S.M.C.

COLLEGE OF DAIRY SCIENCE

ANAND AGRICULTURE UNIVERSITY
ANAND - 388110

ASSIGNMENT
ON

Hurdle Technology
SUBJECT: Advanced Dairy Processing (DT-511)

SUBMITTED TO: Dr. J.P.Prajapati.

DDPO & Associated
Proffesor,
Dairy Technology
Department,
S.M.C. College of Dairy
Science,
AAU, Anand.
SUBMITTED BY: Hardik Patel.
Reg. No. 04-2747-2015
S.M.C. College of Dairy science, AAU, Anand.

Index

Sr.
No.
1.
2.
3.
4.
5.
6.
6.1
6.2
6.3
6.4
7.
8.
9.
10.

Contents
Introduction
Different hurdles
Effect of Single hurdle in food
Hurdle effect
Example that explain Hurdle Effect
Basic Aspects of hurdle Technology
Homeostasis
Metabolic exhaustion
Stress reaction
Multi target preservation
Significance of Hurdle Technology
Advantages of Hurdle Technology
Conclusion
References

Page
no.
3
4
5
6
6
8
8
9
11
12
13
13
14
15

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1. Introduction
The spoilage and poisoning of foods by micro-organisms is a problem that
is not yet under adequate control, despite the range of preservation
techniques available (e.g. freezing, blanching, pasteurizing and canning).
In fact, the current Consumer demand for more natural and fresh-like
foods, which urges food manufacturers to use only mild preservation
techniques (e.g. refrigeration, modified-atmosphere packaging and
biocoaservation), should make this problem even greater.
Thus, for the benefit of food manufacturers there is a strong need for new
or improved mild preservation methods that allow for the production of
fresh-like, but stable and safe foods. The concept of hurdle technology is
not new but addresses this need in full.
Hurdle means a problem or difficulty that must be overcome. Hurdles in
food are substances or processes inhibiting deteriorating processes. The
parameters like water activity, low temperature, acidification, redox
potential and preservatives etc. are called hurdles.
Hurdle technology (also called combined methods, combined processes,
combination preservation, combination techniques or barrier technology)
means combining various bacteria inhibiting or bacteria killing factors (the
hurdles) so as to achieve a safe product with optimal shelf life and an
acceptable taste and consistency.
Hurdle technology foods are defined as products whose shelf life and the
microbial safety are extended by use of several factors none of which
individually would be totally lethal towards spoilage or pathogenic
microbes.
The combination of preservative factors influences the microbial stability
and safety of foods. This hurdle technology is used in various food
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products, including fruits and vegetable products, dairy products, fish, and
so on.

2. Different Hurdles
2.1 Physical hurdles
High temperature
(sterilization, pasteurization and
blanching)
Low temperature (Chilling &
freezing)
Radiation (Microwaves, UV,
Irradiation etc)
High electric field pulses

Oscillating magnetic field pulses

Radiofrequency energy

Ultrahigh pressure

Ultra sonification
Packaging film (plastic,
multilayer, active coatings
and edible coatings)
Packaging (aseptic packaging,
Vacuum or modified
atmosphere or active
packaging, edible coatings
etc )
Food microstructure (emulsions,
fermented sausage, ripened
cheese)
Photodynamic inactivation

2.2 Physico- chemical hurdles

Water activity Carbon dioxide
pH
Redox
Potential

Oxygen
Ozone

Acetic acid,
Acetate
Ascorbic acids
Sorbates

Phosphates
Phenols
ChelatorsBHA, BHT,
TBHQ
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Salt

Organic acids

Sulphite

Lactic
acids, Lactate
Maillard
reaction
products
LactoperoxidaseLysozyme

Smoking

Surface treatment
Agents
Ethanol

Spices

Herbs

Chlorine

Natamycin

Nitrite,
Nitrate
Propylene
Glycol

2.3 Microbiologically derived hurdles

Competitive flora
Protective cultures

Bacteriocins
Antibiotics

2.4 Miscellaneous hurdles

Chitosan
Chorine

Free fatty acids

3. Effects of single hurdle in food

Hurdle (used alone)
Refrigeration
Freezing

Controlled atmosphere
Pasteurization
Sterilization
Drying

Undesirable effect
Chilling injuries, weight loss
Nutritional, texture losses,
Discoloration, aesthetic
Change, enzymatic browning
Softening, discoloration
Nutritional losses, sensory
Losses
Nutritional losses, sensory
Losses
Discoloration, flavour changes,
Mould growth
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Preservatives

