Innovation in Food Products Using Ozone Technology

Ozone application is a cutting-edge, non-thermal technology increasingly utilized in food preservation. As a powerful oxidant, ozone effectively treats water and air, particularly for disinfection processes in the agriculture and food industry sectors. The purpose of this article is to highlight the potential applications of ozone technology in the cultivation, harvest, and postharvest management of fruits and vegetables in Mexico. Foliar spraying and irrigation with ozonated water have been proven effective against pathogens, bacteria, and pests. The use of ozone has shown significant improvements in the quality of fruits and vegetables, enhancing parameters like color, flavor, and soluble solids in products such as mango, sugarcane, citrus fruits, and nopal. This technology has increased the shelf life of fresh produce by up to 15 days post-harvest. Protocols have been developed by TRIO3 to meet producer requirements, suggesting a broad adoption of this green technology in agriculture.

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1. Introduction

Ozone (O3), known as trioxygen, is a gaseous substance with three oxygen atoms connected by angular geometry. It forms when energy is applied to O2 molecules, splitting them into O3. This homonuclear molecule stands as one of the most potent oxidants used for water and air treatment, particularly in disinfection processes for agriculture and the food industry. Ozone is eco-friendly and classified as Generally Recognized as Safe (GRAS) by the Food and Drug Administration (FDA).

Functioning as a universal disinfectant, ozone reacts effectively with contaminants, removes unwanted colors and odors, and destroys molds, bacteria, viruses, and algae. Its deodorant effect is achieved through the oxidation of compounds like ketones, hydrocarbons, acids, sulfides, and nitrogen derivatives. Ozone can eradicate cell walls and membranes, attacking DNA and RNA, rendering microorganisms unable to develop immunity against it, unlike other chemical compounds. While traditional sanitizers may be cheaper, they are often less effective against new outbreaks or newly detected food pathogens.

Ozone is widely used in food preservation to improve organoleptic qualities under good manufacturing practices. It can be dispensed into postharvest cold rooms or drawn into water streams using a Venturi injection system. However, excess ozone must be captured and neutralized to prevent corrosion and personal injury. A viable method involves using UV light combined with catalytic agents like granulated activated carbon. This article discusses various case studies of ozone application in agriculture, meeting state regulations and producers' expectations.

2. Biological factors involved in the deterioration of fruits and vegetables (F & V)

The postharvest conditions of raw materials are heavily influenced by their metabolic processes. Respiration in living cells triggers energy release via carbon chain breakdown and the formation of new compounds necessary for maintenance and synthetic reactions post-harvest. Lower respiration rates can extend the shelf life of perishable fruits, while ethylene concentration acts as a maturation hormone, especially in climacteric fruits. Precise instrumentation can monitor ethylene levels. Studies like those by Fundo et al. have shown that ozonation can affect quality parameters such as color, vitamin C, carotenoids, and antioxidant activity in cantaloupe melon juice.

Ripening is a crucial phase affecting the growth and development of fruits and vegetables, involving enzymatic changes that soften fruits, convert storage materials to sugars, and change pigmentation, especially in climacteric fruits. Flavor enhancements are also notable, influenced by sugars, acids, and volatile compounds.

2.1 Physical damage and pathological deterioration

Factors impacting raw material maturity include water loss, size, shape changes, and surface alterations. Ensuring these are mitigated in marketable products is essential to prevent postharvest losses. Manual or instrumental texture measurement can determine fruit maturity. Studies, including those by Paciulli et al., have assessed the softening of frozen vegetables like asparagus stems and green beans, noting blanching treatment effects. Preventing improper handling or biodeterioration by microorganisms, pests, or rodents is crucial to reducing losses.

3. Applications of ozone

Water is integral in harvesting, freezing, packaging, and processing fresh fruits and vegetables. This use increases the risk of contamination with plant pathogens and food safety microorganisms. Proper procedural application is critical to prevent contamination and disinfect water effectively. Ozone, whether in gas or dissolved form, has proven effective in reducing microorganisms such as Escherichia coli and Penicillium Italicum, thereby preventing fruit damage and extending postharvest life. Appropriate doses of ozone eliminate pests and insects, providing an excellent alternative to chemical products.

Studies by Feston et al. have highlighted ozone's effectiveness in reducing bed bug populations in various life stages. Pest damage extends beyond physical harm to fungal development, often promoting mycotoxin production.

3.1 Ozonated water by foliar spraying

Foliar application of ozone allows nutrient addition and pest and disease elimination. Ozone effectively reduces fungi, molds, spores, viruses, bacteria, and insect populations without adversely affecting food characteristics. By suppressing microorganism metabolism, ozone reduces disease incidence, fertilizer doses, and operating costs. Researchers like Ali have demonstrated that foliar spraying enhances papaya quality, maintaining parameters like weight loss, firmness, ripening, and soluble solids concentration.

