Effect of Processing on Mycotoxin Content in Grains

Mycotoxins that commonly occur in cereal grains and other products can contaminate finished processed foods on account of their high toxicity. The mycotoxins that are commonly associated with food grains include aflatoxins, ochratoxin A, fumonisins, deoxynivalenol, and zearalenone. Various food-processing operations include sorting, trimming, cleaning, cooking, baking, frying, roasting, flaking, and extrusion that have variable effects on mycotoxins. The nature of the processing operation viz. physical, chemical, or thermal plays an important role in this; usually, the processes that utilize the higher temperatures have greater effects on mycotoxin dissipation. In general, the processes are known to reduce mycotoxin concentrations significantly, but do not eliminate them completely. However, roasting and extrusion processing result in lowest mycotoxin concentrations, since these involve higher temperatures. It is observed that very high temperatures are needed to bring about high reduction in mycotoxin concentrations, approaching acceptable background levels. The treatment with chemicals like ammonia, bicarbonate, citric acid, or sodium bisulfite is also effective in resulting in significant decline in mycotoxin concentrations.     

Effects of processing on mycotoxin stability in cereals

The mycotoxins that generally occur in cereals and other products are not completely destroyed during food‐processing operations and can contaminate finished processed foods. The mycotoxins most usually associated with cereal grains are aflatoxins, ochratoxins, deoxynivalenol, zearalenone and fumonisins. The various food processes that may have effects on mycotoxins include cleaning, milling, brewing, cooking, baking, frying, roasting, flaking, alkaline cooking, nixtamalization, and extrusion. Most of the food processes have variable effects on mycotoxins, with those that utilize high temperatures having the greatest effects. In general, the processes reduce mycotoxin concentrations significantly, but do not eliminate them completely. This review focuses on the effects of various thermal treatments on mycotoxins. © 2014 Society of Chemical Industry     

Fate of Fusarium mycotoxins in maize flour and grits during extrusion cooking

Extrusion technology is used widely in the manufacture of a range of breakfast cereals and snacks for human consumption and animal feeds. To minimise consumer exposure to mycotoxins, the levels of deoxynivalenol (DON) and zearalenone (ZON) in cereals/cereal products and fumonisins B₁ and B₂ (FB₁ and FB₂) in maize are controlled by European Union legislation. Relatively few studies, however, have examined the loss of Fusarium mycotoxins during processing. The behaviour of FB₁, FB₂ and fumonisin B₃ (FB₃), DON and ZON during extrusion of naturally contaminated maize flour and maize grits is examined using pilot-scale equipment. DON and ZON are relatively stable during extrusion cooking but the fumonisins are lost to varying degrees. There is some loss of ZON when present in low concentrations and extruded at higher moisture contents. The presence of additives, such as reducing sugars and sodium chloride, can also affect mycotoxin levels. Moisture content of the cereal feed during extrusion is important and has a greater effect than temperature, particularly on the loss of fumonisins at the lower moistures. The effects are complex and not easy to explain, although more energy input to the extruder is required for drier materials. However, on the basis of these studies, the relationship between the concentration of Fusarium toxins in the raw and finished product is toxin- and process-dependent.     

Reduction of fumonisin B₁ in corn grits by twin-screw extrusion

Abstract: This study was designed to investigate the fate of fumonisins in flaking corn grits during twin‐screw extrusion by measuring fumonisin B₁ (FB₁) and its analogs with a mass balance approach. Food grade corn grits and 2 batches of grits contaminated with FB₁ at 10 and 50 μg/g by Fusarium verticillioides M‐2552 were processed with or without glucose supplementation (10%, w/w) with a twin‐screw extruder. Extrusion reduced FB₁ in contaminated grits by 64% to 72% without glucose and 89% to 94% with added glucose. In addition, extrusion alone resulted in 26% to 73% reduction in the levels of fumonisin B₂ and fumonisin B₃, while levels of both mycotoxins were reduced by >89% in extruded corn grits containing 10% glucose. Mass balance analysis showed that 38% to 46% of the FB₁ species detected in corn extruded with glucose was N‐(deoxy‐D‐fructos‐1‐yl)‐FB₁, while 23% to 37% of FB₁ species detected in extruded corn grits with and without added glucose was bound to the matrix. It was also found that the hydrolyzed form of FB₁ was a minor species in extruded corn grits with or without added glucose, representing <15% of the total FB₁ species present. Less than 46% of FB₁ originally present in corn grits could be detected in the fumonisin analogues measured in this study. Research is needed to identify the reaction products resulting from extrusion processing of fumonisin‐contaminated corn products. Practical Application: Twin‐screw extrusion is widely used in food industry for its versatility. This technology may reduce the level of fumonisins in corn particularly with added glucose.     

