CIP Strategies Food safety issues Biofilm control

Transcription

1 1 CIP Strategies Food safety issues Biofilm control Tony Erickson Principal Chemist 12 June 2013

2 2 CIP in Biofilm Control General observations for discussion Good cleaning and effective sanitizing are the base of any biofilm control program Hard to reach biofilms are a substantial issue Standard chemistry less effective on established biofilm Microclimates in equipment are varied and widespread Non-traditional biofilms common C&S issue

3 3 CIP in Biofilm Control Key elements of a good program Chemical concentration verification Proper wash time Mechanical design Flow rates Spray balls Dead legs Heating capacity etc Proper use of heat Critical component Gasket maintenance

4 4 Biofilm Issues Traditional biofilms generally not an issue Stainless steel pipes and tanks are clean and sanitized - Confirmed by ATP swabs and micro sampling Residual soil acts as hybrid biofilm/soil matrix - Non-traditional biofilms Nooks and Crannies Gasketed joints Valves Plate heat exchangers Evaporators Low flow areas Biofilms newly generated during long runs

5 Difficult to Reach Biofilms 5

6 6 Difficult to Reach Biofilms Fluorescent dye intrusion caused by thermal cycling

7 7 Difficult to Reach Biofilms Degraded gaskets showing intrusion and voids

8 Dairy CIP Simulation 8

9 9 Dairy CIP Simulation CIP system standardized with 175 F water for 10 min Inoculated milk circulated 5 hours at 40 F Gram negative field isolate CIP using high temp (145 F) or low temp (110 F) Sanitized Circulated water recovery performed Plate counts run on recovery water

10 3/8/2011-Excel CIP 145 3/9/2011-Excel CIP 145 3/10/2011-Advantis LT 110 3/15/2011-Excel CIP 145 3/16/2011-Advantis LT 110 3/17/2011-Advantis LT 110 3/18/2011-Excel CIP 145 3/22/2011-Excel CIP 145 3/23/2011-Advantis LT 110 3/24/2011-Excel CIP 145 3/25/2011-Advantis LT 110 3/29/2011-Advantis LT 110 3/30/2011-Advantis LT 110 3/31/2011-Excel CIP 145 4/1/2011-Excel CIP 145 4/5/2011-No Chemistry 110 4/6/2011-Advantis LT 110 4/7/2011-Advantis LT 110 4/8/2011-No Chemistry 110 4/12/2011-Advantis LTFE 110 4/13/2011-Advantis LTFE 110 4/14/2011-Advantis LTFE 110 4/15/2011-Advantis LTFE 110 4/19/2011-Advantis LTFE 110 4/20/2011-Advantis LTFE 110 4/21/2011-Advantis LT 110 4/22/2011-Excel CIP 145 4/29/2011-Advantis LTFE 110 5/3/2012-Advantis LTFE 110 5/4/2012-Advantis LTFE 110 5/5/2012-Advantis LTFE 110 5/6/2012-Advantis LTFE 110 5/20/2012-Advantis LTFE 110 Average Plate Count (CFU/L) 10 Dairy CIP Simulation Circulated Water Recovery Total Bacteria Gram Negative Random temperature/chemistry changes for subsequent runs Analysis showed no statistical difference for single runs Weekend Effect observed when system was not re-sanitized

11 Gram Negatrive Bacteria Recovered (CFU/L) 11 Dairy CIP Simulation 120 F vs 130 F With Same Cleaning Chemistry F F 0.1 Same chemistry and CIP temp were repeated multiple runs

12 12 Difficult to Reach Biofilms Temperatures Max 144 F S1 137 F S2 101 F Thermal imaging shows areas with much lower temperature than bulk CIP solution

13 13 Difficult to Reach Biofilms Overall Bacteria Recovery VS ATP Swab Counts (1) (2) (3) (4) (5) (6) (7) ATP Swab Counts

14 14 Valve Pulsing in CIP Proper valve pulsing is critical Valve seats and back of valves sites for biofilm Long term soil build up

15 15 Heat Exchanger Biofilm Issues Plate heat exchangers are difficult to fully clean Very difficult to confirm a proper clean Buildup of soil in low flow regions Optimal growth conditions for thermophiles Long runs lead to high counts later in run

16 16 Heat Exchanger Biofilm Issues Evaporators difficult to clean properly Low flow areas often not fully cleaned

17 17 Interventions Global Best Practices for Biofilm Issues Premium SEEC chemistry Peracid sanitizing Sanitizer use Membranes, Evaporators, Pasteurizers Aggressive C&S every CIP, not when problems arise

18 18 Interventions Two Part SEEC Chemistries Produce gas bubbles in and on soil and biofilms Improves cleaning in low flow areas Greatly increases micro-turbulence

19 19 Difficult to Reach Biofilms *. : : *. : : Current Peracid Pretreatment *. : : : : *. *. : : OH - OH - OH - OH - :: :: *. *. OH- *. OH - OH - : OH - : Current Method: NaOH (Caustic) - Caustic causes top layer of soil to swell and form gel - This doesn t allow chemistry to reach next layer of soil - Takes longer for chemistry to reach all soil layers New Method: Pretreatment + NaOH - Pretreatment penetrates into soil - Caustic triggers ph activation - Caustic reacts with pretreatment chemistry and creates ruptures in soil layers - This breaks up the soil and allows chemistry to have greater soil contact - Takes less time to clean

20 20 Interventions Peracid Sanitizers on Heat Processing Equipment Traditionally not performed Heat will take care of it Thermophiles / Thermoduric Hot peracetic acid very volatile and pungent Good and Bad can get at hard to reach areas Corrosion levels low if Chloride levels under 500 ppm 304 / 316 SS at required use concentration

21 Ave MPY 21 Interventions Peracid Sanitizers on Heat Processing Equipment ACCELERATED STAINLESS STEEL CORROSION 180 deg F for 2 Weeks (solutions changed daily) SS 316 SS MPY 0 ppm Cl MPY 50 ppm Cl ppm 1.00% 2800ppm 1.00% 2800ppm 1.00% 2800ppm 1.00% POAA POAA Mixed Mixed POAA POAA Mixed Mixed Peracid Peracid Peracid Peracid 304 SS 304 SS 304 SS 304 SS 316 SS 316 SS 316 SS 316 SS

22 22 Interventions Peracid Sanitizers on Heat Processing Equipment Global survey of plants producing low count powder Some of the highest performing were using hot sanitizer Research project conducted to look at the spore survival rate with a variety of hot peracid formulations

23 Interventions - Spores Bacillus spp spore cocktail 50 C Test Contact Average Average Log Substance Time Survivors Log Reduction (min) (CFU/mL) Mixed x Peracid x ppm 10 <10 <1 >5.1 Peracid 2 <10 <1 >5.1 Cleaner 5 <10 <1 > ppm x Experimental 2 <10 <1 >5.1 Peracid 5 <10 <1 > ppm 10 <10 <1 > Proprietary Information of Ecolab, Inc.

24 24 CIP in Biofilm Control Global Best Practices The Goal Get back up and running ASAP New Zealand has proven ability to produce low spore count powder Source of spores is primarily biofilm in Evap and other equipment Interventions SEEC products when appropriate Peracid or peroxide Fast Washes or Peracid Flush Add sanitizer or antimicrobials to PHE, evaps, membranes Gasket maintenance

25 25 CIP in Biofilm Control Conclusion A sound C&S program is the base of a biofilm control program Selective interventions may be appropriate Non traditional use of detergents, sanitizers and heat can yield improved outcomes We are open to discussing specific problems Ecolab R&D is currently trialing best practices and interventions with outcome-based metrics.