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<front>
<journal-meta>
<journal-id journal-id-type="publisher-id">Front. Soft Matter</journal-id>
<journal-title-group>
<journal-title>Frontiers in Soft Matter</journal-title>
<abbrev-journal-title abbrev-type="pubmed">Front. Soft Matter</abbrev-journal-title>
</journal-title-group>
<issn pub-type="epub">2813-0499</issn>
<publisher>
<publisher-name>Frontiers Media S.A.</publisher-name>
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<article-meta>
<article-id pub-id-type="publisher-id">1750630</article-id>
<article-id pub-id-type="doi">10.3389/frsfm.2026.1750630</article-id>
<article-version article-version-type="Version of Record" vocab="NISO-RP-8-2008"/>
<article-categories>
<subj-group subj-group-type="heading">
<subject>Original Research</subject>
</subj-group>
</article-categories>
<title-group>
<article-title>Foam cleaning in closed circuits: effect of surfactant type on foam structure and <italic>Bacillus subtilis</italic> spore removal from stainless steel surfaces</article-title>
<alt-title alt-title-type="left-running-head">Al Saabi et al.</alt-title>
<alt-title alt-title-type="right-running-head">
<ext-link ext-link-type="uri" xlink:href="https://doi.org/10.3389/frsfm.2026.1750630">10.3389/frsfm.2026.1750630</ext-link>
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<name>
<surname>Al Saabi</surname>
<given-names>Ahmad</given-names>
</name>
<xref ref-type="aff" rid="aff1">
<sup>1</sup>
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<xref ref-type="aff" rid="aff2">
<sup>2</sup>
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<sup>&#x2020;</sup>
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<sup>3</sup>
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<sup>&#x2020;</sup>
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<sup>&#x2021;</sup>
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<sup>4</sup>
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<given-names>Christine</given-names>
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<sup>2</sup>
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<aff id="aff1">
<label>1</label>
<institution>EPLEFPA - ENILV La Roche sur Foron</institution>, <city>La Roche sur Foron</city>, <country country="FR">France</country>
</aff>
<aff id="aff2">
<label>2</label>
<institution>University Lille, CNRS, INRAE, Centrale Lille, UMET</institution>, <city>Lille</city>, <country country="FR">France</country>
</aff>
<aff id="aff3">
<label>3</label>
<institution>ABTE, UR 4651 Universit&#xe9; de Caen Normandie</institution>, <city>Caen</city>, <country country="FR">France</country>
</aff>
<aff id="aff4">
<label>4</label>
<institution>ACTALIA Food Safety Department</institution>, <city>Saint-L&#xf4;</city>, <country country="FR">France</country>
</aff>
<aff id="aff5">
<label>5</label>
<institution>Polytechnic University Hauts-de-France, LAMIH CNRS UMR 8201, Campus Mont-Houy</institution>, <city>Valenciennes</city>, <country country="FR">France</country>
</aff>
<author-notes>
<corresp id="c001">
<label>&#x2a;</label>Correspondence: Heni Dallagi, <email xlink:href="mailto:heni.dallagi@unicaen.fr">heni.dallagi@unicaen.fr</email>
</corresp>
<fn fn-type="other" id="fn002">
<label>&#x2021;</label>
<p>ORCID: Heni Dallagi, <ext-link ext-link-type="uri" xlink:href="http://orcid.org/0000-0003-4584-1834">orcid.org/0000-0003-4584-1834</ext-link>; Piyush Kumar Jha, <ext-link ext-link-type="uri" xlink:href="http://orcid.org/0000-0003-1919-491X">orcid.org/0000-0003-1919-491X</ext-link>; Fethi Aloui, <ext-link ext-link-type="uri" xlink:href="http://orcid.org/0000-0003-2157-9528">orcid.org/0000-0003-2157-9528</ext-link>; Thierry Benezech, <ext-link ext-link-type="uri" xlink:href="http://orcid.org/0000-0001-8594-5879">orcid.org/0000-0001-8594-5879</ext-link>; Christine Faille, <ext-link ext-link-type="uri" xlink:href="http://orcid.org/0000-0002-2786-1412">orcid.org/0000-0002-2786-1412</ext-link>
</p>
</fn>
<fn fn-type="equal" id="fn001">
<label>&#x2020;</label>
<p>These authors share first authorship</p>
</fn>
</author-notes>
<pub-date publication-format="electronic" date-type="pub" iso-8601-date="2026-03-04">
<day>04</day>
<month>03</month>
<year>2026</year>
</pub-date>
<pub-date publication-format="electronic" date-type="collection">
<year>2026</year>
</pub-date>
<volume>6</volume>
<elocation-id>1750630</elocation-id>
<history>
<date date-type="received">
<day>20</day>
<month>11</month>
<year>2025</year>
</date>
<date date-type="rev-recd">
<day>01</day>
<month>02</month>
<year>2026</year>
</date>
<date date-type="accepted">
<day>05</day>
<month>02</month>
<year>2026</year>
</date>
</history>
<permissions>
<copyright-statement>Copyright &#xa9; 2026 Al Saabi, Dallagi, Jha, Aloui, Benezech and Faille.</copyright-statement>
<copyright-year>2026</copyright-year>
<copyright-holder>Al Saabi, Dallagi, Jha, Aloui, Benezech and Faille</copyright-holder>
<license>
<ali:license_ref start_date="2026-03-04">https://creativecommons.org/licenses/by/4.0/</ali:license_ref>
<license-p>This is an open-access article distributed under the terms of the <ext-link ext-link-type="uri" xlink:href="https://creativecommons.org/licenses/by/4.0/">Creative Commons Attribution License (CC BY)</ext-link>. The use, distribution or reproduction in other forums is permitted, provided the original author(s) and the copyright owner(s) are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.</license-p>
</license>
</permissions>
<abstract>
<p>Foam cleaning represents an environmentally and economically attractive alternative to conventional cleaning-in-place (CIP) processes for removing microbial contamination in food and bioprocessing industries. This study systematically compared three surfactants, sodium dodecyl sulfate (SDS), Ammonyx&#xae; LO, and Capstone&#xae; FS-30, to understand how surfactant type influences foam structure and cleaning performance. Stainless steel coupons contaminated with <italic>Bacillus subtilis</italic> 98/7 spores were cleaned under identical flow conditions using foam generated at a nominal air fraction of 0.5 and a mean velocity of 1.8&#xa0;cm&#xa0;s<sup>-1</sup>. SDS achieved the highest spore removal (1.9 log<sub>10</sub> reduction after 20&#xa0;min), with superior kinetic detachment (K<sub>1</sub> &#x3d; 114.75&#xa0;s<sup>-1</sup>; f &#x3d; 98.2%), while Ammonyx&#xae; LO (0.83 log<sub>10</sub>) and Capstone&#xae; FS-30 (0.55 log<sub>10</sub>) performed significantly worse. These differences were attributed to foam structural properties: SDS produced fine, stable bubbles persisting for 24&#xa0;h, while Ammonyx&#xae; LO and Capstone&#xae; FS-30 collapsed after 8 and 3&#xa0;h, respectively. Image analysis revealed local air fractions of 0.88 (SDS), 0.79 (Ammonyx), and 0.96 (Capstone) in the test section, confirming dry foam behavior. Theoretical analysis using Bretherton&#x2019;s model and microscopic observations showed that SDS&#x2019;s low capillary number promotes strong Marangoni stabilization and thin lamellae, generating sustained wall shear stress fluctuations essential for spore detachment. This study demonstrates that foam cleaning efficiency is primarily determined by surfactant-controlled variations in bubble size, foam stability, and interfacial properties. SDS provides the optimal balance for achieving efficient and sustainable foam-based cleaning.</p>
</abstract>
<kwd-group>
<kwd>
<italic>B. subtilis</italic> spores</kwd>
<kwd>capillary number</kwd>
<kwd>cleaning kinetics</kwd>
<kwd>foam cleaning</kwd>
<kwd>sds</kwd>
<kwd>shear stress</kwd>
<kwd>surfactants</kwd>
</kwd-group>
<funding-group>
<funding-statement>The author(s) declared that financial support was received for this work and/or its publication. This work was supported by the programme Interreg V France-Wallonie-Vlaanderen (GoToS3 - Veg-I-Tec project), the European Regional Development Fund (R&#xe9;gion Hauts-de-France - programme op&#xe9;rationnel 2014&#x2013;2020) and the French National Research Agency (FEFS project).</funding-statement>
</funding-group>
<counts>
<fig-count count="4"/>
<table-count count="3"/>
<equation-count count="0"/>
<ref-count count="59"/>
<page-count count="13"/>
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<custom-meta-group>
<custom-meta>
<meta-name>section-at-acceptance</meta-name>
<meta-value>Foams</meta-value>
</custom-meta>
</custom-meta-group>
</article-meta>
</front>
<body>
<sec sec-type="intro" id="s1">
<label>1</label>
<title>Introduction</title>
<p>In the food industry, maintaining hygienic surfaces is essential to ensure product safety and prevent microbial cross-contamination. Surface contamination by microorganisms, including highly resistant bacterial spores, can lead to food spoilage, foodborne illnesses, and substantial economic and reputational losses for manufacturers. Contamination risks span the entire food supply chain, from primary production to processing, storage, and distribution, with inadequate surface hygiene being a key contributor (<xref ref-type="bibr" rid="B35">Jha et al., 2026</xref>). Pathogens can persist and proliferate if proper hygiene and cleaning measures are not followed at each stage. According to the World Health Organization, foodborne diseases affect approximately 600 million people globally each year, with over 420,000 resulting deaths (<xref ref-type="bibr" rid="B59">World Health Organization, 2024</xref>). Numerous outbreaks, including <italic>Listeria monocytogenes</italic> in South Africa (<xref ref-type="bibr" rid="B54">Thomas et al., 2020</xref>) and <italic>Salmonella</italic> in Europe (<xref ref-type="bibr" rid="B22">European Centre for Disease Prevention and Control, 2024</xref>), have been linked to inadequate cleaning of processing surfaces. In August 2025, more than 40 industrial cheeses were recalled across France due to <italic>Listeria</italic> contamination, leading to at least 21 confirmed cases of listeriosis and two deaths, while additional recalls followed for raw goat cheeses contaminated with <italic>E. coli</italic> (<xref ref-type="bibr" rid="B58">Whitworth, 2025</xref>). In addition to vegetative cells, spores from <italic>Bacillus</italic> species are particularly problematic due to their exceptional resistance to heat, desiccation, and chemical treatments, and their strong adhesion to stainless steel surfaces commonly used in food processing equipment (<xref ref-type="bibr" rid="B27">Food Safety Institute, 2023</xref>; <xref ref-type="bibr" rid="B60">Albertsdottir Jonsmoen et al., 2025</xref>).</p>