Occurrence and preventive strategies to control mycotoxins in cereal‐based food

Mycotoxins contamination in cereal‐based food is ubiquitous according to systematic review of the scientific documentation of worldwide mycotoxin contamination in cereal and their products between 2008 and 2018, thus representing food safety issue especially in developing tropical countries. Food processing plays a vital role to prevent mycotoxin contamination in food. Therefore, it is with great urgency to develop strategies to inhibit fungi growth and mycotoxin production during food processing. This review begins by discussing physicochemical properties of five most common mycotoxins (aflatoxins, fumonisins, ochratoxins, deoxynivalenol, and zearalenone) found in cereal grains, regulation for mycotoxins in food, and their potential negative impact on human health. The fate of mycotoxins during major cereal‐based food processing including milling, breadmaking, extrusion, malting, and brewing was then summarized. In the end, traditional mitigation strategies including physical and chemical and potential application of biocontrol agent and essential oil nanoemulsions that can be applied during food processing were discussed. It indicated that no single method is currently available to completely prevent mycotoxin contamination in cereal foods.     

Reduced toxicity of fumonisin B1 in corn grits by single-screw extrusion

Corn grits spiked with 30 microg/g fumonisin B1 and two batches of grits fermented with Fusarium verticillioides (batch 1 contained 33 microg/g, and batch 2 contained 48 microg/g fumonisin B1), which were extruded by a single-screw extruder with and without glucose (10%, dry weight basis) supplementation were fed to rats. Control groups were fed uncontaminated grits. Extrusion with glucose more effectively reduced fumonisin B1 concentrations of the grits (75 to 85%) than did extrusion alone (10 to 28%). With one exception, the fumonisin B1-spiked and fermented extrusion products caused moderately severe kidney lesions and reduced kidney weights, effects typically found in fumonisin-exposed rats. Lesions in rats fed the least contaminated grits (batch 1) after extrusion with 10% glucose were, however, significantly less severe and not accompanied by kidney weight changes. Therefore, extrusion with glucose supplementation is potentially useful for safely reducing the toxicity of fumonisins in corn-based products and studies to determine the optimal conditions for its use are warranted.     

Fate of mycotoxins in cereals during extrusion cooking: a review.

Extrusion cooking is one of the fastest growing food-processing operations in recent years due to several advantages over traditional methods. Apart from its main goal of improving the quality of intermediate and final processed products, it may incidentally also improve safety because of the potential to reduce mycotoxin levels in cereals. This review is focused on extrusion cooking and aims to give a general overview of its impact in reducing mycotoxin levels in cereals. Extrusion cooking generally decreases the mycotoxins levels at rates depending on different factors such as the type of extruder, the type of screw, the die configuration, the initial mycotoxin concentration, the barrel temperature, the screw speed, the moisture content of the raw material and the use of additives. Reductions of 100, 95 and 83% for fumonisins, aflatoxins and zearalenone, respectively, have been reported during extrusion cooking of cereals, while lower reductions were observed for deoxynivalenol, ochratoxin A and moniliformin, where maximum reductions did not exceed 55, 40 and 30%, respectively.     

Effects of thermal food processing on the chemical structure and toxicity of fumonisin mycotoxins

Fumonisins are Fusarium mycotoxins that occur in corn and corn-based foods. They are toxic to animals and at least one analogue, fumonisin B1, is carcinogenic to rodents. Their effect on human health is unclear, however, fumonisins are considered to be risk factors for cancer and possibly neural tube defects in some heavily exposed populations. It is therefore important to minimize exposures in these populations. Cleaning corn to remove damaged or moldy kernels reduces fumonisins in foods while milling increases their concentration in some and reduces their concentration in other products. Fumonisins are water-soluble and nixtamalization (cooking in alkaline water) lowers the fumonisin content of food products if the cooking liquid is discarded. Baking, frying, and extrusion cooking of corn at high temperatures ( > or = 190 degrees C) also reduces fumonisin concentrations in foods, with the amount of reduction achieved depending on cooking time, temperature, recipe, and other factors. However, the chemical fate of fumonisins in baked, fried, and extruded foods is not well understood and it is not known if the reduced concentrations result from thermal decomposition of fumonisins or from their binding to proteins, sugars or other compounds in food matrices. These possibilities might or might not be beneficial depending upon the bioavailability and inherent toxicity of decomposition products or the degree to which bound fumonisins are released in the gastrointestinal tract. In this review the affects of cooking and processing on the concentration and chemical structure of fumonisins as well as the toxicological consequences of known and likely fumonisin reaction products are discussed.     

