Electroporator device for pretreating food matrices and process for producing dehydrated products

Abstract

Disclosed is an electroporator device for pretreating food matrices, which comprises: a sine-wave-generating system; a remote digital activation system; an actuator; a high-voltage-generating system; a treatment chamber; a continuous food transport system; a measuring and monitoring system; and a safety and protection system. Also disclosed is a process for pretreating food matrices using the electroporator device, for long-term storage of samples having a moisture content of 2-5%. The device and process reduce dehydration method processing times and, simultaneously, allow good-quality dehydrated products to be obtained.

Description

[0001] ELECTROPORATOR EQUIPMENT FOR PRETREATMENT OF FOOD MATRICES AND PROCESS FOR THE PRODUCTION OF DEHYDRATED PRODUCTS

[0002] TECHNICAL SECTOR

[0003] This technology is related to the food industry; in particular, it presents equipment and a process that minimizes the processing times of dehydration methods and, simultaneously, obtains high-quality dehydrated products.

[0004] STATE OF THE ART

[0005] Dehydration is a fundamental technique for food preservation, as reducing water content limits microbial activity and extends the product's shelf life (Litchfield and Okos, 1992; Ratti, 2001; Kaymak-Ertekin, 2002; Wiktor et al., 2016). However, this process presents significant challenges, primarily high energy consumption and preserving the quality of the dehydrated food. Various food dehydration methods exist, such as solar drying, microwave-assisted drying, vacuum drying, freeze-drying, spray drying, and osmotic dehydration; however, hot air drying is the most well-known and widely used method at an industrial level (Rahman and Perera, 2007; Chen and Mujumdar, 2009; Reis, 2014).Freeze-drying, on the other hand, is one of the techniques that best preserves food quality, as it is carried out at low temperatures and under vacuum conditions, minimizing the deterioration of heat-sensitive compounds (Ratti, 2001). However, it has significant limitations: processing times are long (24–72 hours) and investment and operating costs are high (Wu et al., 2019). These factors limit its use to high-value-added products. Despite advances in dehydration techniques, there remains a need for solutions that reduce processing time and improve energy efficiency. To optimize the dehydration process, pretreatments have been developed that allow for a reduction in the processing time of these foods.

[0006] 1) increased heat transfer by combining with treatments such as microwaves (Jiang et al., 2017; L¡ et al., 2017; Nawirska-Olszañska et al., 2017; Pu et al., 2017; Valadez-Carmona et al., 2017; Zhao et al., 2017), ultrasound (Brines et al., 2015; Amami et al., 2017); and mid-infrared (Oh et al., 2017; Van Bockstal et al., 2017; Xie et al., 2017);

[0007] 2) osmotic pre-dehydration (Jiang et al., 2021) and microwave pre-dehydration (Ferreira et al., 2018); and

[0008] 3) reduction of the mass transfer barrier through thermal, chemical, enzymatic treatments and electric fields (Donsí et al., 2010; Donsí et al., 2011).

[0009] It is important to highlight that advanced physical methods, such as the application of electric fields, have gained relevance due to their ability to act both on the surface and internally of the food, improving drying efficiency (Deng et al. 2019; Almeida et al. 2022). Electric field treatments are used to induce an increase in cell membrane permeability (Lamanauskas et al., 2015a; Lamanauskas et al., 2015b; Parniakov et al., 2016). Electric fields are a type of electrotechnology that reduces the barrier to mass transfer through electroporation in the cell membrane, resulting in a decrease in dehydration time (Barbosa-Cánovas and Altunakar, 2006). The permeabilization produced by electric fields can be reversible or irreversible depending on the intensity of the treatment, the type, and the pulse width (Parniakov et al., 2021).Pulsed electric fields (PEF) have been implemented in processes such as drying, freezing, osmotic dehydration, and extraction to increase mass transfer or increase extraction yields of bioactive compounds in vegetables and fruits (Knorr and Angersbach, 1998; Ade-Omowaye et al., 2001; Vorobiev et al., 2008; Barba et al., 2015a; Barba et al., 2015b; Mok et al., 2015; Parniakov et al., 2015; Bodénés et al., 2016; Dellarosa et al., 2016; Luengo et al., 2016; Parniakov et al., 2016; Wiktor et al., 2016; Wiktor et al., 2020). Electroporation (EP) involves applying very short electrical pulses (1-100 ps), with variable field intensities, to a product located between two electrodes (Alam et al., 2018). EPP uses a current to produce the electroporation phenomenon.To reduce the mass transfer barrier using PEF technology, the energy required to disintegrate tissues is approximately 1–5 kJ / kg of product. In contrast, conventional mechanical (peeling and chopping), enzymatic, and thermal treatments require energies of 20–40, 60–100, and over 100 kJ / kg, respectively (Toepfl et al., 2006). The main advantages of PEF technology are that it allows for food processing in a short time and has high treatment efficiency; however, it has the disadvantage of high implementation costs and high energy consumption. The use of PEF has shown significant reductions in drying time for various products. For example, the application of PEF in carrots has allowed a reduction in dehydration time of 7-8% when using energies of 5-80 kJ / kg (Wiktor et al., 2016), while for fruits such as apples a reduction of between 2-13% has been reported (Wiktor et al. 2013).In addition to reduced processing time, PEF also allows for better retention of bioactive compounds and improved sensory quality of the final product. Despite its benefits, PEF technology presents challenges, such as the high cost of industrial equipment, which can range from €1 million to €4 million for capacities of 5–10 tons per hour (Puértolas et al., 2013). Furthermore, although the energy required to induce electroporation is relatively low (1–5 kJ / kg), total energy consumption can be significant if processing parameters are not properly optimized (Barba et al., 2015b).

