Cork stoppers industry: defining appropriate mould colonization

Aims: The main aims of this work were the study of cork slabs moulds colonization and the evaluation of the moulds diversity during cork processing steps, in different cork stoppers factories. Simultaneously, it was envisaged to perform an evaluation of the air quality. Methods and Results: Moulds were isolated and identified from cork slabs and cork samples in four cork stoppers factories. The identification was based on morphological characters and microscopic observation of the reproductive structures. Airborne spore dispersion was assessed using a two stage Andersen sampler. It was observed that Chrysonilia sitophila was always present on cork slabs during the maturing period, but mould diversity appeared to be associated to the different factory configurations and processing steps. Conclusions: Spatial separation of the different steps of the process, including physical separation of the maturation step, is essential to guarantee high air quality and appropriate cork slabs colonization, i.e. C. sitophila dominance. The sorting and cutting of the edges of cork slabs after boiling and before the maturing step is also recommended. Significance and Impact of the Study: This study is very important for the cork stopper industry as it gives clear indications on how to keep high quality manufacturing standards and how to avoid occupational health problems.

Cork stoppers industry: defining appropriate mould colonization

Aims: The main aims of this work were the study of cork slabs moulds colonization and the evaluation of the moulds diversity during cork processing steps, in different cork stoppers factories. Simultaneously, it was envisaged to perform an evaluation of the air quality. Methods and Results: Moulds were isolated and identified from cork slabs and cork samples in four cork stoppers factories. The identification was based on morphological characters and microscopic observation of the reproductive structures. Airborne spore dispersion was assessed using a two stage Andersen sampler. It was observed that Chrysonilia sitophila was always present on cork slabs during the maturing period, but mould diversity appeared to be associated to the different factory configurations and processing steps. Conclusions: Spatial separation of the different steps of the process, including physical separation of the maturation step, is essential to guarantee high air quality and appropriate cork slabs colonization, i.e. C. sitophila dominance. The sorting and cutting of the edges of cork slabs after boiling and before the maturing step is also recommended. Significance and Impact of the Study: This study is very important for the cork stopper industry as it gives clear indications on how to keep high quality manufacturing standards and how to avoid occupational health problems.

Luminescence Enhancement after Adding Stoppers to Europium(III) Nanozeolite L

Stopper molecules attached to nanozeolite L (NZL) boost the luminescence of confined Eu3+-β-diketonate complexes. The mechanism that is responsible was elucidated by comparing two diketonate ligands of different pKa and two aromatic imines, and by applying stationary and time resolved spectroscopy. The result is that the presence of the imidazolium based stopper is favorable to the sustainable formation of Eu3+-β-diketonate complexes with high coordination by decreasing the proton strength inside the channels of NZL. A consequence is that strongly luminescent transparent films can be prepared using aqueous suspension of the stopper modified composites.

Control by ATR-FTIR of surface treatment of cork stoppers and its effect on their mechanical performance

Fourier transform infrared (FTIR) spectroscopy was applied to determine the type of surface treatment and dose used on cork stoppers and to predict the friction between stopper and bottleneck. Agglomerated cork stoppers were finished with two different doses and using two surface treatments: P (paraffin and silicone), 15 and 25 mg/stopper, and S (only silicone), 10 and 15 mg/stopper. FTIR spectra were recorded at five points for each stopper by attenuated total reflectance (ATR). Absorbances at 1,010, 2,916, and 2,963 cm -1 were obtained in each spectrum. Discriminant analysis techniques allowed the treatment, and dose applied to each stopper to be identified from the absorbance values. 91.2% success rates were obtained from individual values and 96.0% from the mean values of each stopper. Spectrometric data also allowed treatment homogeneity to be determined on the stopper surface, and a multiple regression model was used to predict the friction index (If = Fe/Fc) (R 2 = 0.93)

Discriminant Analysis of Geographical Origin of Cork Planks and Stoppers by Near Infrared Spectroscopy

The objective of this study was to assess the potential of visible and near infrared spectroscopy (VIS+NIRS) combined with multivariate analysis for identifying the geographical origin of cork. The study was carried out on cork planks and natural cork stoppers from the most representative cork-producing areas in the world. Two training sets of international and national cork planks were studied. The first set comprised a total of 479 samples from Morocco, Portugal, and Spain, while the second set comprised a total of 179 samples from the Spanish regions of Andalusia, Catalonia, and Extremadura. A training set of 90 cork stoppers from Andalusia and Catalonia was also studied. Original spectroscopic data were obtained for the transverse sections of the cork planks and for the body and top of the cork stoppers by means of a 6500 Foss-NIRSystems SY II spectrophotometer using a fiber optic probe. Remote reflectance was employed in the wavelength range of 400 to 2500 nm. After analyzing the spectroscopic data, discriminant models were obtained by means of partial least square (PLS) with 70% of the samples. The best models were then validated using 30% of the remaining samples. At least 98% of the international cork plank samples and 95% of the national samples were correctly classified in the calibration and validation stage. The best model for the cork stoppers was obtained for the top of the stoppers, with at least 90% of the samples being correctly classified. The results demonstrate the potential of VIS + NIRS technology as a rapid and accurate method for predicting the geographical origin of cork plank and stoppers

Quality grading of cork stoppers based on porosity, density and elasticity.