Consumer aversion resistance

4. Hurdle Effect
For every microbiologically stable and safe food, a certain set of hurdles is
inherent, which differs in quality and intensity, depending on the particular
product.
In any case, the hurdles must keep the normal population of microorganisms in the food under control.
The micro-organisms present (at the start) in a food should not be able to
overcome (i.e., leap over) the hurdles inherent in this food. This is
illustrated by the so-called hurdle effect, which is of fundamental
importance for the preservation of foods, since the hurdles in a stable
product control microbial spoilage and food poisoning as well as desired
fermentation processes.
5. Examples that explain hurdle effect

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Example 1 represents a food containing six hurdles: high temperature

during processing (F value), low temperature during storage (t value),
water activity(aw), acidity (pH), redox potential (Eh), and preservatives
(pres.).
The micro-organisms present cannot overcome these hurdles, and thus the
food is microbiologically stable and safe. However, example 1 is only a
theoretical case, because all of the hurdles are of the same height (i.e.,
intensity), and this rarely occurs.
A more likely situation is presented in example 2, since the microbial
stability of this product is based on hurdles of different intensity. In this
particular product, the main hurdles are aw and preservatives whereas other
less important hurdles are storage temperature, pH, and redox potential.
These five hurdles are sufficient to inhibit the usual types and numbers of
micro-organisms associated with such a product.
If only a few micro-organisms are present (at the start), a few or low
number of hurdles will be sufficient for the stability of the product
(example 3).The super clean or aseptic packaging of perishable foods is
based on this principle.
On the other hand, as in example 4, if due to bad hygienic conditions, too
many undesirable micro-organisms are initially present, even the usual
hurdles inherent to a product may be unable to prevent spoilage or food
poisoning.
Example 5 is a food rich in nutrients and vitamins, which could foster the
growth of micro-organisms (called the booster or trampoline effect), and
thus the hurdles in such a product must be enhanced, or otherwise be
overcome.
Example 6 illustrates the behavior of sub-lethally damaged organisms in
food. For instance, if the bacterial spores in a food are damaged sublethally by heat, the vegetative cells derived from such spores will lack
vitality; therefore, they will be inhibited by fewer or lower hurdles.
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In some foods, stability is achieved during processing by a sequence of

hurdles, which are important in different stages of a fermentation or
ripening process and lead to a stable final product. A sequence of hurdles
operates in fermented sausages (example 7), and probably in ripened
cheeses or fermented vegetables.
Finally, example 8 illustrates the possible synergistic effect of hurdles,
which likely relates to a multitarget disturbance of the homeostasis of
micro-organisms in foods.

6.

Basic aspects of Hurdle Technology

Food preservation implies exposing microorganisms to a hostile
environment to inhibit their growth, shorten their survival, or cause their
death. The feasible responses of the microorganisms to such a hos- tile
environment determine whether they grow or die. Such an understanding
would be the scientific basis for an efficient application of hurdle
technology in the preservation of foods. Advances have been made by
considering the homeostasis, metabolic exhaustion, and stress reactions of
microorganisms, as well as by introducing the concept of multi-target
preservation for gentle yet effective preservation of foods.

6.1 Homeostasis
It is a process which maintains the stability of the micro-organisms internal
environment in response to changes in external conditions.
Homeostasis is the tendency to uniformity and stability in the internal
status of organisms. For instance, the maintenance of a defined pH within
narrow limits is a feature and prerequisite of living organisms.This applies
to higher organisms as well as to microorganisms.
In food preservation, the homeostasis of microorganisms is a key
phenomenon, which deserves much attention, because if the homeostasis
of these microorganisms is disturbed by preservative factors (hurdles) in
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foods, they will not multiply, i.e., they remain in the lag phase or even die,
before homeostasis is repaired (re-established). Thus, food preservation is
achieved by disturbing the homeostasis of microorganisms in a food
temporarily or permanently.
The repair of a disturbed homeostasis demands much energy, and thus the
restriction of energy supply inhibits repair mechanisms in microbial cells
and leads to a synergistic effect of preservative factors (hurdles).
Energy restriction for microorganisms is, for example, caused by anaerobic
conditions, such as vacuum or modified-atmosphere packaging of foods.
Therefore, low aw (or low pH) and low redox potential act synergistically.
Such interference with the homeostasis of microorganisms or entire
microbial populations provides an attractive and logical focus for
improvements in food-preservation techniques.

