cip industrial case ibs mars 2015 - realco · cip industrial case ibs mars 2015 . gea process...

GEA Process Engineering

SAFEXPERT™ Solution

CIP industrial case IBS Mars 2015


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


Spray Drying

Aseptic Filling

Brewery & Dairy Systems

Pharma Systems

Mechanical Separation

Food Solutions

Homogenizers

Valves

GEA Mechanical Equipment

http://www.westfalia.com/hq/en/products_services/promilk_Hygiene_consumables/products/hygiene/udder_hygiene/noniodinedip.aspx

http://www.westfalia.com/hq/en/products_services/proformance_equipment/products/milking_equipment/milking_components/default.aspx

http://www.westfalia.com/hq/de/products_services/milking_cooling/farm_management/herd_management_software/default.aspx

GEA Process Engineering 4 CIP industrial case

Quality problem on Cheese plant Context Approach Application - Conclusion…..

Case study


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


Observations

6

Biofilms resist to basic cleaning

Biofilm’s screening is difficult to highlight on opened and closed surface

CIP industrial case

1 risk = Biofilms


Biofilms ….

7

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.


SAFEXPERT™ fights biofilm

8

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


SAFESCOPE SAFESCAN

Step 1/ Screening , define the area for intervention

9

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


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Step 1/ Screening, define the area for intervention

With screening Without screening


Step 2/ Enzymatic Treatment

11

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)


Step 2/ EnzymaticTreatment


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


Solution approved by scientists


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,


Solution approved by regulation


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


Step 3/ Analyses


BarTest


Step 3/ Analyses


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


Case Study


• A cheese factory loses 200 000 € of cheese i In One week.

• Customer has detected also a problem on final product quality.

Customer issue


Case Study


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


Case Study


, 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


Case Study


After checking quality of water, we treat biofilms.

Biofilm treatment

Target


Case Study


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


Case study


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


Case study


Day 1 Day 2

Trouble = Biofilm

BarTest Analysis


Case study


Analysis

Metagenomic

Acremonium, aspergilus, tricosporon = Pathogen

= Biofilm

Pseudomonas oryzihabitans =Pathogen = Biofilm


Conclusion


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 !

TM

cip industrial case ibs mars 2015 - realco · cip industrial case ibs mars 2015 . gea process...

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