107: Developing Stable and Safe Lupin Protein-Based Emulsions Gel Using 4D Printing and eBeam Technology

Introduction

Advancements in food processing technologies, including 4D printing and electron beam (e-Beam) technologies, paved the way for groundbreaking innovations in food safety and design. This study aims to develop a 4D printing lupin protein-based gel-emulsion with enhanced safety, shelf life, structural integrity, and physical stability using eBeam technology. 4D printing influenced precise material engineering to create dynamic, customizable food structures with tailored functionalities. Concurrently, e-Beam technology was a non-thermal, energy-efficient method to ensure microbial safety, extend shelf life, and preserve the sensory qualities of food products. Hence, eBeam enhances 4D-printed lupin gels' safety, stability, and functionality.

Methods

Protein-based gel emulsions containing 20 and 25% of lupin protein isolate, 2.0 and 2.5% xanthan gum, 6 and 12% allulose, along with other ingredients (oil, starch, and flavor), were printed into stable 3D structures, baked as 4D post-processing, and subjected to eBeam treatment at 5 kGy. Rheological analysis and polydispersity index of gel-emulsions were performed before 3D printing, and two formulations were selected for 4D printing. Additionally, FTIR spectroscopy was evaluated to study the molecular behavior of emulsions. After eBeam treatment, shelf-life studies through Aerobic Plate Count (APC), Anaerobic Plate Count (AnPC), Mold and Yeast (M&Y), microbial identification, and physical properties (aw and color) were evaluated.

Results

The study demonstrates that a protein concentration of 25% enables the formation of stable 3D-printed structures with minimal hydrocolloid supplementation, balancing structural integrity and printability. FTIR spectroscopy provided evidence that hydrocolloid levels significantly influence the rheological behavior of the gel-emulsion, particularly during extrusion through the needle, by modulating the network dynamics developed in the gelatinization process. Shelf-life studies confirmed that eBeam irradiation at 5 kGy effectively prolongs the microbial and physical stability of the emulsions during room-temperature storage for over 10 weeks, without compromising structural integrity, color fidelity, or aw. Furthermore, microbial identification analyses revealed the complete elimination of all forms of postprocessing contamination, including Staphylococcus cohnii, Staphylococcus capitis, and Staphylococcus epidermidis.

Significance

These findings highlight the potential of 4D food printing and eBeam technologies to develop customizable, microbiologically safe, and shelf-stable food products, preserving their organoleptic qualities and advancing the frontier of food processing science and innovation.

Authors: A. Palma-Acevedo, G. Tabilo-Munizaga, S. Pillai, C. Praveen, P. Saneii, L. Moreno-Osorio M. Pérez-Won