[0010] On the other hand, high-voltage electric fields (HVEF) involve generating an electric field using a high-voltage source and a treatment chamber delimited by electrodes. HVEFs have been used in pasteurization, enzyme inactivation, freezing, compound extraction, and drying (Wang et al., 2018; Anukiruthika et al., 2021). HVEF technology does not use electrical pulses but rather relies on generating an electric field that induces electropermeabilization effects in food tissues (Atuonwu et al., 2020). This technique has proven effective in improving heat and mass transfer in applications such as dehydration and enzyme inactivation (Wang et al., 2018). HVEFs have the advantage of being more economical and adaptable, with simple designs that allow their use in different environments and configurations.However, their electroporation capacity is lower compared to PEFs, which limits their effectiveness in reducing dehydration times for products with more resistant cell membranes (Dalvi-Isfahan et al. 2016).

[0011] In Chile, research into electroporation technologies for food dehydration has advanced in recent years, although there are still no registered patents for electric field generating equipment, nor for treatment chambers or the application of electric fields in the optimization of freeze-drying processes.The inventions that have been registered relate to the use of electric fields (PEF) in: protein stabilization of wine (62343, 2019), preservation of liquid foods (201801305), modification of the viscosity of chocolate (59305, 2015), reduction of the microbial load of a liquid composition (201400045), dehydration or purification of cellulose suspensions (57470, 2014; 57469, 2014), permeabilization of biological cell membranes (201102486), reduction of the shear strength of vegetables and fruits (200101442), preservation of food products by joint application with high pressure (199902524) and the treatment of materials or microorganisms (198800204). The multiple uses of electric fields are evident, but in none of the cases are there national patents protecting their use in optimizing the food dehydration process, specifically in freeze-drying. Internationally, there are more than 15.000 patents related to the generation and use of PEF (Toepfl et al., 2020). The patents of Mil'kov and Zagorul'ko (SU 89009, 1949) and Flaumenbaum and Yablochnik (SU 83502, 1949) describe the processing of vegetables with low-frequency alternating current to increase juice production yields, and represent the first evidence of the application of electric fields in processes linked to the food industry (Vorobiev and Lebovka, 2020). US patents 6214297B1 (2001), 20090087900A1 (2009), 2011 / 0065161A1 (2011), and CN109777732B (2020) protect the design of high-voltage generating devices that employ capacitors requiring time to charge after the application of successive pulses. US patent 20120252087A1 (2012) replaces the capacitors with a transformer and uses switches to generate a bipolar signal.

[0012] Recently, Díaz-Álvarez and colleagues designed and built a prototype high-voltage electrical discharge (HVED) device at laboratory scale to assist in the freeze-drying process of blueberries (Díaz-Álvarez et al., 2022; Díaz-Álvarez et al., 2024). With the prototype, electroporation of the cell membrane of the studied food matrix was achieved, increasing the effective diffusivity of water and reducing freeze-drying time by 30%. Additionally, the color and shape of the blueberries treated with the prototype were maintained prior to freeze-drying for all the electric fields and treatment times evaluated. In contrast, blueberries without HVED treatment showed a high percentage of shrinkage, negatively impacting the shape and appearance of the dehydrated product.The HVED prototype also allows the application of pulsed electric fields (PEF) and was used to increase the extraction yield of sulforaphane from broccoli (Mahn et al., 2022). In the study, PEF technology was used to disrupt broccoli tissue, reducing its resistance to mass transfer and enabling a 50% increase in sulforaphane recovery compared to the traditional solvent extraction method without pretreatment. This research paves the way for the implementation of industrial-scale prototypes that can optimize drying processes and reduce associated costs. Electroporation technologies, such as PEF, HVEF, and HVED, represent promising solutions that can improve drying efficiency and preserve food quality.The development of specific prototypes for applications such as electric field-assisted freeze-drying could offer a viable alternative for the Chilean food industry, contributing to improving the competitiveness and sustainability of the sector.

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[0073] BRIEF DESCRIPTION OF THE FIGURES

[0074] Figure 1: Components of the electroporation equipment. 1) sinusoidal wave generator system, 2) remote digital activation system, 3) actuator, 4) high voltage generator system, 5) treatment chamber, 6) continuous feed transport system, 7) measurement and monitoring system, and 8) safety and protection system.

