dairy Products Research Center,
Moorepark, Fermoy, County Cork,1 and
Department of Microbiology, University College Cork,
Cork,2 Ireland
Received 10 September 1999/Accepted 20 February 2000
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ABSTRACT |
Spray drying of skim milk was evaluated as a means of preserving
Lactobacillus paracasei NFBC 338 and Lactobacillus
salivarius UCC 118, which are human-derived strains with
probiotic potential. Our initial experiments revealed that NFBC 338 is
considerably more heat resistant in 20% (wt/vol) skim milk than UCC
118 is; the comparable decimal reduction times were 11.1 and 1.1 min, respectively, at 59°C. An air outlet temperature of 80 to 85°C was optimal for spray drying; these conditions resulted in powders with
moisture contents of 4.1 to 4.2% and viable counts of
3.2 × 109 CFU/g for NFBC 338 and 5.2 × 107 CFU/g for UCC 118. Thus, L. paracasei NFBC
338 survived better than L. salivarius UCC 118 during spray
drying; similar results were obtained when we used confocal scanning
laser microscopy and LIVE/DEAD BacLight viability
staining. In addition, confocal scanning laser microscopy
revealed that the probiotic lactobacilli were located primarily in the
powder particles. Although both spray-dried cultures appeared to be
stressed, as shown by increased sensitivity to NaCl, bacteriocin
production by UCC 118 was not affected by the process, nor was the
activity of the bacteriocin peptide. The level of survival of NFBC 338 remained constant at ~1 × 109 CFU/g during 2 months
of powder storage at 4°C, while a decline in the level of survival of
approximately 1 log (from 7.2 × 107 to 9.5 × 106 CFU/g) was observed for UCC 118 stored under the same
conditions. However, survival of both Lactobacillus strains
during powder storage was inversely related to the storage temperature.
Our data demonstrate that spray drying may be a cost-effective way to
produce large quantities of some probiotic cultures.
 |
INTRODUCTION |
Given that probiotic microorganisms
play a role in promoting and maintaining health (29) has
stimulated considerable interest in incorporating these into functional
foods and pharmaceutical products. By definition, probiotics are
"living microorganisms, which upon ingestion in certain numbers,
exert health benefits beyond inherent basic nutrition"
(13), and it is recommended that probiotic products contain
at least 107 live microorganisms per g or per ml
(15). Therefore, from a commercial point of view, an
inexpensive method for large-scale production of cultures containing
high levels of viable probiotic cells in a form suitable for product
applications is highly desirable.
In previous studies researchers have investigated the production of
freeze-dried powders and frozen concentrates of probiotic Bifidobacterium and Lactobacillus spp. (10,
12, 24). However, there are many disadvantages associated with
this approach; freeze-drying is time-consuming and expensive, there are
high transport and storage costs associated with frozen concentrated
cultures, and the freeze-thaw process is associated with a loss of
culture viability. In comparison, spray drying, one of the predominant
processing tools used in the dairy industry, can be used to produce
large amounts of dairy ingredients relatively inexpensively; it has been estimated that the cost of spray drying is six times lower per
kilogram of water removed than the cost of freeze-drying
(20). Spray-dried powders can be transported at a low cost
and can be stored in a stable form for prolonged periods. However,
there are obvious challenges associated with using spray drying to
produce viable cultures, including the requirement that the
microorganisms survive the relatively high temperatures used
(5). While freeze-drying is more suitable than spray drying
for some cultures (17), researchers have found that there is
no difference in microbial viability between these methods
(33).
In previous studies, workers have investigated the use of spray drying
as a way to preserve yogurt with viable microorganisms (18)
and dairy starter cultures, such as Lactobacillus bulgaricus and Streptococcus thermophilus (23, 33, 34), and
as a way to attenuate adjunct cultures, such as Lactobacillus
helveticus (16, 17). In addition to maintaining the
viability of probiotic cultures, it is important that probiotic
properties are maintained following the spray-drying process. Although
spray-dried probiotic cultures are available commercially, the
previously published data related to spray drying of such
microorganisms is limited. Some studies have been undertaken to
investigate the survival during spray drying of Lactobacillus
acidophilus cultures chosen for their health-promoting properties
(8, 27, 28). In addition, a process for spray drying
probiotic lactic acid bacteria, including Lactobacillus and
Leuconostoc spp. and Bifidobacterium spp., has been described in a patent application by Meister et al. (N. Meister, A. Sutter, and M. Vikas, 19 March 1998, European Patent Office), who
developed a food powder that contained 109 CFU/g and
exhibited at least 10% probiotic survival per year.
