Aqueous ozone in CIP

Posted by Brialle Veldman on November 30, 2016 under CIP (Clean in Place) | Be the First to Comment

There are many ways that Ozone can be applied to the food and beverage industries. Some of the most essential cleaning duties are those related to the washing of process pipes, tanks, and process vessels where CIP (Clean in Place) systems are of frequent use. In terms of environmentally safe, cost-effective, and increased production, ozone has become a popular alternative to chlorine. In the past, chlorine has been the most common sanitizer used in CIP systems. Even though chlorine is effective, it has the potential to leave residuals and create potentially harmful by-products. However, ozone has become widespread since November 1892 when the FDA gave ozone GRAS approval. Ozone has been utilized pertaining to the beverage industry for disinfection of the fillers, bottles, and product(s). The beauty of ozone is that it has no by-products or residuals that can alter the flavors of a beverage or other product. It also has the ability to replace hot water cycles, eliminate some or all chemicals, reduce transporting and handling risks, and shortening the CIP cycle time. The implementation of ozone in the beverage industry can be of benefit for the process and downtime improvements more than the cost savings. The reasoning for applying ozone in the wine and beer industries is due to the nature of the final product. On the contrary, some beverage industries have favored the use of ozone merely for cost saving measures. With less time in the downtime period, product flow can be increased. According to the ECO3CIP project (2010-2013) which dealt with the original industrial application of an ozone based CIP system and its evidence. “According to the all the data obtained as a consequence of the implementation of the OZONECIP project the integration of the use of ozone in CIP systems  allowed a reduction of the water consumption needed to perform the cleaning and disinfection operations of closed equipments in the winery, brewery and dairy sectors compared to conventional CIP protocols keeping, at least, the same disinfection and cleanliness efficiency and reducing at least by 50% the organic load in the cleaning waste waters produced.” (Reducing costs by integrating ozonated water in the CIP systems)

 

  1. Pascual, I. Llorca and A. Canut, Use of ozone in food industries for reducing the environmental impact of cleaning and disinfection activities. Trends in Food Science & Technology, (18) S29-S35 (2007)

 

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Eradication of Legionella using Aqueous Ozone

Posted by Kaleb Jensen on July 16, 2015 under CIP (Clean in Place) | Be the First to Comment

Legionella causes Legionellosis or Legionnaires disease. Most notably L. pneumophilia.  Legionella species are the causative agents of the human Legionnaires disease and the lesser form, Pontiac fever. Legionella transmission is via aerosols by the inhalation of mist droplets containing the bacteria. Common sources include cooling towers, domestic hot-water systems, and fountains. Natural sources of Legionella include freshwater ponds and creeks. Outbreaks of Legionnaires disease have occurred in or near large building complexes such as hotels, hospitals, offices, and factories.

Initial symptoms are flu-like, including fever, chills, and a dry cough. Advanced stages of the disease cause diarrhea and nausea. Legionnaires disease can be very serious and can cause death in up to 5% to 30% of cases.

The biofilm formed by Legionella has been observed in PVC, stainless steel, rubber, wood, and copper. The biofilm formation can especially be found on the surface of water pipes, tower basins, and heat exchangers. Ozone successfully removes Legionella. It has been found that at an Ozone concentration of about 0.3mg/liter, a 4–5 log10 reduction in the number of organisms is achieved within 20 minutes [1]. Ozone not only removes Legionella, but it also helps to lower corrosion in tubing materials and reduces scale level [2].

It is recommended to keep the residual of disinfectants, so when Ozone is used, a trace of a second disinfectant, like Monochloramine, is needed. Ozone instantaneously inactivates Legionella.

 

 

 

References

[1]. Edelstein PH et al. (1982). Efficacy of ozone in eradication of Legionella pneumophila from

hospital plumbing fixtures. Applied and Environmental Microbiology , 44:1330–1334.

[2]. http://www.ozonesolutions.com/info/using-ozone-in-cooling-towers, accesses July 2015.