An objective control method for grading cork stoppers is presented using a cork stopper quality index based on porosity, density and elasticity, these being the properties which have the greatest influence on the closure capacity of the stopper. The elasticity of the cork stopper is measured through the relaxation ratio, which is defined by the relationship between the relaxation force exerted by the cork in the bottleneck and the compressive force exerted by a caliper to fit the stopper in the bottle. The relaxation ratio, defined in this way, represents the part of the compression force which is applied to the stopper on insertion and which is recovered in the form of the relaxation force to achieve closure. The calculation of the relaxation ratio involves the measurement of the relaxation force of the fitted stopper. This force has been measured rigorously and precisely using a device developed in the Cork Laboratory at the INIA-CIFOR and which is presented for the first time in this paper.

Design of experiments to optimized the determination of TDIs in agglomerated cork stoppers

Isocyanates are included into a class with an extreme commercial importance because their use in the manufacture of polyurethanes. Polyurethanes are used in several applications such as adhesives, coatings, foams, thermoplastics resins, printing inks, foundry moulds and rubbers. Agglomerated cork stoppers are currently used for still wines, semi-sparkle and gaseous wines, beer and cider. Methylene diphenyl diisocyanate (MDI) is presently the isocyanate used in the production of polyurethane based adhesive in use due to its lowest toxicity comparing with toluene diisocyanate (TDI) previously employed. However, free monomeric TDI or MDI, depending on the based polyurethane, can migrate from agglomerated cork stoppers to beverages therefore it needs to be under control. The presence of these compounds are usually investigated by HPLC with Fluorescence or UV-Vis detector depending on the derivatising agent. Ultra Performance Liquid Chromatography with Diode Array Detector (UPLC-DAD) method is replacing HPLC. The objective of this study is to determine which method is better to analyze isocyanates from agglomerated cork stoppers, essentially TDI to quantify its monomer. A Design of Experiments (DOE) with three factors, column temperature, flow and solvent, at two levels was done. Eight experiments with three replications and two repetitions were developed. Through an ANOVA the significance of the factors was evaluated and the best level’s factors were selected. As the TDI has two isomers and in this method these two isomers were not always separated an ANOVA with results of resolution between peaks was performed. The Design of Experiments reveals to be a suitable statistical tool to determine the best conditions to quantified free isocyanates from agglomerated cork stoppers to real foodstuff. The best level’s factors to maximize area was column temperature at 30ºC, flow to 0,3 mL/min and solvent 0,1% Ammonium Acetate, to maximize resolution was the same except the solvent that was 0,01% Ammonium Acetate.

Cork structural characteristics and their influence on the oxygen ingress through wine stoppers

Doutoramento em Engenharia Florestal e dos Recursos Naturais - Instituto Superior de Agronomia - UL

HACCP numa indústria corticeira: implementação, identificação de pontos críticos e proposta de acções correctivas

Mestrado em Engenharia Química

Evaluating the efficiency of a vegetal coagulant in the treatment of industrial effluents

The present work aims at evaluating the efficiency of an organic polymer from vegetal source used as coagulant for treating different types of industrial effluents. This coagulant (Flox-QT) is obtained from the Black Acacia (Acacia mearnsii). The effluents studied were produced in petrochemical, leather, cork stoppers, metalworking, olive oil, glue, paint (printing), textile and paper industries. The parameters analyzed in the effluents before and after treatment were selected according to the type of wastewater and included pH, conductivity, apparent colour, turbidity, total suspended solids (TSS), chemical oxygen demand (COD) and some metals. The coagulant proved to be efficient for almost all effluents tested. The best results were obtained for the paper industry wastewater, with 91% removal of chemical oxygen demand and 95% of total suspended solids removal. The estimated cost of this treatment would be only 0.24 Euro per cubic meter of treated effluent, only regarding the price of the coagulant and the required dosage. The use of this coagulant is also adequate for the valorisation of the sludge obtained, which in this case could be recycled for paper production.

Exposure to fungi in cork: potential occupational hazard

Cork is a light, porous and impermeable material extracted from the bark of some trees. It is in manufacture of stoppers for wine bottles the main application of cork. It is estimated that the area occupied by cork oaks in the Iberian Peninsula is around 33% in Portugal and 23% in Spain. The world production of cork is focused in the south Europe, with Portugal being the most important producer followed by Spain. According to Companies Directory more than 100 manufactories from Portugal has their branch associated with the preparation and fabrication of cork. Cork workers are at risk for developing diseases of the respiratory tract such as occupational asthma and Suberosis, a form of pulmonary hypersensitivity due to repeated exposure to mouldy cork dust. In this review study papers from 2000 were analyzed to better understand which fungi species are associated with occupational disease in cork workers. The most prevalent fungi species in these workers that are associated with those occupational diseases are Penicilliumglabrum, Chrysoniliasitophila and Trichodermalongibrachiatum. Therefore, a specific knowledge about occupational exposure to fungi in the cork industry is the key to better understand the related diseases and to define preventive measures. Given the importance of this occupational setting in Portugal is essential to evaluate the combined exposure of fungi and particles and their metabolites. Further studies concerning exposure assessment to fungi and particles in the cork industry must be developed.