Because of the advantages of spray drying, in the present study we
investigated the use of this method as a way to preserve human-derived
Lactobacillus paracasei and Lactobacillus
salivarius strains. The cultures which we used have been well
characterized previously with respect to both their probiotic
properties (4, 7, 19) and their behavior in dairy products,
including Cheddar cheese and yogurt (11, 30; G. Gardiner, R. P. Ross, and C. Stanton, unpublished data; E. O'Sullivan, G. F. Fitzgerald, and J. K. Collins, unpublished
data). The aim of the present study was to investigate spray drying as
a method for pilot-scale production of dairy-based powders containing
these probiotic Lactobacillus cultures.
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MATERIALS AND METHODS |
Bacterial strains and culture conditions.
Probiotic strains
NFBC 338 and UCC 118, which were isolated previously from the human
gastrointestinal tract (GIT) and were identified as members of L. paracasei subsp. paracasei and L. salivarius
subsp. salivarius, respectively, by sodium dodecyl sulfate-polyacrylamide gel electrophoresis analysis of total cell proteins (26), were obtained from University College Cork,
Cork, Ireland, under a restricted-materials transfer agreement. These strains were routinely cultured as previously described
(11). For spray-drying purposes, both probiotic
Lactobacillus strains were cultured as follows. Cells
harvested by centrifugation (1,600 × g, 10 min) from
overnight MRS broth (6) cultures were concentrated 10-fold
in maximum-recovery diluent (Oxoid Ltd., Basingstoke, Hampshire, United
Kingdom). The resulting culture concentrates were then inoculated (1%)
into 1.8 liters of heat-treated (90°C, 30 min) 20% reconstituted
skim milk (RSM) supplemented with 0.5% (wt/vol) yeast extract (Merck,
Darmstadt, Germany), which was added to aid culture growth. An
additional 1% (wt/vol) sucrose (Sigma Chemical Co., Poole, Dorset,
United Kingdom) was added for L. salivarius UCC 118, as this
organism cannot utilize lactose. The inoculated milk preparations were
incubated at 37°C, and fermentation was terminated just prior to
coagulation by cooling on ice (i.e., after 3.5 and 6 h for
L. salivarius UCC 118 and L. paracasei NFBC 338, respectively). The sensitive indicator strain Bacillus
coagulans NCIMB 9365, which was used to detect bacteriocin
production by L. salivarius UCC 118, was routinely grown in
Trypticase soy broth (Oxoid) supplemented with 0.5% (wt/vol) yeast extract.
Heat challenge experiments.
The heating menstrum used was
heat-treated (90°C, 30 min) 20% (wt/vol) RSM supplemented with 0.5%
(wt/vol) yeast extract; an additional 1% (wt/vol) sucrose was added
for strain UCC 118. The heating method used was essentially the method
described by Teixeira et al. (35). Two 50-ml portions of RSM
in 100-ml bottles were agitated with magnetic stirrer bars and were
placed in a water bath at the following test temperatures: 37°C (for
the control and to obtain the initial count) and 55, 58, 59, 60, and
61°C. One bottle was used to monitor the temperature and, after
temperature equilibration, a 1% inoculum of an overnight culture of
either L. paracasei NFBC 338 or L. salivarius UCC
118 was added to the second bottle. At intervals (between 30 s and
4 min at the temperatures used), 1-ml samples were removed from the
test bottles, serially diluted in maximum-recovery diluent, and pour
plated onto MRS agar. The survivors were counted after 3 days of
anaerobic incubation at 37°C. Duplicate tests were conducted at each
temperature, and the mean log survivor counts were plotted as a
function of heating time for each temperature. At each temperature a
best-fit straight line was obtained by regression analysis, and decimal
reduction times (D values) (the times required to kill 90%
of the cells) were determined by determining the absolute value of the
inverse of the slope of this line (31).