3.2 Ozonated water in the irrigation system

Irrigation can be managed via methods such as gravity, sprinkling, dripping, micro-sprinkling, or capillary diffusion. Ozone irrigation enhances nutrient and oxygen content, root strength, and tree trunk thickness, increasing soluble solids and sugars. Studies have shown ozonated water effectively eliminates viruses and bacteria, controlling pests like Fusarium spp. and Aspergillus spp. in nopal-vegetable. This method destroys root nematodes and secures fruit integrity.

Use cases and impact

Regular use of ozonated water irrigation supplies oxygen to roots, strengthening plants and increasing productivity. The technique is widely applied to fruit trees, vineyards, and nopal-vegetable. Table 1 summarizes ozone usage benefits across various produce types.

CommodityOzone treatmentEffects on qualityReferenceBroccoli0.04 μL L−1, 7 d, 10 °CDelay of metabolic process & oxidative reactions[2]Cucumber0.04 μL L−1, 17 d, 3 °CEnhancement of appearance.
Higher values of Firmness (N) than the observed in control simples.[2]Mushroom0.04 μL L−1, 14 d, 4 °CBlotch in cap surface was diminished.[2]Apple and pears1.5 μL L−1, 100 d, 20 °CTotal soluble solids and firmness were sustained.[6]Orange juiceOzone variable doseControl of decay, abatement of ethylene, removing of pesticides and residues.[7]Fresh cut lettuce1 mg L−1, 10 d, 4 °CStorage life increased, decline of respiration rate & enzymatic browning.[8]Cantaloupe melon juice

7±2.4

gL−1 for 30 & 60 minIncrease of polyphenols and vitamins.[5]Mango10 μL L−1, 3 d, 25 °CDelay of ripening, Improvement of quality characteristics.[7]Papaya2.5–3.5 ppmWeight loss reduction, higher firmness values.[8]Soil and water depositsOzone variable doseBactericidal action on responsible for food delay (P.aeruginosa)[6]

Table 1.

Uses of ozone in several fresh produces and its benefits.

Numerous studies have identified plant disease vectors, including leaf yellow curl virus in tomatoes, whitefly in cotton, and various issues in tropical fruits and potatoes. Regular ozone water irrigation effectively eliminates these disorders without leaving residues. Researchers like Contigiani et al. have reported significant pathogen control differences in strawberries treated with ozonated water, emphasizing ozone’s promise in reducing post-harvest losses.

4. Innovation project: processing of mangoes (Mangifera indica) using ozone technology

4.1 Introduction

The Ataulfo variety mango cultivated in south Mexico is renowned for its quality but matures quickly and decomposes due to high microbiological loads. Local growers frequently use fertilizers and pesticides to avoid infestations, predominantly whitefly. Effective post-harvest techniques are crucial to reduce economic losses.

4.2 Methodology

Researchers led by Pérez-Nafarrate developed ozone gas and water disinfection processes for mangoes in an industrial plant in Guerrero, Mexico, adhering to stringent food safety regulations. Key premises included:

Regular ozone gas application can gradually eliminate pests.

Gas monitoring using an ozone analyzer ensures safety.

Ozone concentrations between 1.5 and 5 ppm in storage reduce ethylene content, delaying fruit ripening.

4.3 Results and discussion

The optimal 3.5 ppm ozone dose preserved mango quality and extended shelf life by 15 days, meeting and surpassing producers' expectations. Empirical data showed improvements in soluble solids, color, flavor, and firmness. Complementary studies by More and Rao indicated similar benefits using UV-C irradiation, guar gum, and ozone water, verifying compliance with good manufacturing practices in reducing fruit deterioration and increasing economic returns.

5. Innovation project: use of ozone in the harvesting and processing of nopal

5.1 Introduction

The nopal vegetable, rich in dietary fiber, grows in semi-arid regions and is widely consumed in Mexico. It adapts well to low precipitation and heat. Key challenges include managing relative humidity to control pests and diseases. Physical and morphological features make nopal susceptible to various bacterial and fungal pathogens. The objective was to enhance nopal-vegetable quality using ozonated foliar spraying and water irrigation.

5.2 Methodology

Good manufacturing practices in soil and water management were vital. An experimental plantation in Matehuala, San Luis Potosi, used regular light watering during dry months with periodic ozone generator requirements monitoring. Soil salinity, hardness, pH, and sedimented solids were recorded. Post-harvest, nopal 'pencas' were packaged in recyclable plastic boxes to avoid oxidation.

5.3 Results and discussion

Ozonated water preserved nopal’s organoleptic qualities, reducing microbial load and extending shelf life. Packaged in plastic bags, the final product was market-ready, with investment proposals for rural cooperative companies capable of processing 500 kg per day.

Good manufacturing practices, water quality, and soil management were essential for successful nopal processing, with ozone technology proving to be an innovative and affordable solution for rural communities in Mexico.

6. Innovation project: use of ozone to counteract Huanglongbing in citrus trees

6.1 Introduction

Huanglongbing (HLB), also known as “yellow dragon,” significantly affects citrus production globally. Diaphorina citri, the insect vector of HLB, spreads the disease, necessitating up to 50 insecticide doses annually. HLB causes severe damage to trees and fruits, stunting growth and reducing quality.