RFID passive tag antenna for cork bottle stopper

In this paper we propose a possible design for a RFID tag antenna embedded into cork. The antenna is small and conformal and intended to be used into bottle stoppers for tracking and logging purposes of wine or other beverages. The proposed design is based on an inductive ring and an added resistance in order to modify the current distributions of the antenna. The resulting antenna has a relatively directive radiation pattern and despite the small efficiency it is able to operate with a commercial RFID reader at a reasonable distance. © 2014 IEEE.

2,4,6- Ttrichloroanisol:a consumer panel evaluation

“Cork taint” is a major problem in wine industry and is caused by contamination of wines. This contamination is usually attributed to wine cork stoppers and 2,4,6-trichloroanisole (2,4,6-TCA) is one of the compounds mostly associated to this off-flavour. In this work, a consumer panel performed “forced choice” triangular tests in order to measure Odour Detection Thresholds (ODT) and Taste Detection Thresholds (TDT) of 2,4,6-TCA in water, hydro-alcoholic solutions (11.5% and 18% ethanol) and white and red wines. A paired preference test was also performed by the panel in order to measure Odour Rejection Threshold (ORT) in white and red wine spiked with 2,4,6-TCA. Results obtained show that the ODT and the TDT for 2,4,6-TCA in water were 0.2 and 0.3 ng/L, respectively. In hydro-alcoholic solutions with 11.5% and 18% ethanol the ODT were 4 and 10 ng/L respectively. In red wine the ODT and the TDT were 0.9 and 1.7 ng/L and in white wine were 1.5 and 1.0 ng/L respectively. ORT for white was 10.4 ng/L and for red wines 16.0 ng/L. These results suggest that although this group of consumers detected very low concentrations of 2,4,6-TCA in wines, they did not reject the wine at these low concentration values.

Dynamics of cork mycobiota throughout stopper manufacturing process: from diversity to metabolite

Dissertation presented to obtain the Ph.D degree in Biology

Melhoria do Processo Produtivo da Pietec Através das Ferramentas Kaizen

Esta Tese de Mestrado foi realizada na empresa Pietec Cortiças S.A.. A empresa Pietec Cortiças S.A. é a unidade industrial responsável pela produção de rolhas técnicas de cortiça do Grupo Piedade. O objetivo desta tese prende-se com a melhoria do processo produtivo de uma das suas secções, a secção da Marcação. Esta secção é responsável pela marcação da superfície da rolha, pela aplicação do tratamento de superfície e pelo embalamento das rolhas. A otimização do processo da secção de Marcação, na qualidade de última secção do processo produtivo, permitirá à empresa obter vantagens competitivas. De forma a atingir o objetivo proposto, foi realizado um levantamento exaustivo do processo produtivo e das respetivas operações. Esta análise permitiu a identificação dos possíveis pontos de desperdício, a sua avaliação e a definição de possíveis melhorias que visam o aumento de produtividade e a redução do número de produtos não conformes. Uma vez identificados os pontos críticos do processo, procedeu-se à definição das ações de melhoria a implementar de forma a melhorar o processo produtivo. As ações tomadas assentam na filosofia Lean e nos seus princípios, utilizando-se algumas das ferramentas desta filosofia para concretizar os objetivos traçados. A ferramenta de análise Plan-Do-Check-Act (PDCA) foi a ferramenta base do projeto, acompanhando na elaboração do plano de ação, na implementação das ferramentas 5S e Single Minute Exchange of Die (SMED), na verificação dos resultados e no plano de manutenção das melhorias alcançadas. Após a implementação das medidas definidas no processo de marcação da superfície das rolhas, foi mensurada uma melhoria de 23 % no tempo médio de setup da máquina de marcação. Esta melhoria global foi alcançada através de intervenções no processo de vazamento do circuito da máquina de marcação, no procedimento de armazenamento dos moldes de marcação e na alteração dos mecanismos de ajuste da máquina de marcar e de orientar. No processo de embalamento das rolhas, as medidas implementadas produziram um aumento de 1,7 % no número de rolhas produzidas e uma redução do número de rolhas não conformes de 3,6 %. Os resultados obtidos no projeto demonstram que é possível continuar a melhorar o estado atual dos processos. Constatou-se ainda que, com a adoção de ferramentas de análise e de proposta de melhoria adequadas, é possível atuar sobre os processos e obter melhorias a curto prazo, sem que para isso seja necessário efetuar grandes investimentos.