NEXT CARE TECHNOLOGIES FOOD INDUSTRY

Transcription

1 Ozone systems for Food&Beverage: low impact solutions to sanitize and extend shelf life NEXT CARE TECHNOLOGIES FOOD INDUSTRY

2 The natural solution: ozone In the Food&Beverage, De Nora with the De Nora NEXT ozone systems ensures deep sanitization of surfaces, purification of air and water, and removal of odours from the environment through every stage of the production process. A know-how gained over 90 years of activity makes De Nora the ideal partner of reference for the study of applications, supply and commissioning of ozone systems. The De Nora NEXT systems, both innovative and easy to use, are based on natural raw materials: air or oxygen. Sustainable, for the environment and humans, they are the ideal solution for those seeking quality, food safety and longer shelf life of the product, with special consideration given to the containment and reduction of consumption and, as a result, costs. ADVANTAGES: innovation and technology ecological sustainability natural resources quality safety reduction and containment of consumption and costs ELECTRICAL O 2 DISCHARGE O 3 Ozone is formed from oxygen, in its pure form or its presence in the air, through an electrical discharge. Such a simple, natural process: once used, it again becomes oxygen. 2

3 Ozone can be used as a gas or dissolved in water (ozonated water) high efficacy against bacteria, viruses, fungi, spores, biofilm and mites no resistant bacteria generated active against odours does not persist in the environment reduces the use, transport and storage of chemical compounds reduces levels of COD, BOD and micropollutants OZONE APPLICATIONS AIR TREATMENT SURFACES TREATMENT PROCESS WATER TREATMENT WASTEWATER TREATMENT FRUIT AND VEGETABLE Storage cells, elimination of ethylene Conveyor belts, storage cells, bins, pallets Sanitization of washing water and irrigation water MEAT Storage cells, and maturation, clean rooms Tables, work equipment, air/water conduits FISH Storage cells, clean rooms Tables, work equipment, air/water conduits CHEESE Storage cells Tables, work equipment, air/water conduits Saline, mozzarella cooling water WINE AND BEER Tanks, casks, barriques Filling machines sanitization BEVERAGES Aseptic clean rooms Water conduits Removal of unwanted flavours and odours, removal of metals PASTA Cooling tunnels, drying tunnels, clean rooms Conveyor belts, work equipment 3

4 Safer fruits and vegetables with ozone Spoilage and pathogenic microorganisms may be transported by food itself, by process water or by air. If not removed, they can easily proliferate and lead to a reduction in shelf life and the possible transmission of illnesses. Moulds and mycotoxins can develop, as well, in the field or on products stored in unsanitized environments. This is the case, for example, with Patulin which can have toxic effects on humans and, specifically, children. Hence, the importance of providing an effective sanitization of the air and water used for the production process, as with the surfaces and equipment with which the products come into contact. UNSANITIZED CELL AIR SANITIZATION The use of gaseous ozone in storage cells provides a substantial reduction of the microbial load (specifically moulds) with a consequent containment of the perishability of the products, slowdown of the processes of maturation, decrease in losses and longer shelf life. SANITIZED CELL SURFACES AND EQUIPMENT The use of ozonated water on surfaces and work equipment provides a deep sanitization which prevents cross contamination and, at the same time, leaves no residues. In addition, it is proven effective in the battle against biofilm. PROCESS WATER AND CLEANING WATER The use of ozonated water to wash foods and in the entire storage process, reduces the presence of mycotoxins such as Patulin, can reduce pesticide residues, and permits the microbial load in cleaning water to be contained, making it possible to re-use it, thereby reducing relative consumption and costs.

5 UP TO 100 % REDUCTION OF BACTERIAL LOAD 70%REDUCTION OF PESTICIDES NO RESIDUES UP TO 100 % INCREASE IN SHELF LIFE REDUCTION OF WATER FOOTPRINT 5

