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Beverage Quality Testing with Innovate™: Real-World Results

In the dynamic landscape of the beverage industry, ensuring product safety and quality is not just a regulatory requirement—it's a critical factor in maintaining consumer trust and brand reputation. Beverage quality testing has become increasingly complex, with manufacturers facing the dual challenge of maintaining rigorous standards while meeting the demands of high-volume production.

Today's beverage market spans a diverse range from traditional to innovative products. Ultra-high temperature (UHT) processed dairy shares shelf space with high-acid fruit juices. Sports drinks and protein shakes cater to health-conscious consumers, while non-dairy alternatives and specialty teas appeal to those seeking variety. 

This wide spectrum of beverages requires sophisticated testing methods to ensure product safety and quality. Traditional approaches to microbial detection, though reliable, often cause significant delays in product release and increase inventory costs. In response, rapid microbial screening systems are making a substantial impact, addressing the unique challenges posed by each beverage type and enabling faster, more efficient quality control processes.

The Innovate™ Rapid Microbial Screening System, utilizing advanced ATP bioluminescence technology, offers a solution to these industry-wide challenges. This rapid detection method is designed to address key issues facing beverage manufacturers:

  1. Significantly reducing time-to-market without compromising safety standards
  2. Meeting the demands of high-throughput testing in fast-paced production environments
  3. Maintaining stringent accuracy while improving overall efficiency in quality control processes
  4. Ensuring compliance with safety standards across a diverse range of beverage types

From large-scale dairy & beverage processors to global manufacturers, this technology is proving its worth in real-world applications. It's not just about detecting microbial contamination; it's about transforming the entire approach to quality assurance in the industry.

In the following sections, we'll explore the science behind this rapid microbial detection system, examine its advantages over traditional methods and showcase real-world case studies that demonstrate its impact on beverage quality testing. 

ATP Bioluminescence: The Science Behind Innovate

ATP bioluminescence, the same process that makes fireflies glow, is the cornerstone of the Innovate System's rapid microbial screening capabilities. Here's a simplified explanation of how it works in beverage quality testing:

  1. Non-microbial ATP must be identified and removed in all product types, leaving the remaining microbial ATP intact
  2. Microbial ATP is extracted and converted into light through a luciferase reaction
  3. This light measurement is quantified and measured by the Innovate System
  4. The light intensity directly correlates to the level of microbial contamination in the product sample.

What sets the Innovate System apart is its ability to differentiate between microbial and non-microbial ATP through a proprietary sample treatment process. This ensures only contaminating microorganisms are detected, resulting in highly sensitive and specific testing while reducing the chances of false positives/negatives. 

This technology enables beverage manufacturers to obtain reliable results for 96 individual samples in less than 30 minutes, a significant improvement over traditional methods that can take days or weeks. 

Why Innovate Excels in Beverage Quality Testing 

Although there are several options on the market, the Innovate System stands at the forefront of beverage quality testing, offering a unique combination of features that address critical industry needs:

  1. Rapid and Sensitive Detection: 
    • Detects microbial contamination within 30 minutes after product incubation. This speed significantly reduces hold times compared to traditional methods that can take days or weeks.
  2. Versatility Across Product Types:
    • Capable of testing a wide range of beverages, from clear liquids to thick, pulpy drinks and non-dairy alternatives.
    • Effective in detecting various contaminants, including hard-to-detect bacteria, often exceeding the performance of traditional methods.
  3. High-Throughput Efficiency:
    • Tests up to 96 different samples on a single microtiter plate every 30 minutes.
    • Autosampler III capabilities enhance throughput without additional staff, ideal for high-volume production environments.
  4. Cost-Effective Operations:
    • Reduces inventory costs by enabling faster product release.
    • Minimizes labor costs through automation and reduced hands-on time.
    • Decreases the need for large storage areas for held products, cutting warehousing expenses.
  5. User-Friendly Design:
    • Features intuitive software with on-screen support and a color-coded graphical user interface.
    • Offers automated data capture and archiving, with integration capabilities for Laboratory Information Management Systems (LIMS).
  6. Enhanced Quality Assurance:
    • Provides objective, quantifiable results, eliminating subjectivity associated with some traditional methods.
    • Enables faster corrective actions, reducing the risk of large-scale product recalls.
    • Improves traceability through automated data capture, supporting quality assurance processes and regulatory compliance.

