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The main objective of this study was to design, build, and test a compact, multi-well, portable dry film FTIR system for industrial food and bioprocess applications. The system features dry film sampling on a circular rotating disc comprising 31 wells, a design that was chosen to simplify potential automation and robotic sample handling at a later stage. Calibration models for average molecular weight (AMW, 200 samples) and collagen content (68 samples) were developed from the measurements of industrially produced protein hydrolysate samples in a controlled laboratory environment. Similarly, calibration models for the prediction of lactate content in samples from cultivation media (59 samples) were also developed. The portable dry film FTIR system showed reliable model characteristics which were benchmarked with a benchtop FTIR system. Subsequently, the portable dry film FTIR system was deployed in a bioprocessing plant, and protein hydrolysate samples were measured at-line in an industrial environment. This industrial testing involved building a calibration model for predicting AMW using 60 protein hydrolysate samples measured at-line using the portable dry film FTIR system and subsequent model validation using a test set of 26 samples. The industrial calibration in terms of coefficient of determination ( R 2 = 0.94), root mean square of cross-validation (RMSECV = 194 g mol -1 ), and root mean square of prediction (RMSEP = 162 g mol -1 ) demonstrated low prediction errors as compared to benchtop FTIR measurements, with no statistical difference between the calibration models of the two FTIR systems. This is to the authors' knowledge the first study for developing and employing a portable dry film FTIR system in the enzymatic protein hydrolysis industry for successful at-line measurements of protein hydrolysate samples. The study therefore suggests that the portable dry film FTIR instrument has huge potential for in/at-line applications in the food and bioprocessing industries.

Industries are continuously looking for dedicated sensor solutions for evaluating the chemical composition of products that can provide valuable insights into process control, process optimization, and product quality. A rapid and robust analytical method, Fourier-Transform Infrared (FTIR) spectroscopy, holds significant potential in this regard as it provides detailed compositional values of food nutrients. The main aim of the present study was to use dry film FTIR spectroscopy as an analytical tool to characterize products from an industrial enzymatic protein hydrolysis process and link this to understand industrial process variations. For this purpose, 463 protein hydrolysate samples were obtained from an industrial enzymatic protein hydrolysis plant. In the same period, systematic variations in process parameters such as raw material composition, enzyme type, and water addition, were performed. All samples were analyzed using dry film FTIR spectroscopy. Two subsets containing 200 and 68 hydrolysate samples were chosen for measuring average molecular weight (AMW) and collagen content respectively, providing reference data for constructing calibration models based on partial least squares regression (PLSR). The percentage of low molecular weight constituents was derived from the molecular weight distribution of size exclusion chromatograms of protein hydrolysates and also used in the modeling. Calibration models for the prediction of AMW, low molecular weight constituents, and collagen content were obtained with a good fit and lower estimation errors. Principal component analysis (PCA) of protein hydrolysates' FTIR spectra effectively differentiated process variations (enzyme types and raw materials) without extensive reference analysis. One-factor analysis of variance (ANOVA) tests was used to observe the impact of process variation on product quality. FTIR proved to be a sensitive method for liquid protein analysis and process control with a significant potential in process optimization approaches. To the authors' knowledge, this is the first time dry film FTIR spectroscopy has been used to evaluate an industrial bioprocess with designed process variations. [Display omitted] • Dry film FTIR was used to evaluate an industrial bioprocess with process variations. • Dry film FTIR can be used to characterize industrial protein hydrolysate quality. • FTIR calibration models were built with low estimation errors for three parameters. • FTIR spectroscopy was successfully used to comprehend industrial process variations. [ABSTRACT FROM AUTHOR]

Whereas industrial laboratory systems for Fourier-Transform Infrared (FTIR) spectroscopic characterization have been available for decades, dedicated FTIR solutions for in-line process control or for industrial at-line analysis of protein quality are still scarce. Thus, the present study aimed to compare two industrially viable sampling techniques, namely attenuated total reflectance (ATR) and dry film FTIR spectroscopy, for qualitative and quantitative analysis of liquid protein solutions. For this purpose, two sample sets were acquired: set 1 consisted of 95 protein hydrolysate samples produced in the laboratory from salmon processing by-products, and set 2 consisted of 133 protein hydrolysate samples obtained from an industrial processing plant of poultry by-products. Average molecular weights (AMW) and Brix measurements of protein hydrolysates were used as reference values for obtaining regression models. AMW was predicted with higher accuracy and lower estimation errors using dry film FTIR compared to ATR measurements for both sample types. The difference in predictive performance was higher in poultry hydrolysates because the protein and tissue complexities are higher than in salmon hydrolysates, and information from the amide I region in the FTIR spectra is needed to provide good calibration results. ATR, on the other hand, was more reliable for the prediction of Brix values of protein hydrolysates. The study also showed that FTIR spectroscopy can be used to predict protein quality features of industrially produced protein hydrolysates with a sensitivity of high industrial relevance. Therefore, developing industrially viable portable instruments for at-line process analysis in the food, feed, and biotech industries is a natural next development stage. [Display omitted] • This is the first study to compare ATR and dry film FTIR spectroscopy for quantitative analysis of liquid protein solutions. • Dryfilm FTIR showed higher accuracy for prediction of average molecular weight (AMW) in liquid protein hydrolysates. • FTIR can be used to predict the AMW of industrial protein hydrolysates with a sensitivity of high industrial relevance. • ATR proved to be a more reliable method for the prediction of Brix values. [ABSTRACT FROM AUTHOR]