[0075] Figure 2: Silicon iron transformers connected in series for high-voltage generation. 1) Transformer input voltage 220 VAC, and 2) Transformer output voltage 2,000 - 10,000 VAC. Figure 3: Treatment chamber of the electroporation equipment; a) side view, and b) interior view perpendicular to the two parallel square stainless steel plates.

[0076] Figure 4: Schematic of the parallel plate treatment chamber.

[0077] Figure 5: Single-line diagram of the electroporator equipment.

[0078] Figure 6: Side view diagram of the continuous transport system.

[0079] Figure 7: Diagram of the rectangular tank formed by three pieces of 2 mm thick 316 stainless steel; (1) tank body, (2) right and left sides of the tank. Figure 8: Diagram of the front view of the continuous conveyor system with emphasis on the modular belt.

[0080] Figure 9: Cell disintegration index of chestnut treated with electric fields. A) PEF 0.4 kV / cm for 10 seconds, B) PEF 0.8 kV / cm for 10 seconds, C) continuous electroporation equipment 0.4 kV / cm for 10 seconds, D) continuous electroporation equipment 0.8 kV / cm for 10 seconds, E) HVEF 3 kV / cm for 15 minutes, and F) HVEF 6 kV / cm for 15 minutes.

[0081] Figure 10: Cell disintegration index of Michay treated with electric fields. A) PEF 0.4 kV / cm for 10 seconds, B) PEF 0.8 kV / cm for 10 seconds, C) continuous electroporation equipment 0.4 kV / cm for 10 seconds, D) continuous electroporation equipment 0.8 kV / cm for 10 seconds, E) HVEF 2.2 kV / cm for 15 minutes, and F) HVEF 4.4 kV / cm for 15 minutes.

[0082] Figure 11: Lyophilization kinetics of chestnuts treated with electric fields. A) PEF 2.4 kV / cm for 10 seconds, B) continuous electroporation equipment 0.8 kV / cm for 10 seconds, and C) control or without electric field treatment.

[0083] Figure 12: Lyophilization kinetics of michay treated with electric fields. A) PEF 2.4 kV / cm for 10 seconds, B) continuous electroporation equipment 0.8 kV / cm for 10 seconds, and C) control or without electric field treatment. DESCRIPTION OF THE INVENTION

[0084] This paper presents an electroporation system and process that utilizes electric field technology for the pretreatment of food matrices before freeze-drying as a dehydration method for plant-based matrices. This system minimizes processing times for dehydration methods while simultaneously producing high-quality dehydrated products. This approach avoids the high energy consumption associated with traditional food dehydration.

[0085] Unlike existing PEF equipment, which can only be applied intermittently (in batches), thus limiting process efficiency, this electroporator applies electric fields continuously to induce electroporation in food. Unlike PEF, this electroporator uses transformers instead of capacitors, allowing for continuous, uninterrupted treatment, which accelerates food pretreatment before freeze-drying.

[0086] This device operates in an intermediate zone between PEF and HVEF technologies, that is, at high voltage, low current, and intermediate frequency, for an adjustable period of time. This technology generates electroporation of the cell membrane of plant-based food matrices.

[0087] The technology alone does not reduce the freeze-drying time of plant-based food matrices, but the electroporation phenomenon it causes allows for the use of less intensive food dehydration methods.

[0088] The invention accelerates the primary drying (sublimation) of the freeze-drying process through electroporation of food, reducing its dehydration time. The invention improves mass transfer through electroporation, thus requiring less energy to complete the freeze-drying process. The electroporation equipment comprises at least the following parts, detailed below:

[0089] 1) Sinusoidal wave generator system;

[0090] 2) Remote digital activation system;

[0091] 3) Actuator;

[0092] 4) High voltage generating system;

[0093] 5) Treatment chamber;

[0094] 6) Continuous food transport system;

[0095] 7) Measurement and monitoring system; and

[0096] 8) Security and protection system.

[0097] Figure 1 shows the arrangement of the components of the electroporation equipment. The electrical power source for the operation of the electroporation equipment is the three-phase network (380 VAC), which ensures the operation of the electroporation equipment in any industrial installation.

[0098] The present invention employs a frequency converter as a sinusoidal wave generator (1), this device modulates the frequency of the single-phase sinusoidal wave used to power the high-voltage generating system.

[0099] The remote control system (2) consists of a 5VDC, 2A single-phase transformer, an ESP32 microprocessor (Espressif Systems Co., Ltd., Shanghai, China), and a relay module. This remote control system allows the activation of the high-voltage generation system to be controlled via a computer or mobile device. The system features a simple and intuitive interface that enables remote control of the electroporator for enhanced user safety. The interface includes: a) the IP address that allows access to the remote control system programmed into the ESP32 microprocessor, b) the power switch of the electroporator, and c) the protection switch of the electroporator. This ensures that the high-voltage generation system is activated only when both switches are engaged, preventing accidental activation (especially on touchscreen devices).The advantage of controlling the electroporator prototype via a touchscreen is that the user will not be in direct contact with the electroporator or the treatment chamber during operation. The remote control system consists of a relay module, where each relay is activated by a switch on the digital control interface. The relays are connected in series, so both must be activated to send power to the actuator. The actuator (3) is a three-phase contactor, where the contactor coil is energized by a single-phase signal from the relays in the remote control system.