Spray drying of probiotic cultures.
The pH values of
cultures of both probiotic strains grown in RSM as described above were
adjusted to 6.8 with 4 N NaOH, and the cultures were warmed to
~15°C and then spray dried with a laboratory-scale spray dryer
(model B191 Buchi mini spray dryer; Flawil, Switzerland) by using a
constant inlet air temperature of 170°C. The fermentate was atomized
and sprayed into the drying chamber by using a two-fluid nozzle, and
the product dried almost instantaneously; the residence time was very
low. To investigate the effect of the outlet air temperature, the feed
rate was varied to obtain outlet temperatures ranging from 60 to
120°C. Each trial was conducted in duplicate for both probiotic
strains. The data obtained in these trials indicated that the optimal
drying conditions for both Lactobacillus cultures were an
air inlet temperature of 170°C and an air outlet temperature of 80 to
85°C, which yielded powders with moisture contents within the
recommended range (21). The powders were then stored in
sealed polyethylene bags at 4, 15, and 30°C, and probiotic viability
was assessed over time.
Determination of probiotic viability in spray-dried powders.
We assessed the viability of the probiotic lactobacilli in the
inoculated milk preparations before spray drying and in the resulting
powders by examining duplicate MRS pour plates after 3 days of
anaerobic incubation at 37°C. To 0.1 g of powder, 9.9 ml of
maximum-recovery diluent was added (1:100 dilution); the preparation
was allowed to rehydrate for ~1 h and then diluted further with
diluent, and appropriate dilutions were pour plated. The percent
survival at each of the outlet temperatures tested was calculated as
follows: % survival = (N/N0) × 100, where N0 is the number of bacteria per gram of
dry matter before drying and N is the number of bacteria per
gram of dry matter in the powder.
We also assessed the viability of the probiotic
Lactobacillus cultures in spray-dried powders by using
confocal scanning laser microscopy (CSLM) and LIVE/DEAD
BacLight viability staining. With this technique, two
nucleic acid stains, propidium iodide and SYTO 9, were used to
differentiate viable and nonviable bacterial cells based on membrane
permeability. A Zeiss model LSM310 confocal scanning laser
microscope (Carl Zeiss Ltd., Welwyn Garden City, Herts, United Kingdom)
was used to acquire digital images which were 525 by 512 pixels with a
resolution of 0.2 µm/pixel. A 2× stock solution of the LIVE/DEAD
BacLight viability stain (Molecular Probes Inc., Eugene,
Oreg.) was prepared according to the manufacturer's instructions. One
hundred microliters of the stain was then mixed with an equal volume of
RSM powder. Following 1 h of incubation in the dark, 2.5 µl of
the stained milk was placed on a microscope slide and covered with a
coverslip. Simultaneous pseudocolor dual-channel CSLM imaging with
488-nm excitation was used to display green fluorescence and red
fluorescence, which represented live and dead cells, respectively. An
image analysis of the color CSLM images was then performed by using a
Kontron model KS400 image analysis system (Imaging Associates Ltd.,
Thame, Oxon, United Kingdom) to separate the red and green fluorescence
signals and to calculate the area of green fluorescence as a percentage
of the total bacterial fluorescence. In this way, the effect of outlet temperature during spray drying on probiotic viability was determined. In addition, in order to observe the probiotic lactobacilli in situ in
skim milk powder, a small amount (~10 µg) of powder was mixed with
~20 µl of 0.1% (wt/vol) Nile blue A stain (sulfite salt; catalog
no. CI 51180; Sigma Chemical Co.) in a 90% (vol/vol) solution of
polyethylene glycol (molecular weight, 200; Sigma Chemical Co.). CSLM
was used to observe the powders 20 to 30 min after staining by using
633-nm excitation.
Electron microscopy of spray-dried powders.
Spray-dried
powders were attached to brass stubs and coated with gold by using a
model E5100 scanning electron microscopy coating system (Bio-Rad,
Hercules, Calif.). Samples were then examined with a JEDL model JSM-35
scanning electron microscope by using an accelerating voltage of 20 kV.
Micrographs were taken at various magnifications.