6 Ozone: quality and food safety start here The applications of ozone in the food industry, dairy industry, in the processing and transformation of meat and fish, and production of fresh pasta are extremely varied and can be introduced synergistically across the entire chain: today, consumers demand safe, healthy food which is not overly-processed and is able to satisfy their nutritional and organoleptic desires. Ozone is a natural solution, leaves no olfactive residues and does not alter the flavour of foods. It is able to guarantee high qualitative standards for the food market in developed countries, as well as an opportunity in developing countries which are defining their own standards of food quality. AIR SANITIZATION The use of gaseous ozone in the cheese industry is effective in the maturation rooms against mites and microorganisms of the genus Listeria and reduces the development of unwanted moulds in all environments where processing UNSANITIZED CELL SANITIZED CELL and packaging are performed. It is also used in the meat, fish and fresh pasta industries to contain the microbial load. It can also be used for the sanitization of air in work environments such as clean rooms, cooling rooms and storage of products to guarantee a longer shelf life. SURFACES AND EQUIPMENT During food processing, the use of ozonated water keeps the microbial load at low and consistent levels unlike untreated water, where the levels tend to increase over the course of the day. In addition, the passage through pipes reduces any biofilm present and prevents it reforming and contaminating the product. PROCESS AND CLEANING WATER The use of ozone to sanitize process water guarantees a reduction of the microbial load and cross contamination by microorganisms. If used in the treatment of cooling water for mozzarella, it can reduce the presence of Pseudomonas aeruginosa or Pseudomonas fluorescens. The treatment of rinse water used in CIP cycles prevents the transfer of any surviving contamination from one tank to another, following the sanitization process.

7 CASE HISTORY Fishing industry: ozone at the service of the entire production chain Ozonated ice longer shelf life no contamination from ice Air treatment odour reduction Treatment of fattening tanks reduction of fish kill increased weight up to 30% Mollusc farming effective against viruses and bacteria greater oxygenation of water Crustacean storage water improvement in water quality no cross contamination Surfaces and equipment no cross contamination reduction of bacterial load 7

8 Beverages: hygiene and savings with ozone In the beverages industry, sanitization is a key issue. On one side, there is the need to guarantee high standards of hygiene, and on the other is the need to reduce impact on the environment and treatment costs. The use of ozone not only allows maximum safety to be achieved, thereby decreasing the microbial load and presence of chemical residues, it also provides substantial savings in water and electricity, optimisation of the production processes, increased operator safety, a noticeable reduction in environmental impact, resulting in lowered costs to the company. AIR SANITIZATION The use of gaseous ozone reduces the levels of fungi in the air and environments. In the wine industry, in particular, it can lead to a reduction in the number of spores which can be deposited on products and, in addition, proves effective in combating the presence of insects, specifically, Drosophila suzukii. SURFACES AND EQUIPMENT The use of ozone in the treatment of steel, resin and cement tanks, as well as barriques and casks, reduces the growth of bacteria, mould, fungi and yeasts, of the genus Brettanomyces bruxellensis reducing the generation of unwanted odours, biogenic amines, acetic acid, ethyl and vinylphenols. Dissolved in water, it becomes an effective means of combating the formation of biofilm in conduits and process lines without the risk of leaving a residue from disinfectants or chemical compounds. PROCESS WATER AND CLEANING WATER The use of ozone also proves effective in the treatment of water used to produce beverages for the purpose of preventing unwanted flavours and odours. It also allows the removal of metals, iron and manganese in particular and if used during CIP processes, it prevents contamination with the water used during the rinse stages. Lastly, it can be used in the rinsing machines which are employed in the normal bottling process. 8

9 CASE HISTORY Wine industry: sanitization with ozone is convenient. All the advantages compared to chemical products. Containment of the level of humidity prevents the growth of microorganisms Reaches places difficult to reach with water improves the effectiveness of the treatment Reduction in water and energy consumption no water used the pumps consume less power Reduction of mould, yeasts and bacteria effective against Brettanomyces bruxellensis does not create resistant strains Reduction of volumes of water sent to the purifier 40% less production of sludge 9

10 Waste water and sludge: reduce the costs with ozone Among the principal costs faced by the food industry and livestock breeders, in addition to water and energy, are the costs of waste water treatment; above all if contaminated by biological and chemical products responsible for the increased levels of COD, BOD and micropollutants. The use of ozone systems allows a substantial reduction in levels of COD, BOD and micropollutants, resulting in lower usage of chemical compounds. The use of ozone in a biological purifier can improve its effectiveness and reduce the sludge produced, leading to a positive economic impact on disposal costs. It also prevents the creation of enormous collection tanks. If used prior to biological treatment, ozone can reduce the COD before the waste water is introduced into the tank; the BOD/COD ratio increases as well as the biological efficiency. Used after the biological treatment, ozone can reduce the residual presence of COD and germs. In this way, the discharge limits are managed in accordance with current laws. Ozone, in addition, may be successfully used to reduce the production of organic dewatered sludge. The improved sedimentation and lower index volume of sludge, as well as increased dehydration and the consequential decrease in the use of chemical products, guarantee improved efficiency of the treatment system.

