direct detection of biofilms and cip-related problems in ... · and mirror-polished end cap during...
TRANSCRIPT
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Direct Detection of Biofilms and CIP-Related Problems in Liquid Process Systems
Mark Fornalik
Ethox International
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Product Quality & Process Health
• Product quality depends in large part on cleanliness of the liquid product transfer line
• Traditional methods of monitoring system health:– Analyzing final product– Analyzing residual product in process water flush– Swabbing interior surfaces of tanks & lines for biofilms (ATP,
PCR analysis)
• But…..– Most bacteria recovered don’t grow in culture in the microbiology
lab– Analyzing effluent water does not provide any indication of what
remains behind on the pipe wall– ATP and PCR methods require critical cell mass for signal
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Transfer Line Contamination
Contamination Problems:• Cross contamination between
product types• Physical waste – spots,
streaks, particles, filter plugging, viscosity changes
• Chemical waste – chemical contamination of final product
• Increased brand change time• Loss of product flow• Increased production runs to
allow for waste
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Insoluble Wall Fouling• Fouling: The unwanted formation of insoluble
residues on engineering materials in contact with flowing solutions
• Fouling is what is left on wall surface after even a proper water flush clean
• Chemical cleaning must be designed to address water-insoluble wall fouling
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• Organic • Inorganic• Biological (bacteria, fungi, algae - BIOFILMS)• Particulate (corrosion)• Crystallization/Scale (boilers, heat exchangers)• Combination (any two or more of the above)
Insoluble Wall Fouling Types*
* T.R. Bott, * T.R. Bott, Fouling of Heat ExchangersFouling of Heat Exchangers, Elsevier (1995), Elsevier (1995)
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The goal of cleaning is to return the system to the induction periodlevel of fouling
Fouling Rate
time
fou
ling
mas
s
physical
chemical
induction period
secondary fouling
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Fouling Cell: Sanitary Cross with Polished End Caps
Product Flow
Material that adsorbs (sticks) on pipe wall also adsorbs on mirror-polished end caps (fouling cell discs)
Insoluble material deposits on pipe wall and mirror-polished end cap during product flow
Mirror-polished end caps
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Measuring Wall Fouling
Fouled end cap (fouling cell disc)
Fourier transform infrared beam
Spectrum from reflected infrared beam
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FTIR provides a “chemical fingerprint” of the fouling, as well as an indication of fouling amount
Fouling Identification
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Process Cleaning: A Structured Approach
System Design
Water Flush Optimization
Chemical Clean Optimization
Biofilm Control
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0.0001
0.001
0.01
0.1
1
10
100
1000
0 5 10 15 20 25 30 35
Time (minutes)
Per
ce
nt
of
Dye
in t
he
Flu
sh S
olu
tio
n
Magenta
Yellow
Cyan
Insufficient water flush leaves product behind in pipe; optimized water flush reaches “plateau” more
quickly for faster cleaning times
Water Flush Effluent: Product Displacement
Old process water flush end point
Water flush “plateau “
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Powerflush (Two-Phase Flow)Cleaning
Cleaning efficiency varies as a function of the ratio of air flow to water flow
Efficient flow ratio Water-rich flow ratio
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Measuring PowerflushCleaning Efficiency with FTIR
-0.0010
-0.0005
0.0000
0.0005
0.0010
0.0015
0.0020
0.0025
0.0030
0.0035
0.0040
0.0045
0.0050
0.0055
0.0060
0.0065
0.0070
0.0075
0.0080
Abs
orba
nce
1000 1500 2000 2500 3000 3500
Wavenumbers (cm-1)
-0.0010
-0.0005
0.0000
0.0005
0.0010
0.0015
0.0020
0.0025
0.0030
0.0035
0.0040
0.0045
0.0050
0.0055
0.0060
0.0065
0.0070
0.0075
0.0080
Abs
orba
nce
1000 1500 2000 2500 3000 3500
Wavenumbers (cm-1)
Peak height data correlate to effectiveness of cleaning: the smaller the peak, the more effective the cleaning
Before powerflush
After powerflush
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Chemical Cleaning Variables
� Chemical cleaner formulation� Concentration� Temperature� Order of addition
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Measuring Chemical Cleaning Efficiency
0%
20%
40%
60%
80%
100%
TSP NaOCl TSP/NaOCl NaOH Citric acid
clea
nin
g e
ffic
ien
cy
FTIR peak height before & after cleaning provides an estimate of
cleaning efficiency
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Studying Chemical Cleaning Parameters
0%10%20%30%40%50%60%70%80%90%
100%
25 C 45 C 65 C5% NaOH
clea
nin
g e
ffic
ien
cy
Impact of temperature
0%10%20%30%40%50%60%70%80%90%
100%
0.2% 1.0% 5.0%NaOH wt% @ 60 C
clea
nin
g e
ffic
ien
cy
Impact of concentration
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• Unwanted adhesion of bacteria or other organisms onto surfaces of solution-handling systems
• Not necessarily uniform in space & time• May contain significant amounts of inorganic
materials held together by the polymeric matrix
*(Charackis & Marshall, Biofilms, 1990)
Biofouling/Biofilms*
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Biofilm-Related Contaminants
• Cells (possibly pathogenic)• Anions (acetate, formate, nitrate, etc.)• Proteins, glycoproteins, carbohydrates,
fatty acids• Enzymes• Surfactants• Organic and inorganic particles• Substrate degradation (metals, plastics)
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Biofilm Resistance to Cleaning• Standard CIP methods may not remove biofilm
• Biofilms able to grow after 8 months desiccation• Biofilms withstood 80C or higher water
temperatures• Biofilms withstood 20, 50 and 200 ppm chlorine,
25 ppm iodine∗ Food Protection Report, 7(5):8 (1991)
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Standard Methods to Measure System Health & Cleanliness