<p>To mitigate these risks, the industry primarily relies on cleaning-in-place (CIP) protocols, which involve circulating chemical solutions at high temperatures and turbulent flow rates to generate wall shear stress for mechanical detachment (<xref ref-type="bibr" rid="B11">Dallagi et al., 2023</xref>; <xref ref-type="bibr" rid="B14">Dallagi et al., 2024c</xref>). However, standard CIP systems are resource-intensive, requiring large amounts of water and detergents, and are often inefficient against spores, particularly in areas with complex geometries or surface defects (<xref ref-type="bibr" rid="B33">Jha et al., 2020</xref>; <xref ref-type="bibr" rid="B34">Jha et al., 2022</xref>; <xref ref-type="bibr" rid="B3">Bouvier et al., 2021</xref>; <xref ref-type="bibr" rid="B12">Dallagi et al., 2024a</xref>). As environmental regulations and sustainability goals become more pressing, there is growing interest in alternative cleaning strategies that maintain performance while reducing ecological impact. One such promising approach is foam-based cleaning. Aqueous foams flow dispersions stabilized by surfactants offer unique physical properties that can enhance cleaning efficiency (<xref ref-type="bibr" rid="B44">Saabi et al., 2020</xref>; <xref ref-type="bibr" rid="B13">Dallagi et al., 2024b</xref>). Unlike bulk liquid flows, foams adhere to irregular surfaces, ensure prolonged contact times, and generate localized mechanical actions through bubble motion, film drainage, and capillary forces (<xref ref-type="bibr" rid="B19">Denkov et al., 2006</xref>; <xref ref-type="bibr" rid="B8">Dallagi et al., 2022a</xref>; <xref ref-type="bibr" rid="B49">Sharma et al., 2025</xref>). These dynamic phenomena, including imbibition, wiping, and drainage, have been shown to effectively dislodge bacterial spores from surfaces (<xref ref-type="bibr" rid="B40">Mensire et al., 2016</xref>; <xref ref-type="bibr" rid="B26">Flury and Aramrak, 2017</xref>). Moreover, foam cleaning processes use significantly less water and chemicals than traditional CIP, with life cycle assessments (LCA) demonstrating a drastic reduction in environmental impact (<xref ref-type="bibr" rid="B10">Dallagi et al., 2022c</xref>; <xref ref-type="bibr" rid="B16">Dari et al., 2023b</xref>).</p>
<p>The choice of surfactant has a significant impact on foam structure and cleaning behavior. Foam characteristics such as bubble size, stability, liquid fraction, and film thickness determine the mechanical forces that act at the solid&#x2013;liquid interface (<xref ref-type="bibr" rid="B52">Tcholakova and Petkova, 2024</xref>). Sodium dodecyl sulfate (SDS), an anionic surfactant, is widely used in foam cleaning due to its ability to generate stable foams with balanced drainage (<xref ref-type="bibr" rid="B25">Fameau and Fujii, 2020</xref>). In contrast, Capstone&#xae; FS-30, a fluorinated nonionic surfactant, produces large, rapidly draining foams with a coarser structure (<xref ref-type="bibr" rid="B50">Sheng et al., 2022</xref>), while Ammonyx&#xae; LO, an amphoteric/quaternary ammonium surfactant, forms foams with smaller bubbles and moderate stability (<xref ref-type="bibr" rid="B43">Ren et al., 2013</xref>). These structural differences influence how mechanical energy is delivered to contaminated surfaces and thus could impact cleaning outcomes. It should be noted that foam properties reported in the literature depend not only on the surfactant chemistry but also strongly on the method and conditions used to generate the foam (gas-liquid ratio, energy input, mixing protocol, device geometry, etc.) (<xref ref-type="bibr" rid="B17">Dehghani et al., 2024</xref>). Therefore, previously published data should be interpreted as general tendencies rather than direct comparisons between surfactants, as the foaming setups are not identical across studies. In the present work, all foams were produced using the same generator and under strictly identical operating conditions. This ensures that any structural or functional differences observed between the tested foams arise from the surfactant formulations themselves and not from differences in the foaming method. In practice, however, SDS is not the only option used or considered in industry: fluorinated and quaternary ammonium surfactants are introduced for reasons such as formulation constraints, material compatibility, or targeted antimicrobial performance, even when their foam stability is expected to be lower (<xref ref-type="bibr" rid="B39">Massi et al., 2009</xref>; <xref ref-type="bibr" rid="B48">Shaban et al., 2020</xref>). What is currently missing is a quantitative comparison that treats SDS as a reference and shows how moving to alternative chemistries changes foam microstructure and, in turn, the mechanisms of soil removal in closed, low-shear systems.</p>
<p>Previous studies have shown that SDS-based foams consistently achieve higher spore removal efficiency than foams made with other biosourced surfactants (<xref ref-type="bibr" rid="B16">Dari et al., 2023b</xref>). However, the mechanisms behind these differences remain underexplored. In particular, most available data are limited to global log-reductions and do not resolve how changes in bubble size distribution, foam stability and liquid fraction translate into changes in the fast and slow phases of detachment. Understanding how surfactant-induced foam structure affects cleaning performance is critical for optimizing foam cleaning processes, not to replace SDS at this stage, but to better control and exploit the mechanical properties of foams for specific cleaning scenarios. The objective of this study is to investigate how the foam characteristics driven by three different surfactants, SDS, Capstone&#xae; FS-30, and Ammonyx&#xae; LO, influence the removal of <italic>Bacillus</italic> spores from stainless steel surfaces. We focus on the correlation between foam structure (bubble size distribution, stability, liquid fraction) and cleaning efficacy, under controlled flow conditions. By doing so, we aim to elucidate the physical cleaning mechanisms involved in shear stress fluctuations, capillary forces, and film interactions and to inform the rational design of foam-based cleaning systems that are both efficient and environmentally sustainable.</p>
</sec>
<sec sec-type="materials|methods" id="s2">
<label>2</label>
<title>Materials and methods</title>
<sec id="s2-1">
<label>2.1</label>
<title>Bacterial strain and spore preparation</title>
<p>This study was conducted using <italic>B. subtilis</italic> 98/7, a spore-forming strain isolated from dairy processing lines. Spores were produced following the method described by <xref ref-type="bibr" rid="B24">Faille et al. (2019)</xref> with slight modifications. Sporulation was carried out on Spo8 agar plates, incubated at 30&#xa0;&#xb0;C for 10&#xa0;days, until the sporulation rate exceeded 95%. Spores were then collected by gentle scraping of the agar surface, washed five times by centrifugation in sterile distilled water, and finally suspended in sterile water and stored at 4&#xa0;&#xb0;C until use. Before each experiment, the suspensions were subjected to a 2.5&#xa0;min ultrasonic treatment (Bransonic 2510E-MT, 42&#xa0;kHz, 100&#xa0;W, Branson Ultrasonics, United States) to minimize aggregation and ensure a homogeneous dispersion. The surface hydrophobicity of spores was evaluated using the Microbial Adhesion to Hydrocarbons (MATH) test, as previously described by <xref ref-type="bibr" rid="B24">Faille et al. (2019)</xref>. Briefly, 3&#xa0;mL of spore suspension were mixed with 500&#xa0;&#xb5;L of <italic>n</italic>-hexadecane (Sigma-Aldrich) and vortexed for periods ranging from 5&#xa0;s to 30&#xa0;min. The two phases were allowed to separate for 30&#xa0;min before measuring the absorbance of the aqueous phase at 600&#xa0;nm. The ratio of absorbance after mixing (A<sub>t</sub>) to the initial absorbance (A<sub>0</sub>) was plotted as a function of vortexing time.</p>
</sec>
<sec id="s2-2">
<label>2.2</label>
<title>Surface material and preparation</title>
<p>Cleaning experiments were performed on AISI 316 stainless-steel coupons (45 &#xd7; 15&#xa0;mm, 2B finish) provided by APERAM (Isbergues, France). Before use, the coupons were cleaned using a standardized laboratory procedure. They were first rubbed with a pure alkaline detergent (RBS T105, Traitements Chimiques des Surfaces, France), then immersed for 10&#xa0;min in a 5% (v/v) RBS T105 solution maintained at 60&#xa0;&#xb0;C. Coupons were rinsed thoroughly with tap water followed by deionized water for 5&#xa0;min each, dried, and sterilized by dry heat at 180&#xa0;&#xb0;C for 1&#xa0;h. This protocol ensured the removal of any organic or mineral contaminants and provided reproducible surface conditions. To reproduce the physicochemical properties typically found in industrial environments, an ageing treatment was applied to the stainless-steel surfaces prior to contamination. This treatment simulated repeated cycles of food contact and cleaning processes encountered in dairy production. Each ageing cycle consisted of four successive steps: immersion in a whole milk solution (150&#xa0;g&#xa0;L<sup>-1</sup>, INGREDIA) for 30&#xa0;min at ambient temperature, rinsing under deionized water for 5&#xa0;min, immersion in a 0.5% (w/w) NaOH solution at 60&#xa0;&#xb0;C for 30&#xa0;min, and a final rinse in deionized water for 5&#xa0;min. This four-step cycle was repeated fifteen times. Such ageing was found to significantly modify the surface energy and wetting behavior of the stainless steel, thus providing conditions representative of industrially used materials. Immediately before the experiments, all coupons underwent an additional cleaning step to remove any residual debris. Coupons were rubbed with RBS T105 detergent and immersed for 10&#xa0;min in a 2% (v/v) solution heated to 60&#xa0;&#xb0;C, then rinsed with both hard and deionized water for 5&#xa0;min each. They were then mounted vertically on a stainless-steel holder, separated by bolts to avoid contact, and sterilized at 180&#xa0;&#xb0;C for 1&#xa0;h. For surface contamination, the spore suspensions were prepared in sterile ultrapure water at a final concentration of approximately 10<sup>6</sup>&#xa0;CFU&#xa0;mL<sup>-1</sup>. Sterile stainless-steel coupons were vertically immersed in 250&#xa0;mL of the spore suspension contained in sterile glass beakers and maintained at room temperature for 4&#xa0;h to allow adhesion of spores to the surface. After incubation, the coupons were carefully removed, air-dried under sterile conditions at ambient temperature, and directly used for the cleaning experiments.</p>