Determination of moisture contents of spray-dried powders.
The moisture contents of spray-dried skim milk powders were determined
in duplicate by oven drying the powders at 102°C, determining the
difference in weight, and expressing the weight loss as a percentage of
the powder weight (14). A moisture content of 4% is
recommended for skim milk powder (21).
Salt tolerance test.
In order to investigate possible
cellular damage resulting from the spray-drying process, we determined
the sensitivity of L. paracasei NFBC 338 and L. salivarius UCC 118 cultures to NaCl before and after spray drying
as follows. Fresh overnight MRS broth cultures and culture-containing
spray-dried powders (prepared by using air inlet and outlet
temperatures of 170 and 80 to 85°C, respectively) were pour plated
onto MRS agar supplemented with 4 to 5% NaCl (Prolabo, Paris, France).
The plates were examined after 3 to 6 days of anaerobic incubation at
37°C, and the colony sizes and numbers were compared with the colony
sizes and numbers on MRS plates without NaCl.
Bacteriocin assay and activity.
Prior to spray drying,
L. salivarius UCC 118 was grown in RSM as described above
and filter sterilized by using 0.45-µm-pore-size filters.
Five-microliter portions of the cell-free supernatant were then spotted
onto seeded indicator plates, which were incubated overnight at 37°C.
These indicator plates were prepared by overlaying 3 ml of soft agar
seeded with 300 µl of an overnight culture of the B. coagulans indicator strain on Trypticase soy agar supplemented with 0.6% (wt/vol) yeast extract. Bacteriocin production was revealed by the formation of a clear zone of inhibition in the indicator lawn
after overnight incubation. MRS broth cultures grown from spray-dried
powders were assayed for bacteriocin production in a similar manner.
Protease sensitivity was determined by spotting 5 µl of a 5-mg/ml
solution of proteinase K (Sigma Chemical Co.) close to the cell-free
supernatant spot on an indicator plate. Protease sensitivity was
indicated by inhibition of the zone of clearing. Bacteriocin activity
in the cell-free supernatant was determined as previously described
(25). In addition, bacteriocin production was detected and
bacteriocin activity was determined in spray-dried powders containing
strain UCC 118 as follows. One gram of powder was rehydrated in 10 ml
of maximum-recovery diluent, and a cell-free supernatant was obtained
as described above. Protease sensitivity and bacteriocin activity were
determined as described above. Activity was expressed in activity units
per gram of powder.
 |
RESULTS AND DISCUSSION |
In the present study, we investigated the use of spray drying as a
way to prepare dairy-based powders harboring high numbers of viable
cells of the human-derived strains L. paracasei NFBC 338 and
L. salivarius UCC 118. This study involved assessing the heat resistance of the Lactobacillus strains and subsequent
spray drying at a range of outlet temperatures.
Heat resistance of the probiotic strains.
One of the principal
factors that govern microbial survival during spray drying is the
ability of a strain to withstand high temperatures, and previous
studies have shown that different Lactobacillus spp. vary in
this respect (9, 32). Our initial experiments involved
determining the heat resistance of the probiotic
Lactobacillus strains in the skim milk medium subsequently
used for spray drying. The results showed that L. paracasei
NFBC 338 and L. salivarius UCC 118 did not differ in the
ability to survive at 55°C, but at temperatures above 58°C,
differences in the thermal tolerance of these strains became apparent
(Fig. 1). For instance, when NFBC 338 was
heated at 58°C, 100% of the culture survived, while there was a 46%
reduction in cell numbers (from 8.6 × 106 to 4 × 106 CFU/ml) following incubation at 59°C for 4 min
(Fig. 1A). In contrast, the viability of L. salivarius UCC
118 cells decreased 100- and 1,000-fold after incubation for 4 min at
58 and 59°C, respectively (Fig. 1B). Although at temperatures above
59°C the viability of NFBC 338 decreased more dramatically (from
1.3 × 107 to 3.3 × 104 CFU/ml at
60°C) (Fig. 1A), at these temperatures the reduction in the number of
strain UCC 118 cells was considerably greater than the reduction in the
number of strain NFBC 338 cells (Fig. 1). These data demonstrate that
L. paracasei NFBC 338 exhibited greater heat resistance than
L. salivarius UCC 118.

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FIG. 1.