• Product testing:– Taste– Chemistry– Plating/culturing
• Process testing:– Cleaning water effluent testing
• Plating• Residual product
– Swab testing by plating– ATP and/or PCR testing
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Key Points
• Biofilms exist in chemical as well as water transfer lines
• Biofilms can alter the chemistry of the product or water going through the line
• Biofilms can evade detection by traditional microbiological testing methods because these methods focus on recovering and growing cells from biofilms
• Fouling cell technology relies on measuring exopolymer, not necessarily cells, in place on the surface of interest, avoiding inefficient scraping and culturing methods
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Bacteria Populations in a Pipe
99%
1%
TRADITIONAL SAMPLING: 1% of total bacteria population inside of pipe is planktonic (free swimming organisms from bulk solution)
FOULING CELL SAMPLING: 99% of total bacteria population inside of pipe is sessile (attached biofilm on the wall of the pipe)
Sessile organisms (biofilms) can be very resistant to cleaning
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1 day 2 days
9 days4 days
45°C Ultrapure Water Biofouling
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Biofilm Chemistry Over Time*Subtraction Result:ir1848, 610 NRX disc #26, 3-month exposure, no clean*Subtraction Result:ir1896, 610 NRX, 14 batches (4 days), disc #7 (1/30 - 2/2/98)*Subtraction Result:ir2288, 610, NRX, #10, 24 hours, 5 batches, 2/26 - 2/27/98*Subtraction Result:ir1974, disc 10, 610 NRX, 1 batch, 4 hrs, without santoprene gasket
-0.008
-0.007
-0.006
-0.005
-0.004
-0.003
-0.002
-0.001
0.000
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
0.009
0.010
0.011
0.012
0.013
0.014
0.015
0.016
0.017
0.018
0.019
0.020
Abs
orba
nce
600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000
Wavenumbers (cm-1)
Biofilm changes to cleaning-resistant exopolymer upon aging
2 hrs
8 hrs
24 hrs
6 mo
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Biofilm Resistance to Cleaning: Bleach Treatment
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Mapping Process CIP Efficacy in a Brewery
FTIR & epifluorescence of fouling cells can provide cleaning efficacy data from end to end of a process
FTIR spectra of fouling cells placed in 5 locations of a manufacturing process (stage A through E) for 8 weeks
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Process Mapping in a Brewery: FTIR Peak Heights by Location
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
0.05
A B C D E
abso
rban
ce u
nit
s
PackagingProcess Start
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Brewery Wort Line
2 weeks, 100x objective 8 weeks, 100x objective
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
0.05
A B C D E
abso
rban
ce u
nit
s
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Brewery Aging Line
2 weeks, 100x objective 8 weeks, 100x objective
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
0.05
A B C D E
abso
rban
ce u
nit
s
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Brewery Filler Inlet Line
2 weeks, 100x objective 8 weeks, 100x objective
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
0.05
A B C D E
ab
sorb
an
ce u
nit
s
FTIR determines onset of biofouling in process
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Brewery Filler Inlet Line
8 weeks, 100x objective 8 weeks, 100x objective
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Winery Bottling Line 1 After CIP
1-week exposure, 100x 4-week exposure, 100x
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1-week exposure, 100x 4-week exposure, 100x
Winery Bottling Line 2 After CIP
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After water flush After CIP
Removed by CIP
Not Removed by CIP
Winery Bottling Line 2 Before & After CIP
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Biotech Company Fermentation
2-day exposure before CIP
2-day exposure after CIP
4-week exposure after CIP
CIP: 5% NaOH, 65°C, 30 min daily
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Biotech Company Recovery
2-day exposure before CIP
2-day exposure after CIP
4-week exposure after CIP
CIP: 5% NaOH, 65°C, 30 min daily
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Fermentation vs. Recovery
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Pharma Company Steam System Diaphragm Valve
Areas selected for analysis
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Pharma Company Steam Valve Stereo Microscopy
40X
Organic material
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Pharma Company Steam Valve Confocal Microscopy
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Pharma Company Steam Valve Confocal Microscopy
Region of heavy fouling
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Pharma Company Steam Valve Atomic Force Microscopy
Height image Phase image
Apparent scale formation
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Pharma Company Steam Valve Atomic Force Microscopy
Height image Phase image
Apparent organic material (biofilm exopolymer)
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Process Cleaning Improvement Flow Chart
On-site process assessment:
• system design
• water flush parameters
• wall fouling
Fouling cell studies to determine:
• fouling chemistry
• fouling rate
• presence of organisms
Lab cleaning studies to determine:
• appropriate cleaning chemicals
• chemical concentration, temperature
• chemical contact time, order of addition
Process trials with new cleaning procedure:
• implement new cleaning procedure
• verify improvement
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Conclusions
• In-line fouling cells can provide:– An early warning for issues of process cleanliness
and health– Information on chemistry and rate of fouling within
system– Objective data on CIP efficacy– Ability to determine efficacy of proposed cleaning
changes in the lab, not in production– Ability to screen new products for fouling propensity
• These methods are complimentary to existing process health measures