Application Bulletin

TAB Filtration Significantly Improves Ready toDrink Tea Quality and Yield
Overview
Ready to drink tea, fruit juices and drinks,
carbonated soft drinks, and other beverages are
subject to spoilage due to the presence of heatresistant, acidophilic bacterial spores (TAB). The
thermoacidophilic spores may originate either fromexposure to agricultural raw materials such as infruit juice production, or from contamination in thebeverage ingredients, such as sweeteners, juice
and tea concentrates, or flavors, essences, andcolors from natural extracts. These TAB sporescomprise Alicyclobacillus species of several types,
including A. acidoterrestris, A. acidocaldarius,
A. herbarius, A. acidophilus and others. Their
introduction into the right fluid environment for
germination and microbial growth results in final
beverage quality degradation, due primarily toformation of distinctive off-flavors and odors.
Unfortunately, spoilage is not usually obvious
because TAB organism growth does not produce
gas, and the problem may be unrecognized until
consumer complaints are received.
The spores are highly resistant to heat treatment,
UV radiation, disinfectants, and extreme pH values.
Therefore even the application of preservation
methods for the beverages, such as pasteurization,is often not sufficient to provide spore-free product.
Extensive heat treatment would be necessary tokill these spores, however such treatment may
negatively influence product attributes such as flavor,color and nutritional value, and may be cost- andenergy-intensive.
Alicyclobacillus species, even if non-pathogenic,
cause serious economic damage for beverage
producers. They are difficult to control once inthe processing environment. Specifications forthe ingredient vendors may therefore include therequirement for TAB spore-free product.
Filtration technology that enables spore removalfrom the ingredients or from beverages is an idealsolution for this challenge.

Pall MEMBRAcart XL II Filter Cartridges

The Challenge
A beverage manufacturer creates a variety offlavored ready to drink teas. They are a national
brand with wide distribution, shipping 5 million
liters (1.32 million US gallons) per year to theircustomers.
The manufacturer extracts tea from tea leaves fromvarying foreign sources. From time to time, theyfound TAB spores in the tea, which negativelyimpacted the quality of their end products andresulted in having to discard the affected batches.
At a value of US $ 85,000 per batch of finishedproduct, the financial impact was high and asolution was required.
The manufacturer’s goal was to find an integritytestable filtration solution that would guarantee
final tea quality and eliminate product losses.

The Solution

In the tea application, the MEMBRAcart XL II filters
have performed consistently as expected, yielding
zero TAB spore counts in the tea product. This
result is confirmed with each tea batch by meansof a microbial culture method for presence of TAB
vegetative cells and spores3.

Pall MEMBRAcart XL II (0.45 micron) membranefilter cartridges and a Palltronic® Compact Star
integrity test device were selected to meet theneed for TAB spore removal and filter performancemonitoring.

The filters can be repeatedly steamed in place(SIP) and hot water cleaned, without compromising
their robustness or removal performance. At thetea drink producer, the filters are steamed in placeprior to first use, with a typical sterilization regimeof 121 oC (250 oF) for 20 minutes. After air cooling,filtration begins. At the end of the batch, the filters
are flushed with cold water, then re-steamed,cooled and stored within the filter housing undercarbon dioxide pressure until next use. With eachreuse, the filters are first steamed in place andcooled prior to filtration. Given this protocol, thetea drink producer is able to achieve up to 320
steaming cycles in this application. The filters
typically last up to four months, exhibiting athroughput of 140,000 liters (37,000 US gallons)of tea per 30 inch cartridge. The extremely longservice life drives down filtration-related operating
expenses such as disposable filter spend, water,
cleaning chemicals, and labor, and it reduces
process downtime.

After hot water steeping of the tea leaves, theextracted tea is clarified with a crossflow
microfiltration system, then cooled. Final membrane
filtration for removal of the TAB spores follows. The
resulting filtrate batch is monitored for quality, and if
it passes QA requirements it proceeds to further
downstream processing steps including ingredientaddition, mixing, pasteurization and filling.
The MEMBRAcart XL II filter family of products isused extensively in the beverage industry toprovide secure and reliable removal of spoilage
microorganisms in a variety of applications. In
particular, the 0.45 micron MEMBRAcart XL II
option has been validated for removal not only ofthe model spoilage organism Serratia Marcescens1,
but also for TAB spores 2 (Figure 1).
Extensive laboratory studies involving microbial
challenge tests show that these filters provide
complete retention of TAB spores in different fluids
evaluated under defined test conditions. Whenchallenged with A. Acidoterrestris spores at achallenge level between 105 and 106 / cm2 offiltration area, the 0.45 micron polyethersulfone(PES) membrane demonstrates a log reduction
value (LRV) of greater than 7 in an acidified fluid
model (apple juice) and greater than 7.8 in a highviscous fluid model (corn syrup). It is important tonote, that any microbial rated filter should beaccompanied with robust validation test work anddocumentation, as a micron rating in and of itself
does not guarantee proper outcomes.