The Innovate System's combination of speed, accuracy, versatility, and cost-effectiveness makes it an invaluable tool for beverage manufacturers seeking to optimize their quality control processes. In the following sections, we'll explore real-world case studies demonstrating how the Innovate System has transformed beverage quality testing for various manufacturers.

Case Study 1: Large Dairy Farm & Processor Ensures UHT & ESL Product Safety

Background

A large dairy processor in the southwest US, with over a century of history, operates a herd of nearly 20,000 cows. Their diverse product range includes traditional dairy items like milk, cottage cheese, and ice cream, as well as non-dairy alternatives such as bottled water, juices, and plant-based creamers.

Challenge

The processor needed to maintain high quality standards across their entire product line while keeping pace with large-scale, round-the-clock operations. Ensuring product safety and meeting specifications for both dairy and non-dairy items required a robust and efficient quality control system. The company was specifically interested in detecting Coliform bacteria generally belonging to four genera of the Enterobacteriaceae family: Citrobacter, Enterobacter, Escherichia and Klebsiella.

Solution 

The dairy implemented two Innovate Rapid Microbial Screening Systems with RapiScreen™ reagents. These systems:

  • Run in series, evaluating microbiological loads on finished products
  • Operate 24/7, with machines alternated daily

Results

  • Testing Capacity: Increased to an average of 900 assays per day
  • Time Efficiency: Results delivered in less than 30 minutes following incubation
  • Product Range: Effective across diverse dairy and non-dairy product lines
  • Quality Assurance: Quicker identification of potential contamination issues
  • Operational Impact: Supports continuous 24/7 facility operation

Comments From Our Partner

“We get preventative maintenance twice a year. And if an instrument goes down, we get sent a loaner. Hygiena® troubleshoots the machine with the diagnostics support group. Hygiena’s program is awesome. It’s way better than having a technician come out. It’s important to have a system like that because you will always need assistance with machines.”

Key Takeaways

  • Significantly increased testing capacity matches large-scale operations.
  • Versatile system effectively handles both dairy and non-dairy product testing.
  • Rapid results and continuous operation enhance overall product safety and quality control.

Read the full case study here: How a Large Dairy Farm and Processor Uses Innovate™ to Ensure UHT & ESL Products Stay Safe

Case Study 2: Global Beverage Manufacturer Streamlines Beverage Quality Testing with Innovate 

Background: 

A major beverage manufacturer in North America, generating tens of billions in annual net revenue, operates a facility in the Midwest. This site focuses on producing sports drinks, energy drinks, and non-dairy high-protein nutritional beverages. The company is part of a rapidly growing global market, expected to reach 2-4 trillion USD, driven by increasing demand for sports and energy drinks.

Challenge

The manufacturer needed to maintain high quality standards across their product line while managing high-volume testing requirements. Their existing process involved testing 80-90 bottles daily using traditional plating methods, resulting in 11-14 days for final product release. This process was labor-intensive, requiring significant hands-on work for media preparation, sterilization, and analysis. Additional pH testing required separate sample collection and 10-day incubation periods. With anticipated rapid growth in product demand, a more efficient testing solution was crucial.

Solution

The beverage manufacturer implemented the Innovate™ Rapid Microbial Screening System to streamline their quality testing process. This system:

  • Integrates into existing quality control protocols
  • Applies across various product lines, including sports drinks and energy beverages
  • Enables 100% in-pack incubation, eliminating the need for separate sample preparation

Results

  • Testing Capacity: Scaled from 80-90 bottles to 1,000 product samples daily
  • Time Efficiency: Product release time cut from 11-14 days to just 5 days
  • Operational Efficiency: Eliminated need for media preparation and sterilization
  • Detection Capabilities: Caught microbial contaminants missed by traditional pH methods
  • Cost Savings: Significant reductions in time, labor, and holding costs
  • Sustainability: Aligned with waste reduction efforts and overall cost savings

Comments From Our Partner

"By shaving up to 9 days from our release time, we have seen significant savings - in time, labor and holding costs. In addition, Hygiena® has offered us rapid responses when we request support, further increasing our satisfaction with the results."