[0100] The high voltage generating system (4) is composed of four 2,500 VAC silicon iron transformers connected in series as shown in Figure 2, where 1) is the transformer supply voltage 220 VAC, and 2) is the transformer output voltage 2,000 - 10,000 VAC.

[0101] The primary coil enameled wire cross-section is AWG12 / 2.05 mm² and the secondary coil enameled wire cross-section is AWG20 / 0.81 mm². The transformer's silicon steel core measures 80 x 90 mm.

[0102] Figure 3 shows a detail of the treatment chamber (5) of the electroporation unit; a) side view, and b) interior view perpendicular to the two parallel square stainless steel plates. The treatment chamber consists of two parallel square (10 x 10 cm) stainless steel plates (2 mm thick), mounted on white high-molecular-weight polyethylene (HMW-PE) plates (15 mm thick), secured with stainless steel bolts and plastic spacers to form two electrodes separated by 10 cm and immersed in an electrolyte of potable water with an electrical conductivity of 200 pS / cm. The treatment chamber connections are insulated from the metal structure of the modular belt in which it is inserted using HMW-PE bolts and nuts.Figure 4 shows a schematic of the treatment chamber, a) high molecular weight polyethylene plates, b) square stainless steel plate or electrode, and c) clamping perforations.

[0103] The continuous feed transport system (6) consists of a rectangular stainless steel tank with four vertical supports (one at each corner) fitted with plastic wheels at the bottom. Inside the tank is a 6-meter-long, gooseneck-shaped modular conveyor belt that transports the feed from the left side of the tank into the electrolyte chamber where the treatment chamber is located. The conveyor then removes the electroporated feed submerged in the electrolyte and discharges it at the right side of the tank. The continuous transport system also includes a frequency inverter and a worm gear motor, allowing the treatment time to be adjusted between 2 and 10 seconds.

[0104] The measurement and monitoring system (7) consists of an oscilloscope, a current probe, and a high-voltage probe that allow for the measurement, monitoring, and storage of the electric field treatment conditions in the electroporator prototype (equipment). It also includes digital voltmeters and ammeters on the door of the electroporator prototype's (equipment) electrical cabinet, as well as pilot lights to monitor the power supply phases, the active waveform generator system, and the active emergency stop. The oscilloscope measures and records the signal applied during treatment, verifying the amplitude, width, and frequency of the current and voltage in the treatment chamber.

[0105] The protection and safety system (8) consists of a magneto-thermal circuit breaker to prevent overloads and short circuits, and a differential protection system (30 mA) for the safety of personnel operating the electroporator prototype (equipment). It also includes an emergency stop safety device. The single-line diagram of the user protection and safety system is shown in Figure 5, where (E) is a 380 VAC 25 A industrial plug, (A) is a digital current meter (Amperes), and (V) is a digital voltage meter (Volts). The system also includes: i) a thermomagnetic circuit breaker (MCB) with a tripping curve B and a capacity of 25 A, ii) an IP 10A automatic and differential circuit breaker with a tripping curve C for the control circuit "1", and iii) a 3P 32A automatic and differential circuit breaker with a tripping curve C and a sensitivity of 30 mA for the power circuit "2".Circuit "1" consists of a 5VDC, 2A transformer, an ESP32 microprocessor, and a relay module. Circuit "2" consists of a three-phase contactor with a single-phase coil controlled by the relay module and the ESP32. At the contactor's output is (A), which corresponds to a digital current meter (Amperes), followed by a unit of four silicon iron high-voltage transformers connected in series to generate the high voltage.

[0106] Figure 6 shows a schematic of the side view of the continuous conveyor system, which includes a rectangular tank and a modular belt. Figure 7 shows a schematic of the rectangular tank, which is made of three 2 mm thick 316 stainless steel pieces: (1) the tank body, and (2) the right and left sides of the tank. The dimensions of the tank body are 400 mm high, 500 mm wide, and 2000 mm long. A 40 mm wide x 20 mm high (folded) rectangular top rim is included. The dimensions of the two side faces are 400 mm high x 500 mm wide, and a 40 mm wide x 20 mm high (folded) rectangular top rim is also included.

[0107] Figure 8 shows a schematic of the front view of the continuous conveyor system, highlighting a detail of the modular belt. The modular belt is supported by two solid stainless steel shafts: one drive shaft and one driven shaft. The main dimensions of the shafts are: 1) Drive shaft: 25.4 mm in diameter x 140 mm long with a keyway 3 mm deep x 6 mm wide, and ends 20 mm in diameter x 70 mm long. Additionally, one end includes a spindle 19 mm in diameter x 90 mm long with a keyway 3 mm deep x 6 mm wide. 2) Driven shaft: 25.4 mm in diameter x 140 mm long, with ends 20 mm in diameter x 70 mm long.