Survival of L. paracasei NFBC 338 (A) and
L. salivarius UCC 118 (B) heated in 20% (wt/vol) RSM
supplemented with 0.5% (wt/vol) yeast extract and in 20% (wt/vol) RSM
supplemented with 0.5% (wt/vol) yeast extract and 1% (wt/vol)
sucrose, respectively, at 55°C ( ), 58°C ( ), 59°C ( ),
60°C (×), and 61°C ( ). The results are means based on data from
duplicate heat challenge experiments.
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The heat resistance of microorganisms can also be defined by a
thermotolerance parameter, the
D value (
31). A
comparison
of the
D values obtained for the two
Lactobacillus strains showed
that at all of the temperatures
investigated, the
D values for
L. paracasei NFBC
338 were greater than the
D values for
L. salivarius UCC 118 (68 to 1.1 and 13.4 to 0.5 min, respectively,
at 55 to
61°C), which reflected the greater heat tolerance of the
former
microorganism. It should also be noted that, prior to the
experiment,
both cultures were in the stationary phase, which may have
resulted
in increased heat resistance as it has been demonstrated
previously
that stationary-phase cultures are more resistant to heat
stress
than cells in the exponential phase of growth (
32).
Although
the
D values obtained in the present study for the
L. paracasei and
L. salivarius strains were lower
than the
D values previously
reported for a strain of
L. bulgaricus in skim milk (
32), they
were higher
than the
D values previously reported for mesophilic
lactobacilli (
9). However, it should be noted that the heat
resistance experiments conducted by Franz and von Holy (
9)
were performed with Ringers solution, whereas skim milk, which
previously has been shown to have a protective effect during heat
treatment (
32), was used in the present study; these results
highlight the difficulty of comparing data obtained in different
studies.
Spray drying of probiotic cultures.
The initial spray-drying
experiments were performed to determine the outlet temperature which
was optimum for probiotic viability and yielded powders with moisture
contents that were not greater than 4% (21). Since L. salivarius UCC 118 was more heat sensitive than L. paracasei NFBC 338 (Fig. 1), lower outlet temperatures (60 to
95°C) were used when strain UCC 118 was spray dried. The probiotic
survival rate decreased during spray drying as the outlet temperature
increased for both NFBC 338 (r =
0.93) and UCC 118 (r =
0.91) (Fig. 2A and
3A), as previously observed in studies performed with other microorganisms (8, 16, 18). The
survival rates for L. paracasei NFBC 338 during spray drying
ranged from 97% at an outlet temperature of 70 to 75°C to 0% at
120°C (Fig. 2A); these survival rates were better than the survival
rates for UCC 118 (only 11% even at the lowest outlet temperature
investigated, 60 to 65°C) (Fig. 3A). These findings may be attributed
to the greater thermal tolerance of strain NFBC 338 (Fig. 1). Indeed, the survival rate of NFBC 338 during spray drying was considerably higher than the survival rate previously obtained for L. acidophilus or Lactobacillus curvatus cultures spray
dried under similar conditions, while the highest survival rate
obtained for UCC 118 (11%) was similar to or lower than previously
reported values (22, 28). Growth studies revealed that both
cultures were in the exponential phase prior to spray drying (data not
shown), which may have increased their sensitivity to the process given
that Teixeira et al. (33) have previously shown that
exponential-phase cells of L. bulgaricus are more
susceptible to spray drying than cells in the stationary phase of
growth. It may be possible to increase the probiotic counts in
spray-dried powders (which ranged from <1 × 101 to
4.8 × 109 CFU/g for NFBC 338 and from 9.1 × 106 to 6.5 × 108 CFU/g for UCC 118) by
using more concentrated cultures for spray drying. In the case of
strain UCC 118, using encapsulation techniques (3) or
carriers such as dextrin (16) may increase the survival rate
during spray drying.

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FIG. 2.
