Impact of processing parameters and formulation on deoxynivalenol content and transfer in oat-based beverage manufacturing

Oat-based beverages (OBBs) offer a well-established plant-based alternative to milk. However, oat grains can be contaminated with Fusarium mycotoxins, particularly deoxynivalenol (DON), which could transfer to OBBs during processing. This study investigates the impact of formulation (oat content) and processing parameters (enzymatic treatment -concentration and liquefaction time- and thermal treatment) on DON transfer and concentration, production efficiency (mass balance and yield), and physicochemical properties (soluble solids, density, turbidity, and stability) of OBBs. High DON transfer rates (66-78%) from flour to OBBs were observed, with enzymatic concentration being the most significant factor. However, oat content was the most relevant parameter affecting DON final concentration (89-228 μg/L). Additionally,
conventional sterilisation did not reduce DON levels. DON leaching models (R²>0.99) effectively estimated mycotoxin extraction, which could contribute to optimising OBB manufacturing. Formulation and processing parameters significantly affected the production efficiency and physicochemical properties of OBBs. Optimal practices for suitable physicochemical properties, maximum production efficiency, and minimum DON content included 100-150 g/kg oat flour, high enzymatic content (α-amylase=0.016 kat/kg; glucoamylase=0.04 kat/kg), and 30 min liquefaction. Nonetheless, the potential DON transfer to OBBs and the lack of DON thermal
reduction highlight the need to establish maximum DON levels to ensure the safety of these beverages