<p>The surface properties of the stainless-steel coupons were characterized prior to use to ensure reproducibility of the experiments. Surface topography was analyzed using a contact profilometer (Perthometer S2, Mahr, France), from which the arithmetic mean roughness (Ra) and the maximum height difference (Rz) were calculated based on the recorded surface profiles. The parameter Ra represents the average absolute deviation of the surface height from the mean line over a given sampling length, while Rz corresponds to the sum of the highest peak and the deepest valley measured within that length. In addition, the wettability of the surfaces was evaluated by measuring the static water contact angle using a DIGIDROP GBX drop-shape analyzer (France). For each material, ten measurements were performed using 1&#xa0;&#x3bc;L droplets (five droplets on each of two independent coupons). Surfaces exhibiting contact angles greater than 90&#xb0; were classified as hydrophobic, whereas those with lower values were considered hydrophilic.</p>
</sec>
<sec id="s2-3">
<label>2.3</label>
<title>Surfactants</title>
<p>Three surfactants with distinct interfacial properties were selected to evaluate how their molecular structure influences foam behavior and cleaning performance: sodium dodecyl sulfate (SDS), Lauramine oxide (Ammonyx&#xae; LO), and Capstone&#xae; FS-30. These surfactants represent different classes: anionic, amphoteric, and fluorinated nonionic, providing a comprehensive comparison of their physicochemical effects on foam formation and stability. Sodium dodecyl sulfate (SDS; &#x2265;98.5% purity, Sigma-Aldrich) was used as the reference surfactant owing to its well-known capacity to produce stable foams and its extensive use in cleaning formulations. Lauramine oxide (Ammonyx&#xae; LO; Stepan Company, United States) is a tertiary amine oxide surfactant that exhibits nonionic behavior under neutral and alkaline conditions and cationic character under acidic environments. It is commonly used as a detergent, emulsifier, and foam stabilizer. Capstone&#xae; FS-30 (Chemours&#x2122;, United States) is an ethoxylated fluorinated nonionic surfactant with high surface activity at low concentrations and strong stability in saline and hard-water media. Its chemical structure enables efficient reduction of surface tension and enhanced wetting, making it relevant for surface cleaning applications. All surfactant solutions were prepared in deionized water and mixed gently until complete dissolution. The critical micelle concentration (CMC) of each surfactant was determined experimentally using surface tension measurements carried out with a DIGIDROP GBX drop-shape analyzer (France) employing the pendant drop method. Measurements were conducted at room temperature (22&#xa0;&#xb0;C &#xb1; 1.5&#xa0;&#xb0;C) using a 1&#xa0;mm stainless-steel needle. For each surfactant, solutions at various concentrations were analyzed, and the surface tension (<inline-formula id="inf1">
<mml:math id="m1">
<mml:mrow>
<mml:mi>&#x3c3;</mml:mi>
</mml:mrow>
</mml:math>
</inline-formula>) was recorded as a function of surfactant concentration. The CMC was defined as the concentration above which <inline-formula id="inf2">
<mml:math id="m2">
<mml:mrow>
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</mml:mrow>
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</inline-formula> remained constant, indicating that additional surfactant molecules preferentially formed micelles in the bulk rather than adsorbing at the air&#x2013;liquid interface.</p>
</sec>
<sec id="s2-4">
<label>2.4</label>
<title>Foam generation and cleaning procedure</title>
<p>Foams were generated and applied using a custom-built experimental rig. The open-circuit foam system consisted of a feeding tank, a foam generator, and a horizontal rectangular duct in which stainless-steel coupons were placed for cleaning tests. The setup allowed visual monitoring of the foam behavior through a transparent Plexiglas section identical in geometry to the test duct. To ensure fully developed flow conditions, the section to be cleaned was positioned more than 40 times the hydraulic diameter downstream of the foam inlet, corresponding to a distance of approximately 1&#xa0;m. The main reservoir (100&#xa0;L capacity) was filled with aqueous surfactant solutions prepared with deionized water (at their respective CMC values, as presented in the Results section). Three types of surfactants were tested: sodium dodecyl sulfate (SDS, anionic), Capstone&#xae; FS-30 (fluorinated nonionic), and Ammonyx&#xae; LO (amphoteric). Each solution was continuously recirculated using a positive displacement pump (VARMECA 21TL055, Leroy-Somer, France) that supplied the feed tank (50&#xa0;L) positioned 3&#xa0;m above the foam generator. This configuration created a constant liquid flow rate through the system by gravity, ensuring stable foam formation throughout the experiment.</p>
<p>Foam was produced by simultaneous injection of air and surfactant solution at a controlled flow rate of 4.5&#xa0;L&#xa0;h<sup>-1</sup> each, yielding a foam quality <inline-formula id="inf3">
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</inline-formula> in the generator of approximately 50% <inline-formula id="inf4">
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</inline-formula>, where Q<sub>g</sub> and Q<sub>l</sub> are respectively the gas and liquid flow rates). The mean foam velocity in the ducts was maintained at 1.8&#xa0;cm&#xa0;s<sup>-1</sup> (Re &#x2248; 50), characteristic of laminar, plug-like foam flow. Although such low-Reynolds conditions limit the contribution of bulk hydrodynamic forces, local wall shear stress, generated by bubble-wall interactions and interfacial oscillations, remains a key determinant of cleaning efficiency. In closed ducts, foam performance therefore arises from the coupling between interfacial phenomena and the microscale shear events produced at the wall. Foam was allowed to stabilize for 1&#xa0;m along the duct before reaching the test zone containing the coupons. Each cleaning experiment was performed at ambient temperature. The test ducts contained five stainless-steel coupons mounted horizontally, of which the three central ones were soiled with <italic>B. subtilis</italic> spores and subsequently analyzed for residual contamination. Cleaning trials were conducted under various foam exposure times (15 s&#x2013;20&#xa0;min). After each cleaning operation, the coupons were gently removed from the ducts and rinsed by immersion in sterile ultrapure water (1&#xa0;L) to eliminate any non-adherent debris. To quantify residual spores, each coupon was transferred into a sterile container containing 10&#xa0;mL of 2% (v/v) Tween 80 in peptone water (0.015&#xa0;g&#xa0;L<sup>-1</sup>, Biokar Diagnostics, France) and subjected to ultrasonication for 5&#xa0;min in a Branson 2510 ultrasonic bath (40&#xa0;Hz). This treatment, validated in a previous study (<xref ref-type="bibr" rid="B44">Saabi et al., 2020</xref>), effectively detaches over 99% of surface-adhered spores.</p>
<p>The resulting suspension was serially diluted in sterile ultrapure water, and 100&#xa0;&#xb5;L aliquots were spread onto nutrient agar plates prepared from 1.3% (w/v) nutrient broth (Bio-Rad, France) and 1.5% (w/v) bacteriological agar (Biokar Diagnostics, France). Plates were incubated at 30&#xa0;&#xb0;C for 48&#xa0;h before colony counting. The number of viable spores recovered from each coupon after cleaning (N<sub>resid</sub>) was compared to that obtained from control coupons before cleaning (N<sub>0</sub>). Cleaning performance was expressed as the logarithmic percentage of residual spores log<sub>10</sub> ((N<sub>resid</sub>/N<sub>0</sub>)&#xd7;100). A two-phase kinetics model was used to fit the data using GInaFIT (<xref ref-type="bibr" rid="B29">Geeraerd et al., 2005</xref>) through a biphasic model composed of two first-order kinetics (<xref ref-type="bibr" rid="B6">Dallagi et al., 2018</xref>; <xref ref-type="bibr" rid="B7">2019</xref>). At least 3 repetitions were carried out for the quantitative analysis of the residual contamination after cleaning. Data were analysed using MATLAB R2024a (University of Caen, France), and Statistical analyses were performed by general linear model procedures using SAS V8.0 software (SAS Institute, Gary, NC, United States). Variance analysis and Tukey&#x2019;s grouping (Alpha level &#x3d; 0.05) were performed to determine how the bacteria removal, as described by the kinetic parameters (residual contamination at different cleaning times and model parameters), was affected by the tested cleaning conditions.</p>
</sec>
<sec id="s2-5">
<label>2.5</label>
<title>Foam stability and bubble size characterization</title>
<p>Foam stability tests were performed to compare the persistence and drainage behavior of foams generated from the three surfactant formulations. For each surfactant, foams were produced under identical operating conditions corresponding to a foam quality of 50% (air fraction in the foam generator). After a 1&#xa0;m establishment length in the horizontal pipe, the foam underwent drainage and structural reorganization, leading to a local air fraction higher than that initially generated. This ensured that the foam reached a stable flowing regime with well-defined Plateau borders before sampling. Immediately after generation, the foam was collected in a 1000&#xa0;mL graduated cylinder, and the time required for the complete disappearance of the visible foam and separation of the liquid phase was recorded at room temperature. This operational measure was used solely as a comparative indicator of foam persistence under identical conditions for SDS, Capstone&#xae; FS-30, and Ammonyx&#xae; LO. It reflects the combined effects of drainage, coalescence, and gas loss, without implying a specific stabilisation mechanism.</p>