Loss of Fuminosin B1 in Extruded and Baked Corn-Based Foods with Sugars

The objective of this work was to determine the effect of added sugars on fumonisin B₁ (FB₁) levels in baked corn muffins and extruded corn grits. Muffins containing added glucose had significantly lower FB₁ levels than muffins with sucrose, fructose, or no added sugar. Extrusion cooking of the grits resulted in significant (p< 0.05) reductions of FB₁ in all treatments relative to unextruded controls, but use of glucose resulted in greater reductions of FB₁ (45.3 to 71%) than did the use of fructose (29.5 to 53%) or sucrose (19.2 to 39%). When extrusion conditions were optimized, 92.1% loss of FB₁ was found when grits were extruded with glucose. Adding glucose to thermally processed food can result in a substantial reduction in FB₁ levels.     

河南省粮食及其制品中真菌毒素污染情况调查

目的了解河南省市售粮食及其制品中真菌毒素污染的种类和程度。方法 2018—2019年采集河南省市售粮食及其制品,采用同位素稀释超高效液相色谱-串联质谱(UPLC-MS/MS)法测定16种真菌毒素含量,检测结果按照GB 2761—2017《食品安全国家标准食品中真菌毒素限量》进行评价分析。结果 100份玉米面、玉米渣及玉米粒中伏马菌素、玉米赤霉烯酮、黄曲霉毒素、脱氧雪腐镰刀菌烯醇是主要污染真菌毒素,检出率范围为0.0%～95.7%;220份小麦粉、面条和馒头中脱氧雪腐镰刀菌烯醇检出率分别为78.0%(124/159)、64.3%(18/28)和87.9%(29/33);其他真菌毒素含量较低或未检出。结论河南省粮食及其制品中存在不同程度的真菌毒素污染问题,尤其是玉米及其制品中伏马菌素有较高的检出率,应及时开展溯源调查,尽快采取相应控制措施。     

The fate of mycotoxins during secondary food processing of maize for human consumption

Mycotoxins are naturally occurring fungal metabolites that are associated with health hazards and are widespread in cereals including maize. The most common mycotoxins in maize that occur at relatively high levels are fumonisins (FBs), zearalenone, and aflatoxins; furthermore, other mycotoxins such as deoxynivalenol and ochratoxin A are frequently present in maize. For these toxins, maximum levels are laid down in the European Union (EU) for maize raw materials and maize-based foods. The current review article gives a comprehensive overview on the different mycotoxins (including mycotoxins not regulated by EU law) and their fate during secondary processing of maize, based on the data published in the scientific literature. Furthermore, potential compliance with the EU maximum levels is discussed where appropriate. In general, secondary processing can impact mycotoxins in various ways. Besides changes in mycotoxin levels due to fractionation, dilution, and/or concentration, mycotoxins can be affected in their chemical structure (causing degradation or modification) or be released from or bound to matrix components. In the current review, a special focus is set on the effect on mycotoxins caused by different heat treatments, namely, baking, roasting, frying, (pressure) cooking, and extrusion cooking. Production processes involving multiple heat treatments are exemplified with the cornflakes production. For that, potential compliance with FB maximum levels was assessed. Moreover, effects of fermentation of maize matrices and production of maize germ oil are covered by this review.     