▲

To confirm membrane filter performance, aPalltronic Compact Star filter integrity test
instrument is used both prior to and after completionof each filtration batch (Figure 2). The Pall Compact
Star is a simple to use, portable device based on
the principle of pressure decay integrity test. Results
can be printed or downloaded to supplement
Quality Assurance records.

Figure 1: Alicyclobacillus species are gram positive,
thermoacidophilic spore-forming bacteria which cause
serious economic damage for beverage producers.

With the Pall solution, the customer’s disposable filter spend represents
about 0.02% or a fraction of the value of the production. Additional
operating costs related to cleaning and sanitizing operations, and labor for
filter change-out are negligible when considering the disproportionately
high benefit of securing product quality and maximizing yield.

Quality Monitoring for TAB Contamination

The Benefits

As processes increase in size and complexity, amanufacturer’s risk of exposure to economic loss
due to quality insufficiencies increases. Robustand high performing filtration techniques deliver
desired outcomes, however an integrated quality
assurance program that monitors critical control
points in the process is indispensable.

With the MEMBRAcart XL II and Palltronic Compact
Star solution, the tea drink producer has achieved
its goals, realizing these benefits:of TAB spore-free product with validated
filtration performance• Increased product yield due to total eliminationof TAB-contaminated batches• Preservation of organoleptic product quality• Low filtration operating costs due to long filter
service life

• Monitoring, assurance, and documentation offilter performance with simple integrity test▲

Every step of the process, from raw material
receiving to final packaging and managing utility
fluids (e.g. water) is a potential point of unwanted
microbial contamination. Pall’s GeneDisc® RealTime PCR system is a rapid, sensitive, and reliableeasy to use detection and identification method for
TAB spoilage bacteria, yielding results in a matterof hours. This quick confirmation tool for productquality not only reduces time to shipment, butalso provides informative monitoring with which
processors can diagnose or prevent problems at
the different critical control points of a process3.

• Brand protection, due to consistent production

Figure 2: Palltronic Compact Star is a simple to use, portable
test device used to monitor and document filter integrity.

Footnotes
1 Pall Technical Report FBTPD1006 Rev 2: “Microbial Performance of MEMBRAcart XL II 0.45

Micron Final Filter Cartridges”
2 Pall Technical Report FBTPD1017: “Removal of TAB Spores by MEMBRAcart XL II 0.45 Micron

Filter Cartridges”
3 Pall offers GeneDisc Real-Time PCR system for TAB spore detection and identification. Please

request additional information, including Pall Technical Bulletin FBTBGDTABEN “Novel Molecular
Assay and Sample Preparation Method for the Detection of Alicyclobacillus in Fruit Juice
Concentrates and Bottling Process Materials.”

About Pall Corporation
Pall Corporation is a global filtration, separation and purification leader providing solutions to meet thecritical fluid management needs of customers across the broad spectrum of life sciences and industry.
We work with our customers to advance health, safety and environmentally responsible technologies.
Pall Food and Beverage provides products and services to ensure product quality and maintain processreliability in beverage and food production. Our solutions also assist in consumer protection, waste
minimization and reduction of operating costs.

Pall Food and Beverage

Visit us on the Web at www.pall.com/foodandbev

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Port Washington, NY 11050+1 516 484 3600
telephone+1 866 905 7255
toll free US

Pall Corporation has offices and plants throughout the world. For Pall representatives
in your area, please go to www.pall.com/contact

foodandbeverage@pall.com

Please contact Pall Corporation to verify that the product conforms to your national
legislation and/or regional regulatory requirements for water and food contact use.
Because of technological developments related to the products, systems, and/orservices described herein, the data and procedures are subject to change without notice.
Please consult your Pall representative or visit www.pall.com to verify that thisinformation remains valid.
© Copyright 2015, Pall Corporation. Pall,Palltronic, and GeneDisc are trademarks of Pall
Corporation. ® Indicates a trademark registered in the USA. Filtration. Separation. Solution.SM andBETTER LIVES. BETTER PLANET. are service marks of Pall Corporation.

FBABMEMTEAEN

December 2015