Fouling is a widespread and costly issue, faced by all food-processing industries. Particularly, in the dairy sector, where thermal treatments are mandatory to ensure product safety, heat-induced fouling represents up to 80% of the total production costs. Significant environmental impacts, due the massive consumption of water and energy, are also to deplore. Fouling control solutions are thus desperately needed, as they would lead to substantial financial gains as well as tremendous progress toward eco-responsible processes. This work aims at presenting a novel and very promising dairy fouling-mitigation strategy, inspired by nature, and to test its antifouling performances in real industrial conditions. Slippery liquid-infused surfaces were successfully designed directly on food grade stainless steel, via femtosecond laser ablation, followed by fluorosilanization and impregnation with an inert perfluorinated oil. Resulting hydrophobic surfaces (water contact angle of 112°) exhibited an extremely slippery nature (contact angle hysteresis of 0.6°). Outstanding fouling-release performances were obtained for these liquid-infused surfaces as absolutely no trace of dairy deposit was found after 90 min of pasteurization test in pilot-scale equipment followed by a short water rinse.

This work aims at presenting and comparing the antifouling and antibacterial behaviour of three biomimetic surfaces targeting dairy fouling reduction, namely atmospheric plasmasprayed silane-based thin films, lubricated slippery surfaces and femtosecond laser textured lotus-like surfaces. Fouling tests were conducted on a pilot-scale pasteurization plant fed with a model whey protein and calcium foulant solution and tested samples were placed in isothermal holding-like conditions. Detailed characterizations of the substrates before and after fouling test allowed connecting their surface properties to their antifouling performances. The best result was obtained with the nano-rough plasma coatings which led to a substantial fouling reduction for two consecutive pasteurisation runs. These surfaces were subsequently tested towards bacterial adhesion with three different foodborne pathogenic strains, again demonstrating better performances than bare stainless steel.

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