(A) Survival of L. paracasei NFBC 338 during
spray drying in 20% (wt/vol) RSM supplemented with 0.5% (wt/vol)
yeast extract at different air outlet temperatures (bar graph). The
line shows the moisture contents of the resulting powders. The air
inlet temperature was maintained at 170°C. The results are means
based on data from duplicate spray-drying trials, and standard
deviations are indicated by vertical bars. (B and C) CSLM micrographs
of NFBC 338-containing powders produced at air outlet temperatures of
70 to 75°C (B) and 120°C (C). The powders were stained with the
LIVE/DEAD BacLight viability stain; live cells are green,
and dead cells are red. Bars = 10 µm.
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FIG. 3.
(A) Survival of L. salivarius UCC 118 during
spray drying in 20% (wt/vol) RSM supplemented with 0.5% (wt/vol)
yeast extract and 1% (wt/vol) sucrose at different air outlet
temperatures (bar graph). The line indicates the moisture contents of
the resulting powders. The air inlet temperature was maintained at
170°C. The results are means based on data from duplicate
spray-drying trials, and standard deviations are indicated by vertical
bars. (B and C) CSLM micrographs of UCC 118-containing powders produced
at air outlet temperatures of 60 to 65°C (B) and 90 to 95°C (C).
The powders were stained with the LIVE/DEAD BacLight
viability stain; live cells are green, and dead cells are red.
Bars = 10 µm.
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The moisture contents of the powders increased as the outlet
temperature decreased (Fig.
2A and
3A) (
r =

0.87 and
r =

0.99
for the NFBC 338 and UCC 118 powders,
respectively), as reported
previously during preparation of spray-dried
powders containing
other microorganisms (
8,
16). In general,
an air outlet temperature
of 80 to 85°C was necessary in order to
obtain powders with moisture
contents that did not exceed the level
required for prolonged
powder storage life and stability (4%) (Fig.
2A
and
3A) (
21).
At this outlet temperature, the survival rates
for NFBC 338 and
UCC 118 were 66 and 1%, respectively, which
represented viable
counts of 3.2 × 10
9 and 5.2 × 10
7 CFU/g, respectively. Skim milk powders prepared in
this way could
be used to incorporate these probiotic microorganisms
into a wide
range of food and pharmaceutical products. Indeed, the NFBC
338
powder described here could be diluted up to 200-fold and still
have a viable count of

10
7 CFU/ml, which would satisfy
recommendations regarding the level
of viable cells in a probiotic food
(
15).
CSLM of probiotic powders.
CSLM micrographs were
obtained after powders were stained with the LIVE/DEAD
BacLight viability stain, which stained dead cells
red and live cells green; skim milk powders containing both probiotic
strains prepared at the highest and lowest outlet temperatures were
examined (Fig. 2 and 3). The fact that L. paracasei NFBC 338 survived better than L. salivarius during spray drying was apparent. The influence of the air outlet temperature during spray drying on probiotic viability was also evident in the micrographs; powders of both cultures dried at the maximum outlet temperatures (120 and 90 to 95°C for NFBC 338 and UCC 118, respectively) contained only
dead cells (Fig. 2C and 3C). The UCC 118 powder prepared at an outlet
temperature of 90 to 95°C contained 9.1 × 106
CFU/g, while previous work has shown that the limit of detection of the
CSLM method is 107 CFU/g (M. A. E. Auty and G. Gardiner, unpublished data). In addition, although scanning electron
microscopy of the NFBC 338 powders did not reveal that the probiotic
lactobacilli were present (Fig. 4A), the
optical sectioning capability of the CSLM technique revealed that the
probiotic Lactobacillus cells were encapsulated in the milk
powder particles (Fig. 4B), which may have protected the culture during
spray drying.

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FIG. 4.
(A) Transmission electron micrograph of L. paracasei NFBC 338-containing spray-dried skim milk powder.
Bar = 500 µm. (B) CSLM micrograph of the same NFBC
338-containing spray-dried powder stained with Nile blue A stain.
Lactobacillus cells encapsulated in a powder particle are
indicated by an arrow. Bar = 10 µm.
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Salt tolerance of cultures as an indicator of stress damage.