Since 2010, HLB has spread in the Americas, particularly in regions with frequent rainfall and temperate climates. In Mexico, HLB threatens citrus production on over 526 thousand hectares, representing a significant economic risk. Collaborative research is urgent to address this crisis.

6.2 Methodology

In 2013, a protocol was signed between TRIO3 Food Technologies, INIFAP, and Los Limones Orchard to evaluate ozone's effect on eradicating HLB. The study focused on early detection of infected trees and assessing vector damage on advanced disease stages. Fifteen hectares of lemon trees were irrigated with ozonated water and nutrients every third day for six months.

6.3 Results and discussion

Ozone significantly reduced larvae and adult vector populations, improving citrus production. Additional benefits included enhanced foliage coloration and strengthened trunk and roots. Similar studies using organic mixtures confirmed ozone’s rapid insecticide action compared to traditional methods. More research is needed to eradicate HLB in Mexico and its neighboring regions.

7. Innovation project: use of ozone to control diseases of sugarcane

7.1 Introduction

Sugarcane is a crucial raw material for producing sugar concentrates, molasses, and other derivatives. Proper disease management is essential for its cultivation. Common sugarcane diseases include red rot, wilt, grassy shoot, leaf scald, smut, brown rust, and orange rust, each caused by a variety of pathogens.

Key diseases affecting sugarcane are:

Mosaic disease, caused by Sugarcane mosaic virus, leading to stunted growth and production loss.

Eyespot, characterized by black spore masses and lesions, spread via wind, rain, irrigation, seeds, or animals.

Rust, from Puccinia fungi, causing leaf spots and thin stems.

Leaf scald, a bacterial disease causing sudden plant death, dubbed gomosis in Latin America for its gum production.

Ratoon stunting disease, caused by Leifsonia xyli spp., resulting in stunted stems and short internodes.

Ozonated water irrigation provides oxygen to sugarcane roots, promoting stronger, more productive plants and reducing disease incidence. This method, widely used in various crops, mitigates chemical use, improving product shelf life and quality.

7.2 Methodology

A collaborative project was initiated in 2008 to evaluate ozonated water’s effect on sugarcane. Red ferritic soil was used to grow agamic seeds from five sugarcane varieties. Experimental design involved 180 buds per variety, treated with ozonated water for varying durations alongside control and traditional treatments.

7.2.1 Treatment with ozonated water

The irrigation system used ozonated water, progressively reducing fungicides to control fungus and pests. Experimental buds were immersed in ozonated water for 10, 20, or 30 minutes before planting.

7.2.2 Witness without treatment

Control buds were soaked in water for 24 hours without additional treatments.

7.2.3 Hydrothermal + chemical treatment

Buds received a hot water and propiconazole treatment to eliminate diseases such as leaf scald.

7.2.4 Biological treatment

This involved immersing buds in water and an organic insecticide solution before planting at an experimental station. Measurements and analyses occurred 30 days post-planting.

7.3 Results and discussion

Results showed significant differences across treatments. Ozonated water immersion, particularly for 10 minutes, achieved the highest germination rates. This method drastically reduced disease incidence, maintaining seed viability. Thus, ozonated water immersion proved beneficial for sugarcane seed viability and disease control.

8. Conclusion

Ozone technology has proven effective in postharvest management of climacteric fruits like mangoes and papayas. This eco-friendly and cost-effective technology holds significant promise for developing countries in Latin America. Ozone irrigation in Nopal opuntia crops effectively controls diseases and enhances plant health. Effective ozone irrigation systems prevent bacterial and pest growth in citrus trees and other fruits, offering an alternative to chemical controls. Ozone-irrigated sugarcane and other tropical crops show increased yields and reduced disease losses, boosting economic benefits. TRIO3 acknowledges the contributions of producers and researchers in these advancements.

Acknowledgments

Thanks to TRIO3 Food Technology support and the Superior Technological Institute Zacatecas Norte (ITSZN-TecNM).

Conflict of interest

The authors declare no conflict of interest.

The dairy field has considerable economic relevance in the agri-food system, but also has the need to develop new 'green' supply chain actions to ensure that sustainable products are in line with consumer requirements. In recent years, the dairy farming industry has generally improved in terms of equipment and product performance, but innovation must be linked to traditional product specifications. During cheese ripening, the storage areas and the direct contact of the cheese with the wood must be carefully managed because the proliferation of contaminating microorganisms, parasites, and insects increases significantly and product quality quickly declines, notably from a sensory level. The use of ozone (as gas or as ozonated water) can be effective for sanitizing air, water, and surfaces in contact with food, and its use can also be extended to the treatment of waste and process water. Ozone is easily generated and is eco-sustainable as it tends to disappear in a short time, leaving no residues of ozone. However, its oxidation potential can lead to the peroxidation of cheese polyunsaturated fatty acids. In this review we intend to investigate the use of ozone in dairy production,