11 UP TO 40 % REDUCTION OF SLUDGE - COD, - BOD - MICROPOLLUTANTS - DISPOSAL COSTS EFFECTIVE AGAINST MICROORGANISMS - CHEMICAL PRODUCTS 11

12 Ozone systems AIR SANITATION FEATURES DCU OZ MODULAR (OZ80, OZ1000,OZ2000) CUBO O3 POWER OZONE GENERATOR OZONE PRODUCTION WITH AIR OZONE PRODUCTION WITH CONCENTRATED OXYGEN (PSA) OZONE PRODUCTION WITH PURE OXYGEN GAS GAS GAS GAS, GAS+WATER 12; 24 g/h 0,5 g/h 8 g/h g/h; 8 g/h - 8 g/h; 16 g/h; 24 g/h; 32 g/h; 64 g/h; 104 g/h; 160 g/h COOLING SYSTEM AIR AIR AIR AIR AIR FILTERS - X (OZ1000 / OZ 2000) - AIR DRYERS - X (OZ1000 / OZ 2000) - OZONE DESTROYER (DOT OR DOCAT) BLENDING SYSTEM OZONE Optional Optional (GAS+WATER) OZONE SENSORS Safety; process Safety; process Safety; process PLC/HMI Optional INTERFACE Safety; process OTHER Transportable 12

13 PROCESS WATER SANITATION WASTE WATER TREATMENT STERILINE IMPIANTI SU SKID MCP TPF WATER (batch & continuous) WATER (batch & continuous) WATER (batch & continuous) WATER (batch & continuous) 53g/h (O3 3% w/w) 53g/h-735g/h (O3 3% w/w) 53 g/h; 105 g/h; 210 g/h; 367 g/h; 735 g/h (O3 3% w/w) from 0,5 kg/h up to 10 kg/h (O3 3% w/w) up to 100 g/h (O3 from 6 to 10% w/w) 70g/h-1000g/h (O3 from 6 to 10% w/w) 70 g/h; 140 g/h; 280 g/h; 500 g/h; 1000 g/h (O3 from 6% to 10% w/w) from 1,3 kg/h up to 26 kg/h (O3 from 6% to 10% w/w) up to 100 g/h (O3 from 6 to 12% w/w) from 70 g/h to 1000g/h (O3 from 6 to 12% w/w) 70 g/h; 140 g/h; 280 g/h; 500 g/h; 1000 g/h (O3 from 6 to 12% w/w) from 1,3 kg/h up to 26 kg/h (O3 from 6 to 12% w/w) WATER WATER WATER WATER (Not integrated) (Not integrated) (Not integrated) (Not integrated) Safety; process; ozone leak detector Safety; process; ozone leak detector Safety; process; ozone leak detector Safety; process; ozone leak detector MODBUS; PROFIBUS; ETHERNET MODBUS; PROFIBUS; ETHERNET MODBUS; PROFIBUS; ETHERNET MODBUS; PROFIBUS; ETHERNET ORP sensors; Remote control (optional) ORP sensors; Remote control (optional) ORP sensors; Remote control (optional) ORP sensors; Remote control (optional) 13

14 DE NORA: technology at your service R&D, consultancy, service, assistance: these are the key words which make De Nora the ideal partner of reference for the study, supply and commissioning of ozone systems. Thanks to an internal team of specialists and long established relationships with leading Research Institutes and Centres, De Nora works alongside companies in the food industry by analysing operational criticalities, focusing on the applied research and design of custom systems, and providing and implementing the best technological solutions. It is capable, on a case by case basis, of fitting into individual production lines in response to the needs which have been identified. The partnership with individual companies in the sector also caters to on-site training, technical assistance, maintenance and continuous on-going after-sales training, quick and tailored to each partner. De Nora: 360 at your service.

15 IDENTIFICATION OF CRITICALITIES APPLIED RESEARCH PROPER OZONE SYSTEM DESIGN SUPPLY AND COMMISSIONING AFTER-SALES ASSISTANCE AND TAILORED TRAINING 15

16 De Nora next care technologies De Nora, with the De Nora NEXT product line, supplies compact technological systems, with a low environmental footprint, for the production on-site and on demand of innovative solutions with the goal of improving the health and quality of life for individuals, families and the planet. Drawing on strong experience and know-how gained over 90 years of history, today De Nora is the partner of reference for the study of applications, supply and commissioning of ozone systems in a gaseous state or blended in water for the food industry. NEXT CARE TECHNOLOGIES FOOD INDUSTRY via Bistolfi, Milano industriedenora@denora.com Copyright 2016 Industrie De Nora S.p.A. - All rights reserved. De Nora, the ON symbol, our research - your future (and any other trademark name) are trademarks or registered trademarks of Industrie De Nora S.p.A. in Europe and/or in other countries. Other trademarks used here are the registered trademarks of their respective owners. The information contained herein is offered for use by technically qualified personnel at their own discretion and risk without any guarantee of any kind. DNN-Ozono-01-EN 10/2016