Reduction of Moniliformin in Corn by Heat Processing

The effects of autoclaving, baking, extrusion, frying, and roasting on the stability of moniliformin (MON) in spiked (5 μg/g of MON) corn‐based food products were investigated. Roasting corn meal at 218 °C for 15 min had the most significant effect (p ≤ 0.05) on the reduction of MON (44.6%). Autoclaving creamed corn at 121 °C for 65 min resulted in only 10% reduction of MON. Reductions of MON ranging from 5.4 to 28.9% were observed when corn chips were prepared from spiked masa. MON was reduced by 42.2% when corn muffins were baked and by 26.7% when corn grits were extruded. Overall, MON showed heat stability similar to or greater than other Fusarium mycotoxins such as deoxynivalenol and fumonisin B₁     

Fate of aflatoxins and fumonisins during the processing of maize into food products in Benin

The fate of aflatoxins and fumonisins, two mycotoxins that cooccur in maize, was studied through the traditional processing of naturally contaminated maize in mawe, makume, ogi, akassa, and owo, maize-based foods common in Benin, West Africa. Levels of total aflatoxin and fumonisin were measured at the main unit operations of processing, and the unit operations that induce significant reduction of mycotoxin level were identified. Overall reduction of mycotoxin level was more significant during the preparation of makume (93% reduction of aflatoxins, 87% reduction of fumonisins) and akassa (92% reduction of aflatoxins, 50% reduction of fumonisins) than that of owo (40% reduction of aflatoxins, 48% reduction of fumonisins). Sorting, winnowing, washing, crushing combined with dehulling of maize grains were the unit operations that appeared very effective in achieving significant mycotoxin removal. Aflatoxins and fumonisins were significantly recovered in discarded mouldy and damaged grains and in washing water. Fermentation and cooking showed little effect. During the preparation of ogi and akassa, reduction of fumonisin levels measured in food matrix was lower (50%) compared to mawe and makume, probably due to significant fumonisin release in ogi supernatant. Consequently, the use of ogi supernatant for preparing beverages or traditional herbal medicines could be harmful as it is likely to be contaminated with mycotoxin from the raw maize.     

Fate of the fusarium mycotoxins, deoxynivalenol, nivalenol and zearalenone, during extrusion of wholemeal wheat grain

In the European Union, deoxynivalenol in cereals and cereal products is controlled by recent legislation with the objective of minimizing consumer exposure to this mycotoxin. Relatively few studies have examined the loss of Fusarium mycotoxins during processing and whether this is accurately reflected by the processing factors. The behaviour of deoxynivalenol, nivalenol and zearalenone during extrusion of naturally contaminated wholemeal wheat flour has been examined using pilot-scale equipment. Factors examined were temperature and moisture content. Concentrations of the three mycotoxins were little changed by extrusion although the amount of deoxynivalenol decreased at the lowest moisture content. However, this effect did not appear to be temperature-dependent, suggesting that the apparent loss is either due to binding or inability to extract the residue. Under some conditions, concentrations of the mycotoxins, particularly nivalenol, were higher after extrusion.     

粮食中主要真菌毒素及分析方法研究进展

真菌毒素是由某些真菌在适宜条件下产生的有毒次级代谢产物。在粮食中危害严重并持续引起全球食品安全问题的真菌毒素包括黄曲霉毒素、玉米赤霉烯酮、伏马菌素、赭曲霉毒素和脱氧雪腐镰刀菌烯醇,许多国家和地区对这些毒素在粮食中的含量制定了严格的限量要求,在成分复杂的粮食样本中有效提取真菌毒素并进行灵敏准确的检测非常重要。本文介绍了粮食中污染的主要真菌毒素,归纳了粮食中真菌毒素的样本前处理方法和检测方法,并结合实际应用分析了各种方法的优劣,预测了粮食中真菌毒素分析方法的发展方向,为真菌毒素的防控提供理论参考。     

Fate of the fusarium mycotoxins,deoxynivalenol, nivalenol and zearalenone,during extrusion of wholemeal wheat grain

In the European Union, deoxynivalenol in cereals and cereal products is controlled by recent legislation with the objective of minimizing consumer exposure to this mycotoxin. Relatively few studies have examined the loss of Fusarium mycotoxins during processing and whether this is accurately reflected by the processing factors. The behaviour of deoxynivalenol, nivalenol and zearalenone during extrusion of naturally contaminated wholemeal wheat flour has been examined using pilot-scale equipment. Factors examined were temperature and moisture content. Concentrations of the three mycotoxins were little changed by extrusion although the amount of deoxynivalenol decreased at the lowest moisture content. However, this effect did not appear to be temperature-dependent, suggesting that the apparent loss is either due to binding or inability to extract the residue. Under some conditions, concentrations of the mycotoxins, particularly nivalenol, were higher after extrusion.     