[0108] Among the advantages of the equipment we can mention: it generates a high voltage to produce cellular electroporation, operates in a variable frequency range (50 - 400 Hz) to increase the amount of electrical energy applied, works in an intermediate current range to minimize energy consumption (1 -5 A), and operates during adjustable treatment times.

[0109] The process for the pretreatment of different fruits and their subsequent vacuum freeze-drying using this electroporation equipment comprises the following stages:

[0110] 1) Preparation of Biological Material: Select fresh fruits of uniform quality. Wash the fruits to remove impurities. In the case of fruits with shells (such as chestnuts, pine nuts, or hazelnuts), these must be peeled to ensure homogeneous exposure to the electroporation treatment. In the case of berries (blueberries, michay, calafate), leaves, peduncles, or residual pedicels must be removed.

[0111] 2) Conditions Prior to Electroporation: Cool the fruits to refrigeration temperatures (4°C) to minimize enzymatic and microbial activity.

[0112] 3) Electroporation Process: Use the continuous electroporator prototype (equipment) to apply an electric field suitable for inducing electroporation without damaging the internal structure of the fruit. Apply between 4 and 10 kV at 100 Hz for a treatment time of between 2 and 10 seconds. Place the fruit on the continuous transport system for treatment in the chamber. Apply the electric field (0.4–1 kV / cm) continuously, ensuring that all samples are treated uniformly. It is important to note that only one type of fruit should be processed at a time, not a mixture.

[0113] 4) Freezing: After electroporation, the drained fruit is distributed onto the trays of the freeze-drying equipment and subjected to rapid freezing to minimize the formation of large ice crystals. The freezing process must be controlled until temperatures of around -40°C or lower are reached.

[0114] 5) Freeze-drying: Begin freeze-drying by maintaining the sample at a low temperature (-30°C) and low pressure (<50 Pa) to sublimate the ice formed. Gradually increase the temperature to remove residual water, completing the secondary drying of the material at 20°C and 10 Pa. At the end of the process, the samples should have a low moisture content of between 2 and 5% for suitable long-term storage.

[0115] This technology was validated on fresh chestnuts and michay, but the electroporation equipment can be adapted to other food dehydration processes, offering a flexible solution. It increases processing capacity and operational efficiency on production lines by applying continuous treatment instead of batching, as in PEF technology.

[0116] Food pretreatment using the invention does not require critical operational conditions for dehydration. The main impact of pretreatment on the industrial scaling of dehydration corresponds to differences between the processing capacities of the electroporator prototype (equipment) and the equipment in pre-existing dehydration processing lines. In any case, the food dehydration line assisted by electroporation treatments must be custom-designed to avoid bottlenecks during the process. The invention can be used in processing lines in various national and international markets, such as food processing companies, dehydrated fruit and vegetable companies, dehydrated meat companies, dehydrated fish companies, and dehydrated food companies in general.The invention could also be used in the extraction of bioactive or high-value compounds from plant- and animal-based foods, as well as waste products from these industries. This is justified by the increased cell membrane permeability produced by the developed technology, which allows for improved extraction efficiency.

[0117] PEF technology has an energy consumption of 4.0 kW / h, while the invention developed in this patent operates at a high voltage (8 kV), but with a low and intermediate current (1.8 - 2.3 A), resulting in a higher energy consumption of 9.5 kW / h, equivalent to 138% compared to PEF.

[0118] PEF technology uses very short electrical pulses (<2 s) and high-capacity capacitors that require time to recharge. In contrast, the invention employs a frequency converter that modulates the single-phase waveform to power high-voltage transformers connected in series, allowing for more precise control of the treatment and continuous processing without recharge times. PEFs are commonly used in pasteurization, extraction of bioactive compounds, and preservation of liquid foods. The invention, on the other hand, focuses specifically on the pretreatment of plant-based foods for dehydration by freeze-drying, which is not a typical application of PEF. HVEF technology consumes less energy than PEF (0.02 kWh, equivalent to 0.5% of PEF), but its efficiency is low (2% of PEF), requiring longer treatment times (>30 min).The invention is specifically designed for the pretreatment of food prior to freeze-drying, reducing dehydration times without compromising the quality of the final product. The invention allows for adjustment of the treatment time and frequency, providing greater control over the process and adaptability to different types of food and processing conditions. The invention's design is more accessible and less costly compared to PEF equipment, making it a viable option for a wider range of industrial applications. The differentiating attributes of the invention compared to PEF and HVEF technology are presented in Table 1 and can be summarized as follows: 1) adjustable processing time, 2) low energy consumption, 3) low manufacturing cost, and 4) efficient electroporation treatment.