Clean-in-Place Systems benefited by Ozone

Posted by Joel Leusink on June 6, 2011 under CIP (Clean in Place) | Read the First Comment

Ozone is used as a sanitizer in Clean-In-Place (CIP) Systems

The use of ozone sanitation in Clean-In-Place (CIP) systems offers many advantages to the beverage and food industries. Ozone is an environmentally friendly disinfectant that leaves no residual or by-products after the disinfecting process. Ozone is also a safe sanitizer with no need for chemical storage, handling, or related safety issues. The use of ozone may eliminate the need of some hot water cycles, reducing the amount of water used, and the energy costs associated with hot water. These costs savings in conjunction with chemical savings have made ozone a cost saving measure in some applications.

Ozone has been used extensively in the beverage industry for disinfection of the product, bottles, and fillers. The use of ozone in this industry has been widespread since the FDA gave ozone GRAS approval in November 1892 (21 CFR § 184.1563). The use of ozone as a surface sanitizer and for direct contact with food has also grown more recently. In 2001, ozone was give GRAS approval for direct contact with all meat and poultry products (FSIS Directive 7120.1)

Benefits of ozone use in CIP Processes

  • Ozone has no residual or by-products that could alter flavors of a beverage or other product.
  • Ozone sanitation may replace hot water cycles lowering energy costs.
  • Chemicals like chlorine or other sanitizers can be eliminated saving cost and labor in handling/transporting chemicals.
  • CIP rinse/cleaning cycles can be combined using ozone; saving water and time. This may allow for more processing time due to shorter CIP cycle time.
Ozone and Bacteria

Effect of Ozone on Bacteria

Ozone’s reactive properties allow it to quickly kill bacteria. In fact, ozone is ten times stronger than chlorine as a disinfectant.

Potential cost savings of ozone use in CIP Processes

  • Water savings due to fewer cycles during CIP processes.
  • Chemicals may be reduced, saving chemical costs.
  • Water savings will translate to less wastewater, and potentially cleaner wastewater eliminating chemical by-products.
  • Fewer CIP cycles shortens overall downtime for CIP process.
  • Energy costs may be lowered due to less hot water consumption.

Ozone use for CIP Systems in the beverage industry

Ozone and Beverages

The use ozone in the beverage industry can be attributed to process and downtime improvements more than cost savings. In the wine and beer industries, ozone is very attractive due to the sensitive nature of the final product. Ozone is very attractive as there is no residual left behind by the sanitation process to alter the flavor of the wine or beer.

A summary of research done on ozone used to sanitize beer lines and pipes can be found here.

The journal of the International Ozone Association recently published a paper on ozone use for CIP system in the wine industry. This paper can be viewed and purchased here.

Other applications in the beverage industries have favored the use of ozone strictly for cost saving measures. With less downtime from the CIP process production can be increased. A study from 2008 at a beverage plant found total cuts to CIP process of 180 minutes each production day. This resulted in a dramatic profitability improvement to this plant. More about this study can be found here.

Ozone use for CIP Systems in Food Extraction Processes

Extraction processes are continually evolving and using new methods to extract biological components from food products. In the past many extraction processes used heat, and chemicals to dissolve biological components in food products. Today many extraction processes are using cooler and less harsh methods to extract desired proteins. This creates a microbiological concern in the product and manufacturing environment. Ozone has been used successfully in the gaseous form to disinfect the final product, but also in the CIP processes of these systems. Due the lack of residual left by ozone it is an attractive solution to the microbiological problems that may be present in these applications.


Ozone use at Dairy Farms in the CIP process

When thinking of CIP processes dairy farms are not usually the first application that comes to mind. However, dairy farms are one of the most common CIP processes used. Each modern dairy farm uses a pipeline to carry the milk from the individual milking station to the final bulk tank (with a few stops in between). Dairy farms are required to clean these pipes after every milking, which may be 2 or 3 times per day. Traditionally hot water with chemicals were used in these processes consuming a large amount of energy and chemical costs. The use of ozone can eliminate hot water costs, lower chemical costs, and shorten total CIP time, allowing more time for milking.

Ozone as a Sanitizer

Ozone is an extremely effective sanitizer. Historically the most common sanitizer used in CIP systems has been chlorine. While chlorine is a very effective disinfectant it has the potential to leave residuals and create potentially harmful by-products. Other chemicals, caustics, and acids are used in the CIP process also. All of these have challenges with storage, handling, and transportation that has increasing regulation. These factors along with rising costs have broadened the use of ozone in many applications.

For information on ozone use in CIP processes, or any other application, call our application engineers today.