cip industrial case ibs mars 2015 - realco · gea process engineering gea group the gea group is...
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GEA Process Engineering
SAFEXPERT™ Solution
CIP industrial case IBS Mars 2015
GEA Process Engineering
GEA Group
The GEA Group is one of the largest providers for equipment and process technology particularly for the food and energy industries where it ranks among the market and technology leaders. The GEA Group focuses on demanding production processes and supplies its customers with efficient solutions in various end markets.
GEA Group Aktiengesellschaft 2
GEA Process Engineering 3 Safexpert, Safety first !
GEA Segment
Compressors
Packages and Skids
Ice Machines
Freezers
GEA Refrigeration Technologies
Milking & Cooling
Farm Services
Farm Equipment
GEA Farm Technologies
GEA Process Engineering
Spray Drying
Aseptic Filling
Brewery & Dairy Systems
Pharma Systems
Mechanical Separation
Food Solutions
Homogenizers
Valves
GEA Mechanical Equipment
GEA Process Engineering 4 CIP industrial case
Quality problem on Cheese plant Context Approach Application - Conclusion…..
Case study
GEA Process Engineering 5 CIP industrial case
Context
Quality
Security
Guarantee products quality =
Operator security Final consumer security
It’s necessary to evaluate risks to treat and improve your performance !
Industrials want to protect their final product durably against microbial contamination and avoid losses.
Performance levers
GEA Process Engineering
Observations
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Biofilms resist to basic cleaning
Biofilm’s screening is difficult to highlight on opened and closed surface
CIP industrial case
1 risk = Biofilms
GEA Process Engineering
Biofilms ….
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Bacteria in biofilms are much more resistant than other bacteria at planktonic form.
Biofilm can develop on a variety of
surfaces: heat exchangers, tanks, cooling systems, piping
for food products, fibers, membranes…
CIP industrial case
Biofilm consist of a viscous film made up of bacteria and extremely solid organic polymers that promote adhesion and
resistance of microorganisms.
In most cases they are invisible to the naked eye and constitute a reservoir of
microorganisms that protect them from external aggressions, including cleaning
and disinfection.
GEA Process Engineering
SAFEXPERT™ fights biofilm
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Screening
Treatment
Monitoring
Our process expertise and microbiological competence allow to insure final product quality and minimal losses.
Highlight biofilm
Customized enzyme-based cleaning
Measure and control
CIP industrial case
Approach
GEA Process Engineering
SAFESCOPE SAFESCAN
Step 1/ Screening , define the area for intervention
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This device is effective on open surfaces. Using three lamps it detects the presence of biofilm, presenting them as a green color when the light is shone over the area in question.
This device is effective on sealed surfaces. Using lamps and an integrated endoscopic camera, it detects the presence of biofilm, presenting them as a green color. Photos and video recordings can be taken and will be passed on to the client.
GEA can detect and locate the presence of biofilm in a matter of seconds on open and sealed surfaces.
CIP industrial case
GEA Process Engineering 10 CIP industrial case
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Step 1/ Screening, define the area for intervention
With screening Without screening
GEA Process Engineering
Step 2/ Enzymatic Treatment
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Elimination of biofilm allows an optimal hygiene
without risk for your products.
The enzyme transforms organic matters into small water-soluble residues in an irreversible way.
Enzyme works in synergy with cleaning agents
Faster More efficient
CIP industrial case
Some groups of enzymes : - Protease protein (meat, blood,
eggs, - Amylase starch (potatoes,
sugar, pasta) - Lipase lipid (fat, oil) - Cellulase fiber ( fruit)
GEA Process Engineering 12 CIP industrial case
Step 2/ EnzymaticTreatment
GEA Process Engineering 13 CIP industrial case
An European project research named « NETZYM » was implemented by INRA, UCL and RealCo. This scientific project validated the effective power of enzyme on biofilm.
➔ Bacillus mycoïdes, Bacillus cereus, Pseudomonas fluorescens (x2), Kocuria, Sphingonomonas
➔ 67 bacterial strains ➔ 6 strains selected (production of EPS, bacteria resistant basic cleaning
Step 2/ Enzymatic Treatment
Solution approved by scientists
GEA Process Engineering 14 CIP industrial case
Products (detergents) are EPA compliant in regards to their ingredients. Also none of detergents sold in the US have any biocide claim and therefore are not regulated by the FDA/EPA. 2° For the reason explained d above, the regulatory classification does not apply.
Cleaning products conform - to European regulation CE 648/2004 of 31 March 2004 on detergents. - to European directive 67/548/EEC on classification, packaging and
labelling,
Step 2/ Enzymatic Treatment
Solution approved by regulation
GEA Process Engineering
Step 3/ Analyses
15 CIP industrial case
We use ATP Test to qualify all type of water (cleaning,
stagnant water,…).