<p>
<xref ref-type="table" rid="T2">Table 2</xref> summarizes the physicochemical properties of the surfactant solutions and the corresponding flow parameters of the foams generated under identical operating conditions. The capillary force acting on a bubble, Fc, corresponds to the interfacial force generated by surface tension at the bubble interface. It can be expressed as <inline-formula id="inf5">
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</mml:mrow>
</mml:math>
</inline-formula> where &#x3c3; is the surface tension and r the bubble radius (<xref ref-type="bibr" rid="B1">Al-Qararah et al., 2013</xref>). Here, the capillary force represents an order-of-magnitude estimate of the force transmitted at a single bubble-wall meniscus in confined foam flow, rather than the total force acting on a free bubble. These quantities characterize the resistance of a bubble to film thinning, drainage, and coalescence. The balance between viscous drag and surface tension forces acting on the foam during flow is described by the non-dimensional capillary number <inline-formula id="inf6">
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<mml:mi>l</mml:mi>
</mml:msub>
<mml:mrow>
<mml:mn>1</mml:mn>
<mml:mo>&#x2212;</mml:mo>
<mml:msup>
<mml:mi>&#x3b2;</mml:mi>
<mml:mrow>
<mml:mn>1</mml:mn>
<mml:mo>/</mml:mo>
<mml:mn>3</mml:mn>
</mml:mrow>
</mml:msup>
</mml:mrow>
</mml:mfrac>
</mml:mrow>
</mml:math>
</inline-formula>) (<xref ref-type="bibr" rid="B32">Hatschek, 1911</xref>; <xref ref-type="bibr" rid="B5">Chovet, 2015</xref>). Solution viscosities <italic>&#x3bc;</italic>
<sub>l</sub> were estimated from dilution calculations based on manufacturer data for concentrated products. However, at the highly dilute concentrations used (CMC levels), the surfactant contribution to viscosity is negligible, and all solutions exhibit viscosities equivalent to water (<inline-formula id="inf12">
<mml:math id="m12">
<mml:mrow>
<mml:msub>
<mml:mi>&#x3bc;</mml:mi>
<mml:mi>l</mml:mi>
</mml:msub>
</mml:mrow>
</mml:math>
</inline-formula> &#x2248; 1 &#xb1; 0.1&#xa0;mPas at 22&#xa0;&#xb0;C). The mean wall shear stress <inline-formula id="inf13">
<mml:math id="m13">
<mml:mrow>
<mml:mover accent="true">
<mml:mi>&#x3c4;</mml:mi>
<mml:mo>&#xaf;</mml:mo>
</mml:mover>
</mml:mrow>
</mml:math>
</inline-formula> was estimated from pressure drop measurements using <inline-formula id="inf14">
<mml:math id="m14">
<mml:mrow>
<mml:mover accent="true">
<mml:mi>&#x3c4;</mml:mi>
<mml:mo>&#xaf;</mml:mo>
</mml:mover>
<mml:mo>&#x3d;</mml:mo>
<mml:mfrac>
<mml:mrow>
<mml:mo>&#x394;</mml:mo>
<mml:mi>P</mml:mi>
</mml:mrow>
<mml:mi>L</mml:mi>
</mml:mfrac>
<mml:mfrac>
<mml:mrow>
<mml:msub>
<mml:mi>d</mml:mi>
<mml:mi>h</mml:mi>
</mml:msub>
</mml:mrow>
<mml:mrow>
<mml:mn>4</mml:mn>
</mml:mrow>
</mml:mfrac>
</mml:mrow>
</mml:math>
</inline-formula>; where <inline-formula id="inf15">
<mml:math id="m15">
<mml:mrow>
<mml:mo>&#x394;</mml:mo>
<mml:mi>P</mml:mi>
</mml:mrow>
</mml:math>
</inline-formula> is the pressure drop measured using a differential pressure sensor (Schlumberger type 8D, &#xb1;0.5% accuracy), <inline-formula id="inf16">
<mml:math id="m16">
<mml:mrow>
<mml:msub>
<mml:mi>d</mml:mi>
<mml:mi>h</mml:mi>
</mml:msub>
</mml:mrow>
</mml:math>
</inline-formula> is the hydraulic diameter, and L is the measurement distance.</p>
<p>The bubble size distribution within the foams was quantified using high-speed image acquisition with a Panasonic LUMIX DMC-FZ62 camera operating at 200 frames per second. Imaging was performed in a transparent Plexiglas observation section positioned perpendicular to the flow and located at the same streamwise position (1&#xa0;m downstream of the foam generator, corresponding to approximately 40 hydraulic diameters) as the stainless-steel test section containing the coupons. This configuration ensured that the observed foam structure was representative of the foam in contact with the surfaces during cleaning. High-speed acquisition was required to limit motion blur associated with bubble translation and deformation at a mean foam velocity of 1.8&#xa0;cm&#xa0;s<sup>-1</sup> and to enable reliable automated bubble contour detection. Images were acquired under steady-state flow conditions, and repeated acquisitions yielded consistent bubble size distributions, indicating a stationary foam microstructure at the measurement location. Bubble size analysis was performed within a fixed 15 &#xd7; 10&#xa0;mm region of interest located at the top wall, centred across the channel width. Only bubbles fully contained within this region were included in the analysis, while truncated or partially visible bubbles were excluded. For each experimental condition, three independent images were acquired under steady-state flow conditions. Images were calibrated using a micrometer scale to convert pixel dimensions into physical units (&#xb5;m). Image processing and analysis were carried out using ImageJ and Pixim&#xe8;tre software. Raw images were converted to grayscale, background subtraction was applied, and bubble contours were identified using manual thresholding followed by binary segmentation. When necessary, watershed segmentation was applied to separate overlapping bubbles. Equivalent bubble diameters were calculated from the detected contours. Bubble size distributions were fitted using a log-normal model by maximum likelihood estimation in MATLAB. Characteristic diameters, including the percentile diameters (D<sub>10</sub>, D<sub>50</sub>, D<sub>90</sub>), the Sauter mean diameter (D<sub>32</sub>), and the polydispersity index (D<sub>90</sub>/D<sub>10</sub>), were extracted. Measurement uncertainty was quantified using the standard deviation and coefficient of variation, as reported in <xref ref-type="table" rid="T1">Table 1</xref>, ensuring a robust and reproducible characterization of the bubble size distributions.</p>
<table-wrap id="T1" position="float">
<label>TABLE 1</label>
<caption>
<p>Fundamental statistical parameters of bubble size distributions for the three surfactants.</p>
</caption>
<table>
<thead valign="top">
<tr>
<th align="left">Parameter</th>
<th align="left">SDS</th>
<th align="left">Ammonyx&#xae; LO</th>
<th align="left">Capstone&#xae; FS-30</th>
</tr>
</thead>
<tbody valign="top">
<tr>
<td align="left">D<sub>10</sub> (mm)</td>
<td align="right">0.14</td>
<td align="right">0.069</td>
<td align="right">0.504</td>
</tr>
<tr>
<td align="left">Median - D<sub>50</sub> (mm)</td>
<td align="right">0.23</td>
<td align="right">0.1</td>
<td align="right">1.64</td>
</tr>
<tr>
<td align="left">D<sub>32</sub> - Sauter mean (mm)</td>
<td align="right">0.284</td>
<td align="right">0.17</td>
<td align="right">2.3</td>
</tr>
<tr>
<td align="left">D<sub>90</sub> (mm)</td>
<td align="right">0.38</td>
<td align="right">0.24</td>
<td align="right">3.47</td>
</tr>
<tr>
<td align="left">D<sub>90</sub>/D<sub>10</sub> ratio</td>
<td align="right">2.71</td>
<td align="right">3.48</td>
<td align="right">6.88</td>
</tr>
<tr>
<td align="left">Standard deviation (mm)</td>
<td align="right">0.127</td>
<td align="right">0.119</td>
<td align="right">1.506</td>
</tr>
<tr>
<td align="left">Coefficient of variation (%)</td>
<td align="right">51.4</td>
<td align="right">80.4</td>
<td align="right">72.1</td>
</tr>
<tr>
<td align="left">Minimum (mm)</td>
<td align="right">0.07</td>
<td align="right">0.033</td>
<td align="right">0.111</td>
</tr>
<tr>
<td align="left">Maximum (mm)</td>
<td align="right">1.2</td>
<td align="right">0.806</td>
<td align="right">7.432</td>
</tr>
<tr>
<td align="left">Range (mm)</td>
<td align="right">1.13</td>
<td align="right">0.773</td>
<td align="right">7.321</td>
</tr>
<tr>
<td align="left">Skewness</td>
<td align="right">2.15</td>
<td align="right">2.89</td>
<td align="right">1.76</td>
</tr>
<tr>
<td align="left">Log-normal &#x3bc;</td>
<td align="right">&#x2212;1.512</td>
<td align="right">&#x2212;2.354</td>
<td align="right">0.378</td>
</tr>
<tr>
<td align="left">Log-normal &#x3c3;</td>
<td align="right">0.452</td>
<td align="right">0.728</td>
<td align="right">0.892</td>
</tr>
<tr>
<td align="left">R<sup>2</sup> (log-normal fit)</td>
<td align="right">0.984</td>
<td align="right">0.972</td>
<td align="right">0.961</td>
</tr>
<tr>
<td align="left">Local void fraction (%)</td>
<td align="right">88</td>
<td align="right">79</td>
<td align="right">96</td>
</tr>
</tbody>
</table>
</table-wrap>
</sec>
</sec>
<sec sec-type="results" id="s3">
<label>3</label>
<title>Results</title>
<sec id="s3-1">
<label>3.1</label>
<title>Model surfaces, spores, and surfactant solutions characterization</title>
<p>In this study, AISI 316 stainless-steel coupons were used as model surfaces to simulate those commonly encountered in dairy processing equipment. The surface characterization confirmed a smooth but microscopically heterogeneous texture, with an arithmetic mean roughness (Ra) of 0.21 &#xb1; 0.02&#xa0;&#x3bc;m and a maximum profile height (Rz) of 1.52 &#xb1; 0.08&#xa0;&#x3bc;m. These values reflect the presence of grain boundaries and minor polishing defects typical of industrial-grade steel. The static water contact angle measured on the aged surfaces was 49.9&#xb0; &#xb1; 1.5&#xb0;, indicating a moderately hydrophilic behavior consistent with stainless steel that has undergone multiple cleaning and exposure cycles.</p>