Extrusion Cooking Reduces Recoverability of Fumonisin B1 from Extruded Corn Grits

A split-split plot design was used to determine the effects of extrusion cooking on the recoverability of the mycotoxin Fumonisin B₁ (FB₁). Unextruded and extruded samples of spiked corn grits were analyzed for FB₁ by two methods, commercial enzyme linked immunosorbant assay (ELISA) and HPLC. Extrusion cooking resulted in more apparent loss of FB₁ with mixing screws than nonmixing screws. Losses of recoverable FB1 (p≤0.05) were observed at 120°C and 160°C with the mixing screws. A linear increase in loss of recoverable FB₁ was observed (with the nonmixing screws) as the moisture content increased.     

Investigations on the change of fumonisin content of maize during hydrothermal treatment of maize. Analysis by means of HPLC methods and ELISA

The study was subjected to the investigation of the effects of extrusion cooking, gelatinization, and cornflaking on the stability of fumonisins in artificially contaminated maize grits, spiked with fumonisin B₁ and B₂ at levels of 2 mg/kg and 0.6 mg/kg, respectively. All the processed samples were analyzed according to the AOAC-HPLC method, and some selected samples were analyzed additionally by a commercial enzyme-linked immunosorbent assay (ELISA) and after alkaline hydrolysis. All the samples showed significant decreases of the fumonisin levels. If analyzed according to AOAC-HPLC method, cooking extrusion and gelatinization reduced fumonisin levels to approximately 30-55%, cooking the grits for flaking to approximately 20-65%, and roasting the flakes to approximately 6-35% (depending on the selected technological parameters). With ELISA the fumonisin contents were 15-50% and after alkaline hydrolysis 19-380% higher than with the AOAC-HPLC method. However, the fumonisin amount added before the technological tests could not be recovered in any of the samples.     

Mycotoxins in infant cereal foods from the Canadian retail market

Three hundred and sixty-three samples of cereal-based infant foods were collected from the Canadian retail marketplace over 3 years. The samples included oat-, barley-, soy-, and rice-based infant cereals, mixed-grain infant cereals, teething biscuits, creamed corn, and soy-based formulas. Samples were analysed for targeted mycotoxins (deoxynivalenol, nivalenol, HT-2 toxin, zearalenone, ochratoxin A, fumonisins B₁ and B₂, and five ergot alkaloids). Soy-based cereals (which usually contain corn) exhibited the highest incidences of deoxynivalenol (100%), zearalenone (46%) and fumonisins (75%). Overall, deoxynivalenol was the most frequently detected mycotoxin -- it was detected in 63% of samples analysed. Survey results demonstrated the regular occurrence of multiple mycotoxins in cereal-based infant foods.     

Mycotoxin contamination of cereal grain commodities in relation to climate in North West Europe

This study aimed to investigate mycotoxin contamination of cereal grain commodities for feed and food production in North Western Europe during the last two decades, including trends over time and co-occurrence between toxins, and to assess possible effects of climate on the presence of mycotoxins. For these aims, analytical results related to mycotoxin contamination of cereal grain commodities, collected in the course of national monitoring programmes in Finland, Sweden, Norway and the Netherlands during a 20-year period, were gathered. Historical observational weather data, including daily relative humidity, rainfall and temperature, were obtained from each of these four countries. In total 6382 records, referring to individual sample results for mycotoxin concentrations (one or more toxins) in cereal grains were available. Most records referred to wheat, barley, maize and oats. The most frequently analysed mycotoxins were deoxynivalenol, 3-acetyl-deoxynivalenol, nivalenol, T-2 toxin, HT-2 toxin and zearalenone. Deoxynivalenol had the highest overall incidence of 46%, and was mainly found in wheat, maize and oats. Mycotoxins that showed co-occurrence were: deoxynivalenol and 3-acetyl-deoxynivalenol in oats; deoxynivalenol and zearalenone in maize and wheat; and T-2 toxin and HT-2 toxin in oats. The presence of both deoxynivalenol and zearalenone in wheat increased with higher temperatures, relative humidity and rainfall during cultivation, but the presence of nivalenol was negatively associated with most of these climatic factors. The same holds for both nivalenol and deoxynivalenol in oats. This implies that climatic conditions that are conducive for one toxin may have a decreasing effect on the other. The presence of HT-2 toxin in oats showed a slight decreasing trends over time, but significant trends for other toxins showed an increasing presence during the last two decades. It is therefore useful to continue monitoring of mycotoxins. Obtained results can be used for development of predictive models for presence of mycotoxins in cereal grains.