6.2 Metabolic Exhaustion

Metabolic exhaustion of microorganisms could lead to auto
sterilization of a food. This can be understood by different experiments
that are conducted.
Experiment-1
Mildly heated (95C core temperature) liver sausage adjusted to
different water activities by the addition of salt and fat, and the product
was inoculated with Clostridium sporogenes and stored at 37C.
Clostridial spores that survived the heat treatment vanished in the
product during storage if the products were stable.
Later this behavior of Clostridium and Bacillus spores was regularly
observed during storage of shelf-stable meat products (SSP), if these
products were stored at ambient temperatures.

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Bacterial spores that survive the heat treatment are able to germinate in
these foods under less favourable conditions (refrigeration condition).
Thus, the spore counts in stable hurdle-technology foods actually
decrease during storage of the products, especially in unrefrigerated
foods.
A general explanation for this surprising behavior might be that
vegetative microorganisms which can- not grow will die, and they die
more quickly if the stability is close to the threshold for growth, storage
temperature is elevated, antimicrobials are present, and the
microorganisms are sublethally injured (e.g., by heat).
Apparently, microorganisms in stable hurdle-technology foods strain
every possible repair mechanisms for their homeostasis to overcome the
hostile environment, by doing this they completely use up their energy
and die, if they become metabolically exhausted. This leads to an
autosterilization of such foods.
Owing to autosterilization, hurdle-technology foods, which are
microbiologically stable, become more safe during storage, especially at
ambient temperatures.
Experiment 2
Salmonellae that survive the ripening process in fermented sausages will
vanish more quickly if the products are stored at ambient temperature,
and they will survive longer and possibly cause foodborne illness if the
products are stored under refrigeration.
It is also well known that salmonellae survive in mayonnaise at chill
temperatures much better than at ambient temperatures.

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Experiment-3
Unilever laboratories at Vlaardingen have confirmed metabolic
exhaustion in water-in-oil emulsions (resembling margarine) inoculated
with Listeria innocua.
In these products Listeria vanished faster at ambient temperature (25C)
than under refrigeration (7C), at pH 4.25 > pH 4.3 > pH 6.0, in fine
emulsions more quickly than in coarse emulsions, and under anaerobic
conditions more quickly than under aerobic conditions.
From these experiments, it has been concluded that metabolic
exhaustion is accelerated if more hurdles are present, and this might be
caused by increasing energy demands to maintain internal homeostasis
under stress conditions.
Thus, it could be concluded that refrigeration is not always beneficial for
the microbial safety and stability of foods. However, this is only true if
the hurdles present in a food inhibit the growth of microorganisms also
without refrigeration, if this is not the case then refrigeration is
beneficial. Certainly, the survival of microorganisms in stable hurdletechnology foods is much shorter without refrigeration.
6.3 Stress Reactions
Some bacteria become more resistant under stress, since they generate
stress shock proteins.
The synthesis of protective stress shock proteins is induced by heat, pH,
aw, ethanol, oxidative compound, as well as by starvation.
Due to synthesis of protective stress shock proteins by microorganisms,
it might hamper food preservation and will be problematic for the
application of hurdle technology.

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However, the activation of genes for the synthesis of stress shock

proteins, which help organisms to compete with stress situations, should
be more difficult if different stresses are received at the same time.
Simultaneous exposure to different stresses will require energyconsuming synthesis of several or at least much more protective stress
shock proteins, which in turn may cause the microorganisms to become
metabolically exhausted. Thus destruction of microorganism occurs
hence food becomes stable and safe.
6.4 Multi-target Preservation
The concept of multitarget preservation of foods has been introduced by
Leistner.
Multitarget preservation is not only for a gentle but also for most
effective preservation of foods. Different hurdles in a food might not
have just an additive effect on microbial stability, but they could act
synergistically.
A synergistic effect could be achieved if hurdles in a food hit, at the
same time, different targets (e.g., cell membrane, DNA, enzyme
systems, pH, aw, and Eh) within the microbial cells and thus disturb the
homeostasis of the microorganisms present in several respects. If so, the
repair of homeostasis as well as the activation of stress shock proteins
becomes more difficult.
Therefore, employing simultaneously different hurdles in the
preservation of a particular food should lead to optimal microbial
stability.
In practical terms, this could mean that it is more effective to employ
different preservative factors (hurdles) of small intensity than one preservative factor of larger intensity, because different preservative factors
might have a synergistic effect.