[0119] Table 1: Differentiating attributes of the invention

[0120] Attributes PEF Technology HVEF Technology Invention Time

[0121] Short (<2 s) Long (30 min) Intermediate (2-10 s) treatment

[0122] High Voltage (0.1 - 40 kV) High (1 - 40 kV) High (1 - 10 kV) High Current (1 - 200 A) Very Low (1 - 1000 mA) Intermediate (1 - 5 A) Energy

[0123] Medium (1 - 100 J / kg) Low (1 - 50 J / kg) Medium (1 - 100 J / kg) treatment

[0124] High Frequency (>500 Hz) Low Frequency (50 Hz) Intermediate Frequency (50 - 400 Hz)

[0125]

[0126] The invention can be used in dehydration processes or other processes such as those requiring modifications to the structure of food matrices, tenderization, or extraction of valuable compounds. The invention can operate with adjustable treatment times thanks to the integrated system comprised of the modular belt, frequency inverter, and geared motor. In the described system, decreasing the operating frequency reduces the speed of the modular belt, increasing the residence time of the food between the parallel plates of the treatment chamber. Furthermore, the invention can apply voltages of varying intensity by appropriately configuring the sinusoidal wave generation system. The voltage at the output of the high-voltage generation system is proportional (1:10 transformation ratio) to the voltage supplied by the sinusoidal wave generation system at its input.This allows for high-voltage electroporation treatments to be applied across a wide operating range. The sinusoidal wave generation system also allows for modulation of the electroporation treatment frequency within a range of 50–400 Hz.

[0127] The competitive advantages of this invention, applied to food dehydration processes, lie in the increased dehydration speed, reduced processing time, lower energy costs, and minimized nutrient degradation. This primarily benefits end users, who are the producers of dehydrated foods. For the foods with which the electroporator prototype (equipment) has been validated—chestnuts and michay—the invention reduces the primary drying time of the freeze-drying process by 35-70%. The beneficiaries of this technology are producers of dehydrated foods, who can produce high-quality food at a lower cost, and consumers of these food products, who gain access to high-quality nutrients in quantities very similar to those found in fresh food.The electroporator prototype (equipment) is capable of processing 300 grams of product every 12 seconds; therefore, it could process 80 kg / h, including a 12.5% ​​safety margin. The industrial freeze-drying of 100 kg of michay requires approximately 3 hours of freezing and 87 hours of freeze-drying, with a cumulative energy consumption of 7207 kWh, which translates to a monetary cost of $597,946. The cost in man-hours for the aforementioned period is $568,750, giving a total cost for these two items equivalent to $1,166,696. Similarly, the industrial freeze-drying of 100 kg of chestnuts requires approximately 3 hours of freezing and 20 hours of freeze-drying, with a cumulative energy consumption of 1780 kWh, which translates to a monetary cost of $147,706. The cost in man-hours for the period mentioned is $150,000, which gives a total value for these two concepts equivalent to $297,706.By employing the invention prior to freeze-drying, approximately $83,159 is saved in the freeze-drying of Brazil nuts and $789,789 in the freeze-drying of michay, representing savings of 28% and 68%, respectively, compared to processes without electroporation treatment. Similar commercially available electroporation equipment (PEF) operates at high voltage, high current, and high frequency, resulting in higher energy consumption compared to this invention.

[0128] The significant reduction in drying time during freeze-drying achieved by this equipment and its operating process allows for lower energy and production costs for dehydrated food producers. This translates into direct monetary savings, as in the case of freeze-drying michay, where savings are estimated at $789,789 per 100 kg batch of fresh product. From a social perspective, the invention allows producers to offer high-quality dehydrated foods at more competitive prices, benefiting consumers by providing access to food products that retain a high nutritional value, similar to that of fresh foods.

[0129] APPLICATION EXAMPLES

[0130] Example 1: Validation of the electroporation equipment

[0131] Validation with chestnuts (Castanea sativa:

[0132] 1) Preparation of Biological Material: Select fresh chestnuts of uniform quality. Wash the fruits to remove impurities. Peel the chestnuts to ensure homogeneous exposure to the electroporation treatment. Cool the fruits to refrigeration temperature (4°C) to minimize enzymatic and microbial activity.

[0133] 2) Electroporation Process: Use the continuous electroporation equipment to apply a suitable electric field to induce electroporation without damaging the internal structure of the chestnuts. Apply between 4 and 10 kV, at 100 Hz, and a treatment time of between 2 and 10 seconds. Place the chestnuts on the continuous transport system for treatment in the chamber. Apply the electric field (0.4–1.0 kV / cm) continuously, ensuring that all samples are treated uniformly.

[0134] 3) Freezing: After electroporation, the drained fruit is distributed onto the trays of the freeze-drying equipment and subjected to rapid freezing to minimize the formation of large ice crystals. The freezing process must be controlled until temperatures of around -40°C or lower are reached.

[0135] 4) Freeze-drying: Begin freeze-drying by maintaining the sample at a low temperature (-30°C) and low pressure (<50 Pa) to sublimate the ice formed. Gradually increase the temperature to remove residual water, completing the secondary drying of the material at 20°C and 10 Pa. At the end of the process, the samples should have a low moisture content of between 2 and 5% for suitable long-term storage.

