Food science - full life cycle egg protection coating

Antimicrobial eggshell coating development

to improve food safety in sustainable egg production

This project aims to develop and validate a bio-inspired, durable antimicrobial coating system to improve microbiological safety and extend the shelf life of table eggs in industrial production. The proposed approach aligns with Horizon Europe Cluster 6 objectives, including promoting safe and sustainable food systems, reducing foodborne diseases, and advancing innovative bio-based material solutions compatible with current agri-food infrastructures.

Although strict hygiene regulations and ozone-based shell disinfection are widely implemented, eggs remain a frequent source of Salmonella and other pathogen outbreaks across Europe. This indicates that existing disinfection strategies, although initially effective, fail to provide sustained protection against recontamination, cross-contamination, or quality degradation during storage and distribution. Furthermore, industrial cleaning and disinfection processes partially remove the natural eggshell cuticle, a biologically evolved antimicrobial and pore-sealing barrier, thereby heightening susceptibility to bacterial penetration and internal contamination.

The proposed solution seeks to restore and enhance the natural protective layer by applying a water-based, food-compatible antimicrobial coating inspired by the structure and function of the eggshell cuticle. This coating will incorporate naturally derived antimicrobial compounds within optimized bio-based polymer matrices, including chitosan, shellac, polylactic acid (PLA), and polysaccharide systems. The resulting layer will be transparent, gas-permeable, mechanically stable, and suitable for integration with industrial egg-processing lines.

The project will conduct systematic microbiological screening of candidate antimicrobial agents against both Gram-positive and Gram-negative bacteria, with particular emphasis on Salmonella enterica serovariants, especially Salmonella Enteritidis, the leading cause of egg-associated outbreaks. Synergistic combinations of antimicrobial agents will be assessed to maximize potency while ensuring food-contact safety and adherence to regulations.

After selecting active compounds, formulation optimization will address key parameters, including polymer composition, porosity, adhesion, thickness, and long-term antimicrobial durability. Application technologies, such as spraying or dipping, will be developed to enable seamless integration into existing egg-processing lines, minimising operational disruption and ensuring high scalability.

In addition to direct food safety improvements, the project adds to broader European Union sustainability objectives by:

·         Reducing food waste through the extension of shelf life

·         Enhancing the strength and safety of protein supply chains

·         Supporting safe-by-design innovation in bio-based materials

·         Strengthening buyer trust in high-quality European egg production systems

The project integrates expertise in microbiology, materials science, food technology, and industrial process engineering. It provides a scalable, regulation-compliant solution aligned with the objectives of the EU Farm to Fork strategy and contributes to safer, increasingly sustainable animal production systems.

Partnerships are sought with Horizon Europe stakeholders, including:

·         Universities and research institutes specializing in food microbiology

·         Food safety laboratories and validation centers

·         Industrial egg producers for pilot-scale testing

·         Regulatory and EFSA-aligned advisory partners

·         Bio-based material research groups

The consortium intends to position this technology within Horizon Europe Cluster 6 calls that concentrate on sustainable food systems, innovative bio-based materials, and the reduction of foodborne pathogens.

Resysten Hungary Ltd. is uniquely positioned to lead this project due to its established expertise in developing durable, science-based antimicrobial coating technologies and its proven capability to translate advanced material innovations into scalable, industry-ready solutions within regulated environments.