Bühler launches optical sorter to reduce mycotoxin contamination in pet nutrition products

11 Apr 2023 --- Swiss technology group Bühler launched SORTEX LumoVision, which uses a spectral scale to reduce mycotoxin contamination in pet food. Mycotoxin are byproducts from the metabolism of molds, which are often found in corn used in pet food, causing animal sickness and brand damage through market recall of products.

Mycotoxins are toxic substances produced by fungi that can grow on crops and food in warm and humid conditions, particularly on grains, produce, nuts, seeds and spices. 

Bühler explains LumoVision is an optical sorter that can reduce aflatoxin levels (a common mycotoxin) by up to 90%, as indicated by industrial trials. With this reduction, many samples would meet regulation levels, which saves companies from the costs of large-scale material waste and market recall. 

“Mycotoxins are a worldwide concern,” notes Dr. Gerardo Morantes, director of the Food Safety-Americas Region at Bühler.

Mycotoxins are produced by fungi that can grow on crops and food in warm and humid conditions.“However, technology made possible by Bühler SORTEX enables a preventative solution, meaning that mycotoxins can be dealt with early, stopping the spread and removing the contamination to meet regulatory standards.”

Bühler notes that mycotoxin contamination of grain continues to increase. The most frequent mycotoxins in grains are aflatoxin, deoxynivalenol, cearalenon, fumonisin and ergot alkaloids. 

Detecting contamination with UV lights 
The company discovered an “invisible indicator” of contamination on the spectral scale. The machine analyzes the color of each kernel fluoresces as they pass under UV lighting in the sorter. Contaminated seeds fluoresce a specific bright green pigment known as kojic acid. The Aspergillus fungus produces this fluorescence at the same time that it produces aflatoxin. 

LumoVision’s sensitive cameras and LED-based UV lighting system can detect this fluorescence color. Milliseconds after detection, air nozzles blow contaminated kernels out of the product stream. 

Bühler explains that early intervention is critical to reducing pets’ toxins and lower wastage and environmental footprints. Without cleaning and sorting, poisonous mycotoxins can cause large-scale wastage of materials, mass market recalls and harm to pets.

Mycotoxin contamination can be a high cost for businesses due to market recalls, material waste and harm to brand reputation. 

What is the issue?
Market recall is a significant cost of mycotoxin contamination, which includes product disposal, reimbursing customers and business interruption. Bühler refers to a Consumer Brands Association (CBA) survey that estimates the average market recall cost of US$10 million in direct costs. 

The CBA survey further showed that 81% of respondents considered the financial risk of market recalls significant to catastrophic. 

In addition, brand image can be harmed through market recall as consumers lose trust. Bühler estimates this can cost companies millions in lifetime value. 

The optical sorter identifies contaminated kernels with UV lighting and blows them out of the product stream (image credit: Bühler).The company notes that if a batch has a high concentration of mycotoxins during testing, the entire batch would be destroyed in many cases. 

According to Bühler, two highly contaminated grains in a batch of 10,000 can render the entire batch unsafe. The Food and Drug Administration (FDA) estimates that US$932 million is lost annually to crops contaminated with mycotoxin. 

Pet food market 
The FDA alerted customers in 2021 of fatal levels of aflatoxin found in 1,000 pet food lots. This is a strand of mycotoxin that attacks the liver. It was reported that 130 dogs died from this bad batch. 

A study by the Environmental Working Group found household pets are routinely exposed to hazardous levels of PFAS through food packaging.

With a growing demand for natural pet foods, Wild Earth dog food company has developed a cell-based meat broth with a similar nutritional profile to conventional broths and superior health benefits to dogs. 

Edited by Jolanda van Hal