A
potential disadvantage of spray drying as a way to preserve cultures is
the damage caused to bacterial cells during the process. One of the
most susceptible sites in bacterial cells is the cytoplasmic membrane,
which is affected by spray drying (33) and is also sensitive
to other stresses, such as freeze-drying (2) and heat
treatment (22, 35). In addition, increased sensitivity of
sublethally injured bacteria to NaCl has been associated with cell
membrane damage (2, 33, 35). Both probiotic
Lactobacillus strains investigated in the present study
became sensitive to NaCl following spray drying at an air outlet
temperature of 80 to 85°C. This was shown by the fact that prior to
spray drying, there were no differences between the viable counts of
the probiotic strains on MRS alone and the viable counts of the strains
on MRS containing 5% NaCl, while after spray drying, decreases in cell numbers were observed in the presence of 5% NaCl. Prior to spray drying, strain NFBC 338 exhibited only 4% sensitivity to NaCl, but
70% sensitivity was observed following spray drying. This higher level
of sensitivity to NaCl indicates that cell membrane damage occurred as
a result of the spray-drying process. Furthermore, when the NFBC
338-containing spray-dried powder was plated in the presence of high
concentrations of NaCl, colony size was found to be markedly reduced
compared to the colony size prior to spray drying (data not shown).
This morphological change that occurred in the presence of NaCl
indicates that the spray-drying process stressed the cells. The results
obtained for L. salivarius UCC 118 were even more dramatic;
this strain exhibited no sensitivity to 5% NaCl before spray drying
but 100% sensitivity following spray drying, suggesting that it was
damaged to a greater extent by the spray-drying process than NFBC 338. This finding is supported by the lower survival rate of this strain
during spray drying compared with the survival rate of NFBC 338. Other
possible sites in the cell where damage may occur as a result of
spray drying or heat stress include the cell wall and DNA (34,
35). Cellular injury as a result of spray drying is a cause for
concern, particularly in the case of probiotic strains, which
subsequently must survive adverse conditions, such as those encountered
both in fermented foods and in the GIT, in order to be active at the
target site (4).
Effect of spray drying on bacteriocin production.
It has been
shown previously that L. salivarius UCC 118 produces a
broad-spectrum bacteriocin that exhibits activity against microorganisms such as Bacillus, Staphylococcus,
and Listeria spp. (7). Bacteriocin production is
a desirable trait for probiotic cultures (4) and may be used
to competitively exclude undesirable microorganisms in the GIT, thereby
playing a role in probiotic persistence in the host. We investigated
the effect of spray drying on the ability of UCC 118 to produce
bacteriocin and on the activity of the bacteriocin peptide. Following
isolation from spray-dried powders produced at a range of outlet
temperatures, strain UCC 118 retained its ability to produce
bacteriocin, showing that even at outlet temperatures as high as
95°C, this potential probiotic trait was not affected. Furthermore,
the spray-drying process did not affect the activity of the bacteriocin
peptide, as shown by the presence of antimicrobial activity (32,000 activity units/g of bacteriocin) before and after spray drying at all
outlet temperatures. The fact that the antimicrobial activity was due
to the UCC 118 bacteriocin was confirmed by the sensitivity of the
activity to proteolytic action and its failure to inhibit the producing
strain (strain UCC 118). It has been well documented that bacteriocin peptides retain their activity following spray drying; this has been
shown for nisin (Nisaplin; Aplin and Barrett, Towbridge, Wiltshire,
United Kingdom), lacticin 3147 (25), and bacteriocins produced by both lactobacilli and lactococci (22). The
presence of active bacteriocin, as well as viable probiotic
microorganisms, in the UCC 118 powder produced in this study means that
in addition to providing the potential to add viable probiotic
microorganisms to food products, the powder may also play a role in
inhibiting spoilage and pathogenic microorganisms in food systems
(7). Although we found that the spray-drying process did not
affect bacteriocin production by L. salivarius UCC 118, survival of the spray-dried cultures under conditions that are present
in the GIT must also be investigated.
Probiotic survival in spray-dried powders during storage.
Powders of both probiotic cultures that were produced by spray drying
at a constant air outlet temperature of 80 to 85°C were stored at
different temperatures (4, 15, and 30°C), and probiotic viability was
assessed over a 2-month period. We found that following 2 months of
storage, the maximum survival rates for both L. paracasei NFBC 338 and L. salivarius UCC 118 in the skim milk powders
(92 and 13%, respectively) occurred at 4°C (Fig.