[0136] Validation with michav (Berberis darwinii):

[0137] 1) Preparation of Biological Material: Select fresh michay fruits of uniform quality. Wash the fruits to remove impurities, and remove any remaining leaves, peduncles, or pedicels.

[0138] 2) Conditions Prior to Electroporation: Cool the fruits to refrigeration temperature (4°C) to minimize enzymatic and microbial activity.

[0139] 3) Electroporation Process: Use the continuous electroporation equipment to apply a suitable electric field to induce electroporation without damaging the internal structure of the michay fruit. Apply between 4 and 10 kV at 100 Hz for a treatment time of between 2 and 10 seconds. Place the fruit on the continuous transport system for treatment in the chamber. Apply the electric field (0.4–1.0 kV / cm) continuously, ensuring that all samples are treated uniformly. 4) Freezing: After electroporation, the drained fruit is distributed onto the trays of the freeze-drying equipment and subjected to rapid freezing to minimize the formation of large ice crystals. The freezing process must be controlled until temperatures of around -40°C or lower are reached.

[0140] 5) Freeze-drying: Begin freeze-drying by maintaining the sample at a low temperature (-30°C) and low pressure (<50 Pa) to sublimate the ice formed. Gradually increase the temperature to remove residual water, completing the secondary drying of the material at 20°C and 10 Pa. At the end of the process, the samples should have a low moisture content of between 2 and 5% for suitable long-term storage.

[0141] Figure 9 shows the cell disintegration index (CDI) of chestnuts subjected to six different electric field treatments. A higher CDI indicates a greater level of electroporation of the chestnut tissue. A) PEF 0.4 kV / cm for 10 seconds, B) PEF 0.8 kV / cm for 10 seconds, C) continuous electroporation equipment 0.4 kV / cm for 10 seconds, D) continuous electroporation equipment 0.8 kV / cm for 10 seconds, E) HVEF 3 kV / cm for 15 minutes, and F) HVEF 6 kV / cm for 15 minutes. Figure 9 shows that the highest CDIs were obtained with the continuous electroporation equipment and PEF. The CDI values ​​correspond to the average of two replicates.

[0142] Figure 10 shows the cell disintegration index (CDI) of michay subjected to six different electric field treatments. A) PEF 0.4 kV / cm for 10 seconds, B) PEF 0.8 kV / cm for 10 seconds, C) continuous electroporation equipment 0.4 kV / cm for 10 seconds, D) continuous electroporation equipment 0.8 kV / cm for 10 seconds, E) HVEF 2.2 kV / cm for 15 minutes, and F) HVEF 4.4 kV / cm for 15 minutes. Figure 10 shows that the highest CDI values ​​were obtained with the HVEF and PEF equipment; however, when the michay samples treated with HVEF were lyophilized, they behaved the same as the control samples. The CDI values ​​correspond to the average of two replicates and three replicates.

[0143] Figures 11 and 12 show the freeze-drying kinetics of Brazil nuts and michay, respectively. A) PEF 2.4 kV / cm for 10 seconds, B) continuous electroporation equipment 0.8 kV / cm for 10 seconds, and C) control or no electric field treatment. The freeze-drying kinetics were obtained from the average of three replicates. Figure 11 shows that Brazil nuts treated with PEF take approximately 11.5 hours to reach 50% weight loss, Brazil nuts treated with the continuous electroporation equipment take approximately 13 hours to reach 50% weight loss, and untreated Brazil nuts take 20 hours to reach 50% weight loss. The moisture content (%) of the Brazil nuts studied was 52.64 ± 0.83, and it is assumed that the Brazil nuts are freeze-dried when they reach 50% of their weight.Figure 12 shows that michay treated with PEF takes approximately 23 hours to reach 63% weight loss, michay treated with the continuous electroporation equipment takes approximately 26 hours to reach 63% weight loss, and untreated michay takes 87 hours to reach 63% weight loss. The moisture content (%) of the michay studied was 64.91 ± 0.97, and it is assumed that when the michay reaches 63% of its weight, it is lyophilized.

Claims

CLAIMS 1. An electroporation unit for the pretreatment of food matrices CHARACTERIZED in that it uses electric field technology and comprises at least the following components: 1) Sinusoidal wave generator system; 2) Remote digital activation system; 3) Actuator; 4) High voltage generating system; 5) Treatment chamber; 6) Continuous food transport system; 7) Measurement and monitoring system; and 8) Security and protection system.

2. The electroporation equipment, according to claim 1, CHARACTERIZED in that it operates in a variable frequency range (50 - 400 Hz) to increase the amount of electrical energy applied, works in an intermediate current range to minimize energy consumption (1 - 5 A), and operates for adjustable treatment times.

3. The electroporation equipment, according to claim 1, CHARACTERIZED in that the sinusoidal wave generating system employs a frequency converter of the single-phase sinusoidal wave used to power the high-voltage generating system.

4. The electroporation equipment, according to claim 1, CHARACTERIZED in that the remote control system allows control of the activation of the high voltage generation system through a computer or a mobile device and is integrated by a single-phase transformer of 5 VDC and 2 A, an ESP32 microprocessor and a relay module.