We use this test during enzymatic cleaning cycle.
We detect if we are fighting biofilm.
ATP-Test 2G
GEA Process Engineering
Step 3/ Analyses
16 CIP industrial case
BarTest
GEA Process Engineering
Step 3/ Analyses
17 CIP industrial case
Metagenomics
Metagenomics is a methodological technique that aims to study genetic content of a sample from a complex environment.
This method allows:
- Identification of the source of contamination - High number of identifications - Culturable and non culturable flora - Clear picture of microbial community - Improvment of product quality by monitoring
and identifying changes in the flora during process
GEA Process Engineering
Case Study
18 CIP industrial case
• A cheese factory loses 200 000 € of cheese i In One week.
• Customer has detected also a problem on final product quality.
Customer issue
GEA Process Engineering
Case Study
19 CIP industrial case
Storages cream
PASTEURIZER CIP
cheese RO
UF Manifold
how to clean contaminated parts?
how many time to operate treatment ?
how to integrate with the existing CIP?
Screening
GEA Process Engineering
Case Study
20 CIP industrial case
, We highlight biofilm with detection equipment “Safescan and Safescope”.
Screening
Vision SafexpertTM
Vision à oeil nu = RàS
Vanne Fin du circuit d'eau osmosée carbonatée vers tanks Lev. Déclassée
GEA Process Engineering
Case Study
21 CIP industrial case
After checking quality of water, we treat biofilms.
Biofilm treatment
Target
GEA Process Engineering
Case Study
22 CIP industrial case
Storages cream
PASTEURIZER
CIP
cheese
RO
UF Manifold
8h of treatment : •Get Central CIP access •Preparation of enzymatic
solutions •Wash manifold : 8 lines •Disinfection •Basic cleaning
4 h of treatment : •Dedicated CIP •Preparation of enzymatic
solutions •Wash UF •Disinfection •Basic cleaning
Same as Manifold
Biofilm treatment
GEA Process Engineering
Case study
23 CIP industrial case
ATP -Test 2G Description de l'échantillon UltraCheck RLU
ATP RLU
Volume analyse cATP Equivalents
microorganismes log(ME/mL)
mL pg/mL ME/mL
eau de préparation dilution solution enzyme cuve 30577 347 58 1,957 1957 3 cuve UF eau de prep 30577 74 60 0,4034 403 3 eau de réseau 30577 48 50 0,314 314 2 eau de réseau 2 30577 50 50 0,327 327 3 eau process pour remplir cuve 52 30577 67 50 0,4382 438 3 rétentat rinçage final UF 30577 1030 35 9,624 9624 4 Permeat 3eme étage rinçage final UF 30577 35 50 0,2289 229 2 solution enzymatique TMY51 30577 34 50 0,2224 222 2 solution enzymatique TMY51 30577 28 10 0,9157 916 3 solution enzymatique TMY51 30577 35 50 0,2289 229 2 eau fin rinçage TMY51 30577 58 50 0,3794 379 3 eau de rinçage intermediaire ligne de remplissage 30577 140 50 0,9157 916 3 eau de rinçage intermediaire ligne de remplissage 30577 202 51 1,295 1295 3 fin NEP ligne remplissage 30577 43 51 0,2757 276 2 TMY52 solution enzymatique 30577 17 50 0,1112 111 2 fin NEP ligne remplissage 30577 43 50 0,2813 281 2 eau neuve 30577 73 50 0,4775 478 3 eau neuve 30577 87 42 0,6774 677 3 TMY 52 rinçage interm 30577 59 50 0,3859 386 3 TMY51 rincage final 30577 50 52 0,3145 315 2 TMY52 rinçage final 30577 50 47 0,3479 348 3
Red : Warning biofilm Green : No Biofilm
Analysis
GEA Process Engineering
Case study
24 CIP industrial case
Day 1 Day 2
Trouble = Biofilm
BarTest Analysis
GEA Process Engineering
Case study
25 CIP industrial case
Analysis
Metagenomic
Acremonium, aspergilus, tricosporon = Pathogen
= Biofilm
Pseudomonas oryzihabitans =Pathogen = Biofilm
GEA Process Engineering
Conclusion
26 CIP industrial case
First objective: Eliminate losses
Second objective: Durable control OF Biofilm
Global Losses = 800 K€
Reduction Î more than 98 %
Invesment for Customer : 50 K€
Implementation Performance PROGRAMM:
- Criticality analysis - Maintenance plan - TPM / VSM - training
GEA Process Engineering 27 Safexpert, Safety first !
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