5). The survival rates of both strains
decreased more rapidly during storage at 15 or 30°C, and the survival
rates were 11 and 2% after 2 months of storage at 15°C for the NFBC
338 and UCC 118 powders, respectively (Fig. 5). Previous studies have
also shown that temperature is critical for microbial survival during
storage, and higher survival rates have been obtained at lower storage
temperatures (1, 16, 34). It is apparent from the results of
this study and other studies (1, 16, 34) that although
refrigerated storage is impractical from a commercial point of view, it
is necessary for optimal culture viability in spray-dried powders over
time; this finding means that applications of the probiotic products are more limited. NFBC 338 exhibited higher survival rates than UCC 118 during storage at 4 and 15°C but not during storage at 30°C (Fig.
5). The lower survival rates of UCC 118 during storage may be related
to the more extensive cell damage observed in this strain as a result
of spray drying (see above). It is also interesting that UCC 118 exhibited lower survival rates in Cheddar cheese and yogurt than NFBC
338 (11; Gardiner et al., unpublished data; O'Sullivan et al., unpublished data). It may be useful to evaluate the
effect of adding protectants, such as dextrin and antioxidants like
ascorbic acid and monosodium glutamate, during spray drying. These
additives have improved culture viability during powder storage
(1, 33), although other studies have shown that dextrin has
little effect (16) and antioxidants and oxygen absorbers have detrimental effects on culture stability during storage (3, 34).

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|
FIG. 5.
Survival of L. paracasei NFBC 338 (A) and
L. salivarius UCC 118 (B) in spray-dried skim milk powders
during storage at 4°C ( ), 15°C ( ), and 30°C ( ). The
results are means based on data from two replicates, and standard
deviations are indicated by vertical bars.
|
|
Conclusions.
In this study, we found that two
Lactobacillus strains, which were selected on the basis of
their probiotic properties, varied considerably in their ability to
survive during the spray-drying process. Our findings highlight the
need to take into consideration the technological properties of
probiotic strains and emphasize the importance of strain selection with
regard to processing, as well as health-promoting properties. In this
respect, when spray drying was considered, determining thermotolerance
parameters proved to be useful for predicting the behavior of the
probiotic strains during subsequent processing. Although we found that
both probiotic Lactobacillus cultures remained viable during
spray drying and determined an optimal outlet temperature for cell
viability and moisture content of the powders, future work should
include investigations of techniques which prevent cell damage and
optimize viability during spray drying. In order for probiotic powders to be useful, storage at room temperature is desirable, and further work is also needed in this area. Furthermore, although the
spray-drying process did not affect bacteriocin production by L. salivarius UCC 118, further evaluation of both of our dried
cultures is necessary in order to determine if other probiotic
properties remain following processing. Although the laboratory-scale
experiments conducted in this study provide some indication of the
performance of the probiotic Lactobacillus cultures during
the spray-drying process, further studies should evaluate their
performance during pilot-scale and ultimately industrial spray
drying. In conclusion, spray drying is potentially a useful process for
large-scale production of some human probiotic
Lactobacillus strains in a form suitable for transport and
storage. Furthermore, given the numerous applications of skim milk
powders, not only in dairy products but also in foods such as instant
desserts, mayonnaise, and confectionery products, it is possible that
the resulting culture-containing powders could be used in a wide range
of functional food applications.
 |
ACKNOWLEDGMENTS |
The technical assistance of Helen Slattery and Joe Roche is
gratefully acknowledged. We thank William Reville and Myriam Cotter, University College Cork, for electron microscopy.
G.E.G. was supported by a Teagasc Walsh Fellowship. This work was also
supported by the European Research and Development Fund.
 |
FOOTNOTES |
*
Corresponding author. Mailing address: Teagasc, Dairy
Products Research Center, Moorepark, Fermoy, Co. Cork, Ireland. Phone: 353-25-42229. Fax: 353-25-42340. E-mail:
pross{at}moorepark.teagasc.ie.
 |
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Applied and Environmental Microbiology, June 2000, p. 2605-2612, Vol. 66, No. 6
0099-2240/00/$04.00+0
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