Key Takeaways

  • Dramatically increased testing capacity meets growing production demands.
  • Significantly reduced release time improves overall operational efficiency.
  • Enhanced detection capabilities ensure higher product safety standards.

Read the full case study: Major Beverage Manufacturer Turns to the Innovate™ System for Efficient Product Quality Testing of its Products

Case Study 3: Innovate Outperforms Traditional Methods for Clostridium Detection in Beverages 

Background

Aseptic food processing is becoming a preferred method over canning, freezing, or concentration due to decreased processing costs. This technique is now used for various products, including dairy, juice drinks, fruit purees, baby food, puddings, flavored drinks, edible oils, wine and mineral water. 

Challenge

While ultra-high temperature (UHT) pasteurization and aseptic filling systems can meet commercial sterility demands, contamination can occur after heat treatment, during manufacturing and production. Traditional microbial detection methods like plate culture are laborious and time-consuming, and indirect methods like pH readings require follow-up tests. A beverage manufacturer sought a more efficient and accurate method to detect Clostridium bacteria in their dairy-alternative beverages.

Solution

The customer requested that Hygiena compares the Innovate System's performance against three traditional methods for detecting Clostridium in non-dairy beverages:

  • Agar-based plate culture: Accurate but prone to errors, requires anaerobic incubation and skilled technicians.
  • Neogen® Petrifilm® Plates: Simpler than traditional culture but still requires lengthy incubation, especially for anaerobic organisms.
  • pH measurement: A crude estimate requiring additional tests to confirm microbial causes of pH shifts.

Results

  • Detection Accuracy: Matched or exceeded detection rates of traditional methods for Clostridium sporogenes
  • Time Efficiency: Detected Clostridium sporogenes at least 24 hours earlier than traditional agar-plate culture methods
  • Cost-Effectiveness: Reduced testing costs compared to traditional plate count technology and Petrifilm plates
  • Operational Impact: Significantly reduced product hold times due to the uncertainty of contamination

Key Takeaways

  • The Innovate System provides equal or better detection of Clostridium compared to traditional methods.
  • Significantly faster detection allows for quicker response times and reduced risk of contaminated products reaching consumers.
  • Cost-effective solution that streamlines the testing process and reduces resource requirements.

Read the full case study: The Innovate™ System determines Clostridium bacteria presence better, faster than pour plates, Petrifilm plates and pH tests

Case Study 4: Innovate Surpasses Competitor Rapid Methods in Detection of Non-Spore-Forming Bacteria 

Background 

Ultra-high temperature (UHT) pasteurization of milk can achieve a microbe-free shelf life of up to nine months. However, contamination can occur during filling operations due to ineffective cleaning and sanitation programs or from spore-forming bacteria that may survive UHT.

Challenge

Despite UHT treatment, contamination risks persist during filling operations due to inadequate sanitization or from resilient bacteria. Traditional plate culture methods, while accurate, are time-consuming and costly due to long hold times. The industry needs rapid detection methods that match traditional reliability while reducing time-to-market and costs.

Solution

Researchers at the University of Chemistry and Technology, Prague, conducted a study in 2018 comparing the Innovate System to Promicol® BV's Promilite® III. Both systems use ATP bioluminescence technology for rapid microbial screening of dairy products. The study:

  • Focused on detecting non-spore-forming bacteria in UHT milk samples
  • Compared the performance of Innovate and Promilite III at 24 and 48 hours
  • Tested various non-spore forming bacteria, including Strenotrophomonas maltophilia, Shewanella putrefaciens, Citrobacter braakii, and Serratia species

Results

  • Detection Accuracy: Innovate consistently detected microbial contamination in all samples, while Promilite III showed high rates of false-negatives 
  • Quantitative Performance: At 24 hours, Innovate detected RLUs ranging from 25,009 to 49,463, compared to Promilite III's 30 to 75 
  • Consistency: Innovate demonstrated reliable detection across all samples tested 
  • Reagent Stability: Researchers concluded Innovate's superior performance was likely due to more stable reaction reagents

Comments from Researchers

The study, published in the Czech Journal of Food Science, concluded: "Only the (Innovate) RapiScreen system reliably detected microbial contamination in all samples, no matter how high the concentration was."