5. The electroporating equipment, according to claim 4, CHARACTERIZED in that in the relay module of the remote control system each relay connected in series is activated by a switch on the digital control interface.

6. The electroporating equipment, according to claim 1, CHARACTERIZED in that the actuator is a three-phase contactor, where the contactor coil is energized with a single-phase signal from the relays of the remote control system.

7. The electroporation equipment, according to claim 1, CHARACTERIZED in that the high voltage generating system is composed of four 2,500 VAC silicon iron transformers connected in series.

8. The electroporating equipment, according to claim 1, CHARACTERIZED in that in the high voltage generating system the section of the enamelled wire of the primary coil is AWG12 / 2.05 mm, the section of the enamelled wire of the secondary coil is AWG20 / 0.81 mm and the size of the silicon iron core of the transformer is 80 x 90 mm.

9. The electroporation equipment, according to claim 1, CHARACTERIZED in that the treatment chamber is composed of two parallel square plates (10 x 10 cm) of stainless steel (2 mm thick), mounted on white high molecular weight polyethylene (PE-HMW) plates (15 mm thick), secured with stainless steel bolts and plastic spacers to form two electrodes separated by 10 cm from each other and immersed in an electrolyte that corresponds to drinking water with an electrical conductivity of 200 pS / cm.

10. The electroporating equipment, according to claim 1, CHARACTERIZED in that the continuous food transport system is composed of a rectangular stainless steel tank, with four supports Verticals with plastic wheels at the lower end, inside the tank there is a 6 m long modular belt in the shape of a swan neck that transports the feed from the left side of the tank to the inside of the treatment chamber, and then discharges it at the right end of the tank.

11. The electroporating equipment, according to claim 10, CHARACTERIZED in that the continuous food transport system is also composed of a frequency converter and a worm gear motor.

12. The electroporation equipment, according to claim 1, CHARACTERIZED in that the measurement and monitoring system is composed of an oscilloscope, a current probe and a high voltage probe.

13. The electroporating equipment, according to claim 12, CHARACTERIZED in that the measurement and monitoring system is further composed of digital voltmeters and ammeters on the door of the electrical cabinet, pilot lights to monitor the power supply phases, an active wave generator system and an active emergency stop.

14. The electroporating equipment, according to claim 1, CHARACTERIZED in that the protection and safety system is composed of a magneto-thermal protection for the circuit to prevent overloads and short circuits and a differential protection system (30 mA) for the safety of the personnel operating the equipment, in addition to a safety element against accidents (emergency stop).

15. Use of the electroporating equipment, according to claim 1, CHARACTERIZED in that it serves to minimize the processing times of the dehydration methods and, simultaneously, obtain dehydrated products of good quality.

16. Use of the electroporating equipment, according to claim 1, CHARACTERIZED in that it serves to accelerate the primary drying (sublimation) of the freeze-drying process through the electroporation of food, reducing its dehydration time.

17. Use of the electroporation equipment, according to claim 1, CHARACTERIZED in that it serves to be applied continuously without interruptions, to induce electroporation in food.

18. A process for the pretreatment of food matrices prior to vacuum freeze-drying, using the electroporating equipment according to claim 1, CHARACTERIZED in that it comprises the following steps: a) Preparation of fresh and uniform quality food matrices; b) Cool food matrices to refrigeration temperatures (4°C) to minimize enzymatic and microbial activity; c) Use the continuous electroporation equipment, applying between 4 and 10 kV, at 100 Hz and a treatment time of between 2 and 10 seconds; place the fruits in the continuous transport system to be treated in the chamber; apply the electric field (0.4 - 1 kV / cm) continuously, ensuring that all samples are treated uniformly; d) Freezing after electroporation where the food matrices are drained and distributed in the trays of the freeze-drying equipment and subjected to rapid freezing until reaching temperatures of -40°C or lower; e) Start the freeze-drying process by keeping the sample at low temperature (-30°C) and low pressure (<50 Pa) to sublimate the ice formed, gradually increasing the temperature to remove the residual water, completing the secondary drying of the material at 20°C and 10 Pa; and f) When the samples have a moisture content between 2 and 5%, they are stored long-term.

19. The process for the pretreatment of food matrices, according to claim 18, CHARACTERIZED in that the preparation of the food matrices comprises removing impurities such as peels, leaves, peduncles or residual pedicels.

20. Use of the process for the pretreatment of food matrices, according to claim 18, CHARACTERIZED in that it serves to reduce dehydration times without compromising the quality of the final product.

21. Use of the process for the pretreatment of food matrices, according to claim 18, CHARACTERIZED in that it serves to be used in dehydration processes or others, such as those that require modifications of the structure of food matrices; tenderization or extraction processes of bioactive compounds or high added value in foods of plant and animal origin, as well as waste products of these companies.

22. Use of the process for pretreatment of food matrices, according to claim 18, CHARACTERIZED in that it serves to increase the rate of dehydration, decrease the process time, reduce the energy cost and minimize the degradation of nutrients in the products.

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