<p>The biological contaminant used in this work was <italic>B. subtilis</italic> 98/7, which produces hydrophilic spores surrounded by a flexible exosporium (<xref ref-type="bibr" rid="B23">Faille et al., 2014</xref>). This strain was selected as a model soil because <italic>Bacillus</italic> spores are highly resistant to heat and cleaning agents and are frequently encountered in dairy and other heat-treated products (<xref ref-type="bibr" rid="B56">Tu et al., 2021</xref>), making them a relevant worst-case scenario for assessing foam cleaning performance. The hydrophobicity of the spores was quantified using the MATH assay, revealing an aqueous affinity exceeding 90%, thus confirming their highly hydrophilic nature. This strong affinity for water suggests limited adhesion through hydrophobic interactions, making mechanical shear and capillary phenomena the dominant factors in their detachment from surfaces.</p>
<p>To generate the cleaning foams, three surfactant systems were employed: SDS, Ammonyx&#xae; LO, and Capstone&#xae; FS-30. Each exhibited distinct interfacial properties and critical micelle concentrations. The CMC values were experimentally determined as 2300&#xa0;mg&#xa0;L<sup>-1</sup> for SDS, 11&#xa0;&#x3bc;L&#xa0;L<sup>-1</sup> for Ammonyx&#xae; LO, and 100&#xa0;&#x3bc;L&#xa0;L<sup>-1</sup> for Capstone&#xae; FS-30. Surface tension measurements performed at 23&#xa0;&#xb0;C &#xb1; 1.3&#xa0;&#xb0;C revealed equilibrium values of 26.2&#xa0;mN&#xa0;m<sup>-1</sup> for SDS, 32&#xa0;mN&#xa0;m<sup>-1</sup> for Ammonyx&#xae; LO, and 18&#xa0;mN&#xa0;m<sup>-1</sup> for Capstone&#xae; FS-30 (<xref ref-type="table" rid="T2">Table 2</xref>). The SDS value is lower than typical literature values reported for highly pure SDS &#x3e;99% (&#x2248;30&#x2013;36&#xa0;mN&#xa0;m<sup>-1</sup>), likely due to the commercial-grade purity of the SDS used here (&#x2265;98.5%), which may contain impurities affecting surface tension. The measured values were retained because all experiments were performed using this formulation.</p>
<table-wrap id="T2" position="float">
<label>TABLE 2</label>
<caption>
<p>Comprehensive physicochemical properties and flow parameters of surfactant solutions and resulting foams under identical operating conditions (&#x3b2; &#x3d; 0.5, v &#x3d; 1.77&#xa0;cm&#xa0;s<sup>-1</sup>).</p>
</caption>
<table>
<thead valign="top">
<tr>
<th align="left">Parameter</th>
<th align="left">SDS</th>
<th align="left">Ammonyx&#xae; LO</th>
<th align="left">Capstone&#xae; FS-30</th>
</tr>
</thead>
<tbody valign="top">
<tr>
<td align="left">Surface tension (mN&#xb7;m<sup>-1</sup>)</td>
<td align="right">26.2</td>
<td align="right">32</td>
<td align="right">18</td>
</tr>
<tr>
<td align="left">Solution viscosity (mPa&#xb7;s)</td>
<td align="right">1</td>
<td align="right">1</td>
<td align="right">1</td>
</tr>
<tr>
<td align="left">Solution density (kg&#xb7;m<sup>-3</sup>)</td>
<td align="right">997.9</td>
<td align="right">1087</td>
<td align="right">1100</td>
</tr>
<tr>
<td align="left">Foam density (kg&#xb7;m<sup>-3</sup>)</td>
<td align="right">499.6</td>
<td align="right">544.1</td>
<td align="right">550.6</td>
</tr>
<tr>
<td align="left">Foam viscosity (mPa&#xb7;s)</td>
<td align="right">4.85</td>
<td align="right">4.85</td>
<td align="right">4.85</td>
</tr>
<tr>
<td align="left">Wall shear stress (Pa)</td>
<td align="right">2.2</td>
<td align="right">2.12</td>
<td align="right">1.9</td>
</tr>
<tr>
<td align="left">Reynolds number</td>
<td align="right">47.5</td>
<td align="right">51.7</td>
<td align="right">52.3</td>
</tr>
<tr>
<td align="left">Capillary number (Ca)</td>
<td align="right">6.75 &#xd7; 10<sup>&#x2212;4</sup>
</td>
<td align="right">5.52 &#xd7; 10<sup>&#x2212;4</sup>
</td>
<td align="right">9.82 &#xd7; 10<sup>&#x2212;4</sup>
</td>
</tr>
<tr>
<td align="left">Capillary force (Fc)</td>
<td align="right">1.89 &#xd7; 10<sup>&#x2212;5</sup>
</td>
<td align="right">1.07 &#xd7; 10<sup>&#x2212;5</sup>
</td>
<td align="right">9.27 &#xd7; 10<sup>&#x2212;5</sup>
</td>
</tr>
</tbody>
</table>
</table-wrap>
</sec>
<sec id="s3-2">
<label>3.2</label>
<title>Foam stability and structural characteristics</title>
<p>The stability of foams generated from the three surfactant systems was assessed by monitoring the time required for the complete disappearance of the visible foam under static conditions. The results (<xref ref-type="fig" rid="F1">Figure 1</xref>) revealed pronounced differences in foam persistence depending on surfactant type. Foams produced with SDS remained stable for nearly 24&#xa0;h before total collapse, whereas those formed with Ammonyx&#xae; LO and Capstone&#xae; FS-30 disintegrated after approximately 8 and 3&#xa0;h, respectively.</p>
<fig id="F1" position="float">
<label>FIGURE 1</label>
<caption>
<p>Time needed for the total dispersion of the foam resulting from the 3 surfactants.</p>
</caption>
<graphic xlink:href="frsfm-06-1750630-g001.tif">
<alt-text content-type="machine-generated">Bar chart comparing hours for three substances: SDS, Ammonyx LO, and Capstone FS-30. SDS has the highest value at about twenty-four hours, followed by Ammonyx LO around eight hours, and Capstone FS-30 near three hours. Error bars indicate variability.</alt-text>
</graphic>
</fig>
<p>Although the practical cleaning durations in our experiments were limited to 20&#xa0;min, these long-term stability data provide essential insight into the intrinsic ability of each surfactant system to sustain its interfacial structure after flow conditions. Foam longevity reflects the competition between three principal destabilization mechanisms: gravitational drainage, bubble coalescence, and film rupture (<xref ref-type="bibr" rid="B37">Langevin, 2017</xref>; <xref ref-type="bibr" rid="B21">Denkov et al., 2020</xref>).</p>
<p>The foam microstructural characteristics revealed by representative micrographs (<xref ref-type="fig" rid="F2">Figure 2</xref>) are quantitatively substantiated by the cumulative bubble size distributions fitted with log-normal models (<xref ref-type="fig" rid="F3">Figure 3</xref>), providing comprehensive insight into the stability trends observed across surfactant systems. SDS foam (<xref ref-type="fig" rid="F2">Figures 2a</xref>, <xref ref-type="fig" rid="F3">3</xref>) exhibited a homogeneous distribution of small, nearly spherical bubbles characteristic of a wet, plug foam regime. The quantitative analysis (<xref ref-type="table" rid="T1">Table 1</xref>) reveals exceptional size uniformity, with a log-normal distribution (R<sup>2</sup> &#x3d; 0.984) displaying a median diameter (D<sub>50</sub>) of 0.23&#xa0;mm and remarkably narrow polydispersity (D<sub>90</sub>/D<sub>10</sub> &#x3d; 2.7). The low coefficient of variation (51.4%) indicates highly reproducible bubble formation during foam generation, reflecting optimal interfacial stabilization by SDS molecules. This fine, uniform structure ensures homogeneous capillary pressure distribution within the Plateau borders and minimizes localized film thinning, thereby significantly delaying film rupture through balanced disjoining pressure. In comparison, Ammonyx&#xae; LO foam (<xref ref-type="fig" rid="F2">Figure 2b</xref>) presented a distinctly different bubble architecture, characterized by a bimodal distribution comprising both extremely fine bubbles and larger irregular structures. While achieving the smallest median diameter (D<sub>50</sub> &#x3d; 0.1&#xa0;mm), this surfactant exhibited broader size distribution (D<sub>90</sub>/D<sub>10</sub> &#x3d; 3.5) and higher variability (CV &#x3d; 80.4%). The micrographs corroborate this statistical analysis, revealing increased bubble size heterogeneity, with a significant distribution tail extending beyond 0.4&#xa0;mm. This morphological pattern suggests competing mechanisms of rapid bubble nucleation versus insufficient film stabilization, where initial bubble formation generates numerous fine bubbles, but inadequate interfacial cohesion permits subsequent coalescence events, leading to accelerated drainage rates and reduced dilatational modulus. Capstone&#xae; FS-30 foam (<xref ref-type="fig" rid="F2">Figure 2c</xref>) displayed the most heterogeneous structure, characterized by large polyhedral bubbles and relatively thick parietal Plateau borders observable at the wall. The quantitative data robustly support these visual observations, demonstrating the widest size distribution (D<sub>90</sub>/D<sub>10</sub> &#x3d; 6.9) with a median diameter (D<sub>50</sub> &#x3d; 1.64&#xa0;mm) approximately seven-fold larger than Ammonyx. The substantially high Sauter mean diameter (D<sub>32</sub> &#x3d; 2.3&#xa0;mm) indicates low specific surface area, while the significant positive skewness (1.76) confirms the prevalence of oversized bubbles within the distribution. This morphological configuration facilitates rapid coalescence through diminished Laplace pressure gradients and enhanced gas diffusion between adjacent bubbles, consistent with the poorest foam stability observed experimentally.</p>
<fig id="F2" position="float">
<label>FIGURE 2</label>
<caption>
<p>Bubble morphology at the top for the three surfactants. <bold>(a)</bold> SDS, <bold>(b)</bold> Ammonyx LO, and <bold>(c)</bold> Capstone FS-30. The entire width, 1&#xa0;cm.</p>
</caption>
<graphic xlink:href="frsfm-06-1750630-g002.tif">
<alt-text content-type="machine-generated">Three labeled microscope images show foam bubbles. Panel (a) displays large and small bubbles densely packed. Panel (b) shows smaller, more uniformly sized bubbles. Panel (c) presents irregularly shaped and interconnected bubbles. A yellow scale bar indicates 1 centimeter.</alt-text>
</graphic>
</fig>
<fig id="F3" position="float">
<label>FIGURE 3</label>
<caption>
<p>Cumulative fraction of the bubble size distribution for all the foam-based surfactants. The lines represent the Lognormal model fitted to each condition.</p>
</caption>
<graphic xlink:href="frsfm-06-1750630-g003.tif">
<alt-text content-type="machine-generated">Line graph showing cumulative probability versus bubble size in millimeters for three surfactants: SDS (red), Ammonyx LO (green), and Capstone FS-30 (blue). SDS and Ammonyx LO rapidly reach high cumulative probability at small bubble sizes, while Capstone FS-30 increases more gradually with size. Legend identifies each surfactant by color.</alt-text>
</graphic>
</fig>