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This approach is probably not only valid for traditional food-preservation

procedures, but as well for modern processes such as food irradiation,
high hydrostatic pressure, and pulsed technologies.
1. Example 1. Biocides in medical field. At least 12 classes of biocides
are known which have different targets, and sometimes more than
one, within the microbial cell. Often the cell membrane is the
primary target, becoming leaky and disrupting the organism, but
biocides also impair the synthesis of enzymes, proteins, and DNA.
2. Multidrug attack has proven successful in the medical field to fight
bacterial infections (e.g., tuberculosis and leprosy) as well as viral
infections (e.g., AIDS),
And thus a multitarget attack on microorganisms should also be a
promising approach in food microbiology.
7. Significance of hurdle technology
1. It improves product quality and microbial safety.
2. It saves money, energy, and several other resources.
3. Food remains stable and safe, high in sensory and nutritive value due to
gentle process applied.
4. It does not effect the integrity of food pieces.
5. Application in both large and small industries.
8. Application of Hurdle Technology
Major current applications of combined methods (Hurdle Technologies)
for food preservation that used in Industrialized and Developing
Countries.
Industrialized Countries
1. Minimally processed foods (higher quality; freshlike, and
convenient)
2. Safer chilled foods (built in safety hurdles; invisible technology)
3. Fermented foods (in which sequences of hurdles lead to safety and
stability)

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4. Healthful foods (to ensure the safety of foods low in salt, fat, sugar,
preservatives)
5. Minimally packaged foods (with environmentally friendly
packaging procedures)
6. Ultraclean packaging procedures (for low contamination of mildly
preserved foods)
7. Foods with less potentially undesirable preservatives (e.g., sulte,
nitrite)
8. Less energy usage for chilling or freezing (by conversion to
ambient-stable foods)
9. Raw materials decontaminated by multiple hurdles (meat, fruits,
vegetables)
10.
Improved defenses against pathogens (in foods and in vivo)
Developing Countries
1. South America (especially used for fruit products, also meats and
sh).
2. China and Taiwan (improved traditional foods, adaptation of fusion
foods)
3. India (used for variety of dairy, cereal, fruit, poultry, and sh
products)
4. Africa (preliminary work with juices, fruits, and carcass meat)
9. Conclusion
The physiological responses of microorganisms during food
preservation (i.e., their homeostasis, metabolic exhaustion, and stress
reactions) are the basis for the application of advanced hurdle
technology. The disturbance of the homeostasis of microorganisms is
the key phenomena of food preservation. Microbial stress reactions
may complicate food preservation, whereas the metabolic exhaustion of
microorganisms present in stable hurdle technology foods could foster
food preservation.The novel and ambitious goal for optimal food
preservation is the multi target preservation of foods, in which
intelligently applied gentle hurdles will have synergistic effect.

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10.

References

1. Leistner L.(2000) Basic aspects of food preservation by hurdle

technology. International journal of food microbiology., 55 : 181186
2. Leistner L., Hurdle technology. Food engineering
3. Leistner L. (2007) Update on Hurdle Technology for Mild and
Effective

Preservation

of

Foods.

In:

Handbook

of

Food

Preservation.Chap-37. Second Edition. Taylor & Francis Group,

LLC. pp. 895-899.
4. Leistner L. And Gould G.W. (2005) Update on Hurdle Technology
Approaches to Food Preservation. In: Antimicrobials in Food. Taylor
& Francis Group, LLC. pp: 621-623.
5. Leistner L. and Gorris L.G.M. (1995) Food preservation by hurdle
technology. Trends in Food Science & Technology. Vol (6).pp.41-45

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