Ultrasound- and PEF-assisted Industrial Production of EVOO with higher content of Bioactive Compounds

Objectives The aim of the present study was to implement new technologies in olive oil mills and to develop an efficient industrial process for the continuous extraction of a healthier extra virgin olive oil (EVOO), enriched with bioactive compounds such as polyphenols and tocols. EVOO is a cornerstone of the Mediterranean diet. Many studies have highlighted its crucial preventive role against cardiovascular disease, neurodegenerative disorders, metabolic syndrome and cancer, due to the anti-inflammatory and antioxidant synergistic activities of polyphenols and tocols [1]. Methods Non-thermal technologies, namely ultrasound (US) and pulsed electric field (PEF) have been tested separately or in combination to eliminate the need for traditional malaxation. Extensive literature supports the efficacy of ultrasound-assisted extraction (UAE) and PEF treatments in EVOO production [2,3]. Starting from pilot scale trials, different US and PEF equipment were evaluated in the extraction of EVOO from several autochthonous olive cultivars such as Taggiasca, Mattea and Coratina. Extraction yields, physico-chemical and organoleptic characteristics, and polyphenol and tocopherol contents were monitored throughout the trials. Results Our study introduced a unique continuous flow setup integrating a US device with an industrial PEF chamber, which resulted in improved EVOO production (ton/die) through potent non-thermal physical effects such as acoustic cavitation and electroporation. In addition, these innovations enriched the resulting EVOO with nutritionally relevant minor components (8-12% polyphenols, 3-5% tocols), thereby elevating its quality and market value, as well as overall shelf-life. This combined UAE and US-PEF process not only increased daily oil production (near 40%), but also eliminated the need for kneading during malaxation, resulting in significant energy savings (approximately 30%). The introduction of continuous-flow US and PEF technologies heralds a remarkable innovation in the EVOO industry, offering benefits to both producers and consumers. The resulting EVOO from non-thermal continuous-flow production meets the growing demand for healthier, nutrient-enriched products.