<p>The strong correlation between microscopic morphology and statistical size distribution parameters indicates that a small mean bubble size combined with low polydispersity is systematically associated with more persistent foams. SDS foams, therefore, combine a small characteristic diameter with a relatively narrow distribution, whereas Ammonyx&#xae; LO and Capstone&#xae; FS-30 show either larger bubbles or broader, positively skewed distributions. The log-normal fits are consistent with these observations and summarise the main structural differences that underpin the stability contrasts observed among the three surfactant systems. To quantify the actual foam state in the test section, the local air (void) fraction at the top of the duct was determined by image analysis of foam cross-sections using MATLAB. Binary segmentation of the images allowed discrimination between gas-filled regions and Plateau borders/lamellae, from which the areal gas fraction was computed as a proxy for local void fraction. The resulting values were 0.88 for SDS foam, 0.79 for Ammonyx foam, and 0.96 for Capstone foam, confirming that, despite the nominal quality of 0.5 imposed in the generator, the foam arriving in the measurement zone is already in a dry regime with densely packed, polyhedral bubbles. Following the framework of <xref ref-type="bibr" rid="B28">Forel et al. (2016)</xref>, the areal gas fractions measured at the wall (0.88, 0.79, and 0.96) correspond to estimated bulk liquid fractions of approximately 0.14%, 0.45%, and 0.015% for SDS, Ammonyx LO, and Capstone FS-30, respectively. This confirms that all foams are in the very dry regime, with the surface liquid fraction being significantly larger than the bulk liquid fraction, as expected. The locally measured void fractions are fully consistent with the textures observed in <xref ref-type="fig" rid="F2">Figure 2</xref> and justify interpreting the flow as dry foam rather than a wet bubbly dispersion.</p>
<p>The foams generated from the three surfactants exhibited distinct physical and hydrodynamic properties under identical operating conditions (air fraction &#x3d; 0.5, flow velocity v &#x3d; 1.8&#xa0;cm&#xa0;s<sup>-1</sup>), as summarized in <xref ref-type="table" rid="T2">Table 2</xref>. The fundamental physicochemical properties of the surfactant solutions differed significantly, and these intrinsic interfacial properties governed the observed foam structures. SDS demonstrated the lowest surface tension (26.2&#xa0;mN&#xa0;m<sup>-1</sup>), leading to a low capillary number (Ca &#x3d; 6.75 &#xd7; 10<sup>&#x2212;4</sup>). At such low Ca, surface tension forces dominate over viscous stresses, enabling strong Marangoni stabilization of lamellae (<xref ref-type="bibr" rid="B4">Breward, 2002</xref>; <xref ref-type="bibr" rid="B57">Vitasari et al., 2013</xref>) and promoting capillary-controlled bubble formation with narrow size distributions (<xref ref-type="bibr" rid="B38">Mangani et al., 2022</xref>; <xref ref-type="bibr" rid="B41">Ohashi et al., 2022</xref>). These combined effects favor the development of stable lamellae and a more homogeneous foam structure. In contrast, Ammonyx&#xae; LO exhibited higher surface tension (32&#xa0;mN&#xa0;m<sup>-1</sup>), whereas Capstone&#xae; FS-30 displayed the lowest surface tension (18&#xa0;mN&#xa0;m<sup>-1</sup>) but the highest Ca within the same order of magnitude. Despite these differences, the similarity of Ca across all samples indicates that viscous contributions remain negligible for the three systems.</p>
<p>The resulting foam properties followed consistent trends, with density increasing from SDS (499.6&#xa0;kg&#xa0;m<sup>-3</sup>) to Ammonyx&#xae; LO (544.1&#xa0;kg&#xa0;m<sup>-3</sup>) and Capstone&#xae; FS-30 (550.6&#xa0;kg&#xa0;m<sup>-3</sup>). The Reynolds numbers (47.5, 51.7, and 52.3 for SDS, Ammonyx&#xae; LO, and Capstone&#xae; FS-30, respectively) confirm similar flow regimes across all systems. Despite the comparable mean wall shear stress (&#x223c;2&#xa0;Pa), it should be noted that, according to <xref ref-type="bibr" rid="B9">Dallagi et al. (2022b)</xref>, conductimetry and polarography in similar foam-flow geometries showed that instantaneous local wall shear stress at the top wall can reach values up to approximately twice the mean value inferred from pressure drop. Such fluctuations play a crucial role in determining the cleaning behavior, particularly during the second phase of detachment. In the present study, this electrochemical method could not be applied systematically to all surfactants, as the ferri/ferrocyanide redox couple required for polarography destabilised SDS- and Capstone&#xae; FS-30-based foams, leading to rapid collapse.</p>
</sec>
<sec id="s3-3">
<label>3.3</label>
<title>Cleaning kinetics</title>
<p>The cleaning efficacy of foams generated from SDS, Ammonyx&#xae; LO, and Capstone&#xae; FS-30 surfactants was evaluated through detachment kinetics of <italic>B. subtilis</italic> spores from stainless-steel surfaces (<xref ref-type="fig" rid="F4">Figure 4</xref>). All formulations demonstrated time-dependent log<sub>10</sub> reductions in viable spores, though with markedly different kinetic profiles. After 20&#xa0;min of foam flow, SDS achieved the highest spore reduction (1.9 log<sub>10</sub>), followed by Ammonyx&#xae; LO (0.83 log<sub>10</sub>) and Capstone&#xae; FS-30 (0.55 log<sub>10</sub>), establishing a clear cleaning efficiency hierarchy: SDS &#x3e; Ammonyx&#xae; LO &#x3e; Capstone&#xae; FS-30.</p>
<fig id="F4" position="float">
<label>FIGURE 4</label>
<caption>
<p>Cleaning kinetics of <italic>B. Subtilis 98/7</italic> under the effect of different surfactants, red circle: SDS, green diamond: Ammonyx LO, blue triangle: Capstone&#xae; FS 30.</p>
</caption>
<graphic xlink:href="frsfm-06-1750630-g004.tif">
<alt-text content-type="machine-generated">Line graph with three data series showing Log&#x2081;&#x2080;((N&#x209C;*100)/N&#x2080;) on the Y-axis versus Time in minutes on the X-axis. Blue triangles and line represent the highest values, green diamonds and line represent intermediate values, and red circles and line represent the lowest values, all trending downward over time.</alt-text>
</graphic>
</fig>
<p>Kinetic analysis revealed a biphasic detachment mechanism characterized by two distinct removal rates (<xref ref-type="table" rid="T3">Table 3</xref>). The initial rapid phase (K<sub>1</sub>) corresponds to detachment of weakly bound spores, while the subsequent slow phase (K<sub>2</sub>) represents removal of strongly adherent spores. SDS exhibited a substantially higher K<sub>1</sub> value (114.75&#xa0;s<sup>-1</sup>) compared to Ammonyx&#xae; LO (12.61&#xa0;s<sup>-1</sup>) and Capstone&#xae; FS-30 (0.25&#xa0;s<sup>-1</sup>). The fraction of spores removed during this rapid phase (f) was greatest for SDS (98.2%), though statistical analysis indicated no significant differences among surfactants for this parameter. The secondary detachment rates (K<sub>2</sub>) were consistently low across all surfactants (&#x3c;0.05&#xa0;s<sup>-1</sup>), confirming that firmly anchored spores remained largely unaffected within the 20-min cleaning window. Statistical grouping revealed that while K<sub>1</sub> values for SDS and Ammonyx&#xae; LO were significantly different, K<sub>2</sub> values showed no significant variation among the three surfactant systems. These results demonstrate that surfactant selection significantly influences the initial spore detachment rate, with SDS foam achieving substantially faster removal kinetics during the critical first phase of cleaning. The consistent K<sub>2</sub> values across all systems suggest that the secondary removal mechanism is largely independent of surfactant chemistry within the experimental timeframe.</p>
<table-wrap id="T3" position="float">
<label>TABLE 3</label>
<caption>
<p>Kinetic parameters of spore detachment for different surfactant foams. Values with common letters within columns are not significantly different.</p>
</caption>
<table>
<thead valign="top">
<tr>
<th align="left">Parameters</th>
<th align="left">K1 (s-1)</th>
<th align="left">K2 (s-1)</th>
<th align="left">f (%)</th>
</tr>
</thead>
<tbody valign="top">
<tr>
<td align="left">SDS</td>
<td align="left">114.75 (A)</td>
<td align="left">0.023 (A)</td>
<td align="left">98.2 (A)</td>
</tr>
<tr>
<td align="left">Ammonyx&#xae; LO</td>
<td align="left">12.61 (B)</td>
<td align="left">0.04 (A)</td>
<td align="left">79.1 5 (AB)</td>
</tr>
<tr>
<td align="left">Capstone&#xae; FS-30</td>
<td align="left">0.25 (B)</td>
<td align="left">0 (B)</td>
<td align="left">54.5 (B)</td>
</tr>
</tbody>
</table>
</table-wrap>
</sec>
</sec>
<sec sec-type="discussion" id="s4">
<label>4</label>
<title>Discussion</title>
<p>The Reynolds numbers for all three-surfactant systems range between 47 and 52, which is consistent across the systems. This similarity suggests a laminar plug-flow regime, where the foam moves as a coherent slug. These values remain well below the transition to more complex 2D/3D flow regimes, as reported in the literature (<xref ref-type="bibr" rid="B55">Tisn&#xe9; et al., 2004</xref>; <xref ref-type="bibr" rid="B6">Dallagi et al., 2018</xref>). Additionally, the macroscopic flow conditions were consistent across the systems, implying that the observed performance differences stem from microscale interfacial phenomena rather than from a singular bulk hydrodynamic characteristic, such as mean shear stress. This reinforces that the effectiveness of foam-based cleaning is controlled primarily by bubble-scale, through the coupling of foam structure, interfacial rheology, and dynamic shear behavior at the wall. The pronounced contrasts in foam stability and cleaning efficiency among SDS, Ammonyx&#xae; LO, and Capstone&#xae; FS-30 reveal a complex, multi-scale interplay between physicochemical parameters and flow dynamics. Consistent with the cleaning data, SDS showed the longest foam persistence and highest spore removal (24&#xa0;h, 1.9 log reduction), Ammonyx&#xae; LO displayed intermediate stability and cleaning (8&#xa0;h, 0.83 log), and Capstone&#xae; FS-30 showed the shortest persistence and lowest removal (3&#xa0;h, 0.55 log). These differences are rooted in fundamental variations in the ability of each surfactant to sustain