Quality of Tenebrio molitor Powders: Effects of Four Processes on Microbiological Quality and Physicochemical Factors

Tenebrio molitor, the first edible insect approved as a novel food in the EU, is a promising candidate for alternative protein sources, implementing circular and sustainable production systems. This study aims to determine the microbiological quality and physicochemical properties of mealworm powders obtained by four different processing pathways. Contents of dry matter, protein, fat, ash, water activity (aw) and a range of microbial counts were measured and analyzed by one-way ANOVA with Tukey’s test. Results showed small differences in the proximate composition of the powder samples (protein 55.62–57.90% and fat 23.63–28.21% of dry matter, DM), except for the one that underwent a defatting step (protein 70.04% and fat 16.84%), p < 0.05. A level of water activity of less than 0.2 was reached for all pathways. Fresh mealworm samples had high total aerobic counts (8.4 log CFU/g) but were free of foodborne pathogens. Heat treatments applied during transformation were sufficient to kill vegetative cells (reduction of 2.8–5.1 log CFU/g) rather than bacterial endospores (reduction of 0.3–1.8 log CFU/g). Results were confirmed by predictive microbiology. This study validated the efficacy of a boiling step as critical control points (CCPs) of insect powder processing, providing primary data for the implementation of HACCP plans.