Key Takeaways

  • The Innovate System reliably detects microbial contamination in all samples, regardless of concentration.
  • Innovate significantly outperforms Promicol Promilite III in detecting non-spore-forming bacteria.
  • Offers a rapid, reliable alternative to traditional plate culture methods for UHT milk testing.

Read the full case study: Innovate dramatically more reliable detecting microbes in samples than Promilite®

Beyond Innovate: Hygiena's Comprehensive Approach to Beverage Quality

While our case studies have demonstrated the effectiveness of the Innovate System across various beverage types, contamination can occur at any stage of the production process. Our comprehensive suite of solutions is designed to address the unique challenges faced by beverage manufacturers, from raw material testing to final product analysis and everything in between.

Our approach combines cutting-edge technology with industry-specific expertise to provide solutions that not only meet current quality standards but also anticipate future challenges in the rapidly evolving beverage industry.

Ensuring Contamination-Free Production with Hygiena 

Hygiena's commitment to beverage quality extends throughout the entire production process, offering solutions for each critical stage:

This multi-layered approach creates a robust defense against contamination, ensuring beverage safety and quality from start to finish. For a deeper dive into strategies for combating beverage spoilage organisms throughout production, we invite you to read our guide: "5 Essential Strategies for Conquering Beverage Spoilage Organisms," on our website.

By integrating these solutions, beverage manufacturers can implement a comprehensive quality control strategy that addresses potential risks at every stage of production, optimizing operations and protecting brand integrity in an increasingly competitive market.

Specialized Beverage Contamination Testing Solutions for Unique Challenges

The beverage industry encompasses a wide range of products, each with its own set of quality control challenges. Recognizing this diversity, we've developed specialized solutions tailored to specific beverage types and their associated risks.

  1. Beer Quality Assurance
    Our foodproof Beer Screening Kit rapidly detects of over 30 beer-spoiling bacteria in a single test. This is one solution that helps breweries maintain product quality, extend shelf life, and prevent costly recalls. Our comprehensive Beer Spoilage Testing Guide gives brewers an insight into detecting and preventing beer spoilage. 
  2. Fruit Juice and Acidic Beverage Safety
    Alicyclobacillus contamination is a nuisance for juice manufacturers due to its ability to survive pasteurization. Our foodproof Alicyclobacillus Detection LyoKit is intended to help manufacturers catch Alicyclobacillus contamination before contaminated juices reach the customer. For a thorough breakdown on detecting and preventing this bacterium from damaging your brand reputation, refer to our comprehensive Alicyclobacillus Testing Guide.

Experience Unrivalled Beverage Quality With Hygiena 

Throughout this blog post, we've explored how the Innovate System and Hygiena's comprehensive suite of solutions are revolutionizing beverage quality testing across various industry sectors. From large dairy farms to global beverage manufacturers, and from beer breweries to fruit juice producers, our technology has consistently demonstrated its ability to deliver faster, more accurate, and more cost-effective results.

Key takeaways from our exploration include:

  1. The Innovate System's ability to significantly reduce testing time, allowing for faster product release without compromising safety.
  2. Our specialized solutions for unique challenges like beer spoilage and Alicyclobacillus contamination in fruit juices.
  3. The comprehensive nature of our quality control approach, covering every stage from raw materials to finished products.
  4. The versatility of our systems in handling a wide range of beverage types and testing scenarios.

As the beverage industry continues to evolve and face new challenges, Hygiena remains committed to providing cutting-edge solutions that ensure product safety, maintain quality, and optimize operational efficiency. Our ongoing research and development efforts mean that we're not just meeting current industry needs but anticipating future ones as well.

Whether you're a small craft brewery or a large-scale beverage manufacturer, Hygiena has the tools and expertise to elevate your quality control processes. By partnering with us, you're not just investing in a product – you're investing in peace of mind, brand protection and the future of your business.

We invite you to explore how Hygiena's solutions can transform your beverage quality testing processes. Contact our team of experts today to discuss your specific needs and discover how we can help you achieve unrivaled beverage quality.

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