a mechanically resilient bubble network, with SDS exhibiting relatively narrow bubble size distribution and reduced size heterogeneity compared to the other foams, whereas Ammonyx&#xae; LO and Capstone&#xae; FS-30 generate broader, positively skewed distributions that favour Ostwald ripening and coalescence. Rather than being dictated by a single parameter, cleaning performance may emerge from the synergy among capillary number, interfacial rheology, foam drainage kinetics, and bubble morphology. The capillary number provides an essential framework for interpreting these behaviors by expressing the balance between viscous stresses and surface tension forces. The low Ca corresponds to a system where capillary forces dominate, promoting the Marangoni stabilization mechanism: local surface-tension gradients (high &#x2202;&#x3c3;/&#x2202;c) induce liquid backflows that counteract gravity- and capillarity-driven film thinning, preserving lamellae integrity and delaying bubble coalescence (<xref ref-type="bibr" rid="B19">Denkov et al., 2006</xref>; <xref ref-type="bibr" rid="B49">Sharma et al., 2025</xref>). These interfacial mechanisms directly dictate foam microstructure. The influence of wall slip on foam flow and its dependence on capillary effects has been extensively discussed in the literature (<xref ref-type="bibr" rid="B55">Tisn&#xe9; et al., 2004</xref>; <xref ref-type="bibr" rid="B46">Saugey et al., 2006</xref>). Researchers demonstrated that the velocity profile of flowing foam is strongly conditioned by interfacial phenomena at the wall, particularly through the balance between viscous stresses and capillary forces. Their work showed that the onset and magnitude of wall slip are governed by the capillary number, with slip becoming more significant when viscous forces exceed capillary resistance at the bubble-wall interface. This behavior is consistent with the trends observed in our study: under our operating conditions, the capillary number remains low, indicating a regime where surface tension dominates and where slip is limited by strong adhesion of lamellae and Plateau borders to the wall. SDS generated a fine, uniform population of nearly spherical bubbles (D<sub>50</sub> &#x3d; 0.23&#xa0;mm, D<sub>90</sub>/D<sub>10</sub> &#x3d; 2.7), characteristic of wet foams with efficient interfacial stabilization and low gas permeability between bubbles (<xref ref-type="bibr" rid="B20">Denkov et al., 2009</xref>; <xref ref-type="bibr" rid="B53">Tcholakova et al., 2017</xref>; <xref ref-type="bibr" rid="B52">Tcholakova and Petkova, 2024</xref>). The structural superiority of SDS foam compared to Ammonyx LO and Capstone FS-30 suggests favorable interfacial behavior under our dynamic flow conditions. Although SDS interfaces are classically considered highly mobile under equilibrium conditions, the foam undergoes continuous structural modification as it passes through geometric singularities (sudden diameter changes, bends, expansions) and during flow, as evidenced by the change in local air fraction from 0.5 (generator) to 0.88 (test section). These transitions, combined with continuous bubble rearrangements during flow, necessitated an establishment length of approximately 1&#xa0;m (&#x223c;40 hydraulic diameters) to achieve reproducible foam properties for quantitative measurements. These dynamic conditions may generate transient surface tension gradients; determining their specific role in stabilization will be addressed in future studies through direct measurement of interfacial dynamics during flow. In addition, early foam-surface interactions detach biological residues that may momentarily adsorb onto bubble films, potentially increasing their effective resistance to deformation. In contrast, Capstone&#xae; FS-30 formed large, polyhedral bubbles characteristic of a dry, unstable foam with thickened Plateau borders and fragile lamellae. This trend is consistent with prior findings that larger bubbles and dry textures promote faster drainage and shorter film lifetime (<xref ref-type="bibr" rid="B7">Dallagi et al., 2019</xref>; <xref ref-type="bibr" rid="B8">Dallagi et al., 2022a</xref>). Microscopic observations revealed instead rapid drainage and coarse bubble growth, indicating that local film thinning from gravitational and capillary drainage dominates over the stabilization predicted by Ca. Similar discrepancies have been observed downstream of geometric singularities, where foam drainage and coalescence exceed theoretical predictions (<xref ref-type="bibr" rid="B6">Dallagi et al., 2018</xref>; <xref ref-type="bibr" rid="B7">Dallagi et al., 2019</xref>). Previous studies have shown that foam-wall friction depends strongly on structural parameters such as bubble size and liquid fraction (<xref ref-type="bibr" rid="B42">Raufaste et al., 2009</xref>). Although estimated friction forces differed among the foams tested, these differences did not directly correlate with cleaning efficiency. In our experiments, while all three foams generated similar mean wall shear stress values (<xref ref-type="table" rid="T2">Table 2</xref>), their distinct microstructures, particularly bubble size (0.1&#x2013;1.64&#xa0;mm range) and liquid fraction (0.04&#x2013;0.21), likely lead to different local friction dynamics at the bubble-wall interface. It should be emphasized that the wall shear stress inferred from the pressure gradient represents a macroscopic, space- and time-averaged quantity, which does not resolve the local shear peaks associated with individual bubble passages and liquid-film thickness fluctuations. The effective stress experienced by the surface is expected to be governed by local, highly unsteady shear transmitted through thin liquid films and Plateau borders during bubble deformation and sliding, as previously quantified using polarographic measurements for wet foams (<xref ref-type="bibr" rid="B9">Dallagi et al., 2022b</xref>).</p>
<p>The coupling between foam structure and cleaning function is best captured by the two-phase kinetic model for spore detachment (<xref ref-type="bibr" rid="B9">Dallagi et al., 2022b</xref>). In the first, rapid phase governed by K<sub>1</sub> and f small bubbles (&#x3c;0.2&#xa0;mm) generate capillary &#x201c;wiping&#x201d; actions that remove weakly bound spores. The superior K<sub>1</sub> (114.75&#xa0;s<sup>-1</sup>) and f (98.2%) values observed for SDS directly result from its dense, stable network of fine bubbles, ensuring high wall-contact frequency and maximizing capillary interactions. The elevated f further suggests that most spores existed in weakly cohesive multilayers, where inter-spore adhesion is more easily disrupted by cyclic capillary stresses than the direct spore-surface bonds (<xref ref-type="bibr" rid="B18">Deleplace et al., 2022</xref>). The second, slower phase controlled by K<sub>2</sub> relies on fluctuations in local wall shear stress (WSS) to detach the strongly adhered spores. Although K<sub>2</sub> values remained below 0.05&#xa0;s<sup>-1</sup> for all surfactants within 20&#xa0;min, the higher determination coefficient (R<sup>2</sup> &#x3d; 0.83 for SDS, 0.41 for Ammonyx&#xae; LO, 0.16 for Capstone&#xae; FS-30) highlights the superior ability of SDS foam to generate coherent and sustained WSS oscillations. These sustained oscillations reflect the stability of the lamellae and Plateau-border network formed by SDS foams during flow (<xref ref-type="bibr" rid="B9">Dallagi et al., 2022b</xref>). The wet, stable microstructure of SDS preserves a uniform film and Plateau-border network, enabling frequent, small-amplitude oscillations of shear and capillary forces that effectively disrupt spore aggregates and dislodge firmly attached cells (<xref ref-type="bibr" rid="B44">Saabi et al., 2020</xref>; <xref ref-type="bibr" rid="B9">Dallagi et al., 2022b</xref>). By contrast, the large, irregular bubbles of Capstone&#xae; FS-30 induced intermittent, low-frequency wall stresses insufficient to overcome adhesion forces, while Ammonyx&#xae; LO exhibited intermediate detachment behavior. The pivotal role of bubble size and foam wetness in determining cleaning efficiency has been well documented. Foams composed of small bubbles generate higher capillary pressures in their thin films, greatly enhancing detachment (<xref ref-type="bibr" rid="B20">Denkov et al., 2009</xref>; <xref ref-type="bibr" rid="B9">Dallagi et al., 2022b</xref>). In contrast, coarse, dry foams coalesce more readily, diminishing capillary action and leading to a rapid loss of cleaning effectiveness (<xref ref-type="bibr" rid="B21">Denkov et al., 2020</xref>). The high detachment rates achieved with SDS thus arise from its ability to preserve a fine, wet structure that sustains shear oscillations throughout the cleaning process.</p>
<p>Recent work by <xref ref-type="bibr" rid="B47">Schad et al. (2021)</xref> highlighted the importance of bubble size and foam stability on cleaning performance. Their experiments showed that foams composed of small bubbles exhibit enhanced cleaning of oil-contaminated glass surfaces. This improvement was attributed to the combined action of imbibition, drainage, and interfacial wiping. In particular, the authors demonstrated that small bubbles promote stronger imbibition and drainage of oil toward the Plateau borders, a trend that aligns well with our observations. Their study also emphasized that the wiping mechanism, the displacement of the three-phase contact line between the foam, the contaminant, and the solid surface, was more pronounced when the foam was unstable. This is logical in the context of static foams, where structural rearrangements, coalescence events, and intermittent bubble motions occur naturally as the foam ages, thereby intensifying wiping at the interface. Although their conclusions were obtained under static conditions, the underlying mechanisms remain relevant to our system. In our case, the foam is continuously flowing, and the imposed motion generates persistent shear and forced bubble rearrangements. These effects produce strong wiping interactions even when the foam is more stable than in the static case. Nevertheless, excessive instability would not be beneficial in our configuration, as rapid coalescence and the formation of larger bubbles would diminish the efficiency of imbibition and drainage processes that are central to effective cleaning. It should be noted that, within the spatial and temporal scales resolved by our imaging, bubble motion along the top wall is predominantly continuous and advective, with bubbles remaining in contact while sliding and deforming as they are transported by the flow. No clear evidence of frequent, large-scale neighbour-exchange events is observed at this resolved scale. Fast film-scale rearrangements (T1 events), if present, occur below the resolution of the present setup and cannot be quantified reliably.</p>
<p>Beyond the differences observed in foam-mediated cleaning, it is essential to situate the superior performance of SDS within the broader context of surfactant-based cleaning mechanisms. In membrane-filtration systems, SDS is widely recognized for its ability to detach organic foulants and restore permeate flux under relatively mild hydrodynamic conditions, owing to its dual capacity to wet hydrophobic surfaces and solubilize proteinaceous deposits (<xref ref-type="bibr" rid="B45">Sagle et al., 2009</xref>; <xref ref-type="bibr" rid="B30">Gkotsis et al., 2014</xref>). Consequently, SDS is frequently incorporated into commercial cleaning formulations to prevent re-deposition and enhance soil dispersion. Reported efficiencies vary widely depending on the type of foulant, surface chemistry, and operational parameters, reflecting the strong yet context-dependent nature of SDS-driven solubilization (<xref ref-type="bibr" rid="B31">Harendra and Vipulanandan, 2012</xref>; <xref ref-type="bibr" rid="B51">Sisay et al., 2023</xref>). However, these findings cannot be directly extrapolated to microbial contaminants, and especially not to bacterial spores. Static immersion experiments, such as those reported recently, demonstrate that surfactant solutions alone (SDS, decyl glucoside (DG), lauryl glucoside (LG) 10-hydroxystearic acid (10-HSA)) do not significantly remove <italic>B. subtilis</italic> spores from stainless steel compared in static immersion in water, despite the surfactant&#x2019;s potent action against organic soils (<xref ref-type="bibr" rid="B9">Dallagi et al., 2022b</xref>; <xref ref-type="bibr" rid="B16">Dari et al., 2023b</xref>; <xref ref-type="bibr" rid="B15">Dari et al., 2023a</xref>). This discrepancy underscores that SDS efficacy is not governed solely by its chemical interactions but relies critically on mechanical assistance, shear, drainage flows, capillary suction, or dynamic interfacial stresses to detach highly adherent biological particles. Although the stronger ionic and hydrophobic interactions between anionic surfactants and proteins partly explain why SDS tends to outperform nonionic surfactants, these molecular interactions remain insufficient to dislodge spores in the absence of hydrodynamic or interfacial perturbations. In addition to these mechanical contributions, previous studies have shown that SDS can destabilize or denature proteins even at room temperature and at concentrations below the critical micelle concentration (<xref ref-type="bibr" rid="B2">Bhuyan, 2010</xref>). Such denaturation may weaken the proteinaceous components located at the spore surface, potentially lowering the adhesion strength and contributing to spore detachment once hydrodynamic forces are applied. Nevertheless, this molecular effect alone is insufficient to remove spores in static conditions, reinforcing the conclusion that SDS-induced cleaning is strongly dependent on the interplay between chemical action and mechanically driven interfacial stresses.</p>
<p>Lastly, from a mechanistic point of view, the strong performance of SDS reflects the combination of fine, narrowly polydisperse bubbles and resilient interfacial films, which favours Marangoni-driven film stabilisation and a more uniform distribution of capillary pressures along the surface. These features together produce a robust, wet foam that maintains continuous wall contact and delivers the capillary and shear perturbations required for efficient spore removal. This study confirms that the cleaning efficiency of foam systems is an emergent property arising from the integrated interfacial and microstructural dynamics of the surfactant network, rather than being solely determined by static physicochemical parameters. For practical applications, this highlights the value of formulations that sustain film rheology and generate fine, cohesive bubbles. Future improvements may rely on formulating systems that slow drainage and enhance film persistence, through co-surfactants or rheology modifiers, to maintain foam integrity over long distances.</p>
</sec>
<sec sec-type="conclusion" id="s5">
<label>5</label>
<title>Conclusion</title>
<p>This study demonstrated that the type of surfactant strongly governs both the structural stability of foams and their cleaning performance against <italic>B. Subtilis</italic> spores. Among the tested systems, SDS generated the most stable and cohesive foam, exhibiting superior cleaning efficiency and faster detachment kinetics. Its low surface tension, rapid interfacial adsorption, and fine bubble network provided strong capillary forces and sustained wall shear stress oscillations, resulting in efficient removal of both loosely and strongly adhered spores. In contrast, Ammonyx&#xae; LO and Capstone&#xae; FS-30 formed less stable, rapidly draining foams with larger bubbles, leading to intermittent wall contact and reduced mechanical action. From a mechanistic standpoint, the results reinforce the two-phase detachment model: (i) an initial capillary-dominated removal phase governed by bubble size and contact frequency, and (ii) a slower shear-stress-driven phase linked to wall stress fluctuations. Overall, SDS outperformed the other surfactants because it produced the most stable, fine, and cohesive foam, which translated into more efficient spore detachment under the low shear conditions tested. In practical terms, this work provides a physical and chemical basis for optimizing foam-based cleaning systems, with SDS clearly positioned as a benchmark surfactant against which alternative or greener formulations can be evaluated. Future work should incorporate commercially available alkaline cleaning formulations to determine whether the mechanisms identified here persist under realistic industrial conditions and to further elucidate the role of surfactant chemistry in foam-mediated cleaning. Beyond formulation, future developments should aim at improving drainage control and maintaining foam wetness along extended flow paths, for example, through co-surfactant blends or polymeric stabilizers.</p>
<p>To fully elucidate the role of dynamic interfacial mechanics during foam transport and cleaning, further research should include direct, spatially resolved measurements of interfacial dilatational and shear rheology along the flow path. This is particularly important in the presence of biological contamination, where transient adsorption of spores or biofilm fragments may locally stiffen the interface, modifying Marangoni responses and film-thinning dynamics. Although this effect was not quantified here, it constitutes a plausible mechanism that warrants systematic investigation. Understanding such non-equilibrium interfacial processes is essential for the rational design of foam formulations capable of maintaining mechanical integrity and cleaning efficiency under hydrodynamic conditions. Taken together, these perspectives open promising avenues toward more energy- and water-efficient foam-based cleaning strategies for hygienic applications in food, pharmaceutical, and bioprocess environments.</p>
</sec>
</body>
<back>
<sec sec-type="data-availability" id="s6">
<title>Data availability statement</title>
<p>The original contributions presented in the study are included in the article/supplementary material, further inquiries can be directed to the corresponding author.</p>
</sec>
<sec sec-type="author-contributions" id="s7">
<title>Author contributions</title>
<p>AA: Data curation, Formal Analysis, Investigation, Methodology, Software, Writing &#x2013; original draft. HD: Conceptualization, Data curation, Formal Analysis, Investigation, Methodology, Software, Supervision, Validation, Visualization, Writing &#x2013; original draft, Writing &#x2013; review and editing. PJ: Methodology, Writing &#x2013; original draft, Writing &#x2013; review and editing. FA: Conceptualization, Methodology, Resources, Supervision, Validation, Writing &#x2013; review and editing. TB: Conceptualization, Data curation, Funding acquisition, Methodology, Project administration, Resources, Supervision, Validation, Visualization, Writing &#x2013; review and editing. CF: Conceptualization, Data curation, Formal Analysis, Methodology, Resources, Supervision, Validation, Visualization, Writing &#x2013; review and editing.</p>
</sec>
<sec sec-type="COI-statement" id="s9">
<title>Conflict of interest</title>
<p>The author(s) declared that this work was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.</p>
</sec>
<sec sec-type="ai-statement" id="s10">
<title>Generative AI statement</title>
<p>The author(s) declared that generative AI was not used in the creation of this manuscript.</p>
<p>Any alternative text (alt text) provided alongside figures in this article has been generated by Frontiers with the support of artificial intelligence and reasonable efforts have been made to ensure accuracy, including review by the authors wherever possible. If you identify any issues, please contact us.</p>
</sec>
<sec sec-type="disclaimer" id="s11">
<title>Publisher&#x2019;s note</title>
<p>All claims expressed in this article are solely those of the authors and do not necessarily represent those of their affiliated organizations, or those of the publisher, the editors and the reviewers. Any product that may be evaluated in this article, or claim that may be made by its manufacturer, is not guaranteed or endorsed by the publisher.</p>
</sec>
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