USE OF UV REACTORS FOR WATER AND SUCROSE DISINFECTION IN THE JUICE AND BEVERAGE INDUSTRY
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1 USE OF UV REACTORS FOR WATER AND SUCROSE DISINFECTION IN THE JUICE AND BEVERAGE INDUSTRY Doug Yedwabnick Director of Sales Atlantium Technologies Ltd.
2 How Good is your Tapwater For Drinking? 10 to 42% of drinking water groundwater supply wells contaminated with enteric viruses in the U.S. (Reynolds et al 2007) 95% of all individual and small groundwater systems violate one or more primary and secondary drinking water standards in AZ (Marrero-Oritiz et al 2009) It is estimated that tapwater in the U.S. results in 19,500,000 cases of illness per year. (Reynolds et al 2008)
3 How Good is the Tapwater for Food Processing? City Water treatment plants cannot remove 100% of the pathogens 100% of the time. Rainfall events have the biggest impact on performance of drinking water treatment plants. Biofilm build-up occurs in all distribution systems can release of microbes into the distribution system Not very good, especially if you don t have broad spectrum disinfection up front inside your plant.
4 The starting point :does it make a difference? Water critical to industrial processes, but taken for granted. I am ok I use municipal water! EPA rules allow Public Water Suppliers some flexibility You must have more exacting standards to protect your product How can you: Prevent contamination (Much less expensive to the bottom line) Reduce variability and risk Protect the brand Traditionally chemicals Wed: have been the answer but organisms have adapted Sun: Tue: Thu: and will Preliminary Fri: Sat: continue Testto adapt! Retest Mon: No Test Downey Boil Water Order Sept 2008 Results Final Results Mon: Order Announced
5 New Coliform Rule Effective in 2012 Will not require public notification if coliforms found in the distribution system. Only for the presence of actual E. coli
6 Occurrence of bacteria in chlorinated distribution systems Bacillus spp. 4.9% Acinetobacter spp. 5.0% Pseudomonas spp. 13.2% Aeromonas app. 9.5% Citrobacter freundii 1.7% From LeChevallier et al.
7 Determining the Water Safety Risks Municipal vs. Private Supply: How the Risk Assessment & Rules Differ Municipal Water Rules designed to minimize risk of exposure to <1 illness per 10,000 exposures. Average user drinks.5% of water consumed Rules are per service connection sampling, etc. 95% of the water supplied to the users must be on-spec Public notice if off spec goes above 5% or bad sample Public Notice rules expected to change in 2012 Private Supply Rules follow your standards, local health authority, state or PMO PMO sampling rules equivalent to municipal systems with < 25 service connections Indicators show pathways; simply treating for good samples means trouble later Equates to protection for drinking level exposure of <10 illnesses per 100,000 gallons withdrawn Need to accurately assess water safety risk: consider intake & uses
8 Accurately assess water safety risk for plant intake water Types of Risk In process contamination Carbon beds and other filters can be optimum niches for microbial growth Untreated water hoses for cleaning; Storage water tanks, especially without HEPA filters Heat exchangers with pinhole leaks Pipe dead legs Ice chillers and cooling processes RO membranes Post process contamination Pipe Biofilms Flushes for post-pasteurization pipes to the fillers Case washer CIP Etc.
9 How to accurately assess water safety risk for product contact uses Different levels of Risk: Ingredient water Product waters CIP Consider Survivability of microbes of interest in your environment: Food pathogens--salmonella, listeria, crypto, viruses Spoilage organisms (pseudomonas, algae) Biofilm formers(pseudomonas) Endotoxin producers
10 Main Applications for UV For Water Disinfection Chlorine replacement Membrane Protection Post RO Final Protection Chlorine replacement Post Carbon Final Protection Ozone Replacement /Destruction
11 Medium Pressure High Intensity Vs. Low Pressure
12 Important parameters for UV Disinfection Type of UV lamps: LP Vs. MP Level and type of microbiological contamination Dose Distribution and real delivered RED Lamp Output & Water UVT Flow Rate RED: Reduction Equivalent Dose
13 UV Measurement is key Speed of light disinfection, no waiting In-line. On demand. Disinfected or pasteurized water Continuous monitoring Non-chemical disinfection, no off taste, no residual byproducts and no corrosion. Minimum dose, not average dose Built-in alarm & divert; prevents untreated water entering production line Comprehensive control assures the delivered dose Continuous monitoring What you can t measure, you can t control. What you can t control, you can t rely on.
14 Required UV doses for Disinfection
15 Low pressure Vs Medium pressure Lamps LP: Single wavelength: 254nm => Single effect: DNA protein crosslink (dimers) microbes can t reproduce but can recover. MP: Wide UV spectrum => some microbes are more susceptible to some wavelengths => Many modes of action: DNA protein crosslink (dimers) microbes can t reproduce + Enzymes disabled + Mitochondria and RNA damaged microbes can t recover LPHO ; 1.5W/cm cm MPL ; 200W/cm 10cm Same power consumption 16 times more lamps 16
16
17 Example of Post Carbon Bed contamination in a Drink Plant
18 Traditional Reactor: Flow parallel to the lamps
19 Total internal reflection operation principle (as in optical fibers) Unique Optics and Hydraulics to achieve unprecedented performance
20 Principles of Operation : Lamp out of water with hydro-optic disinfection system No chance of Mercury or Quartz breakage in water WATER Reflector MPHI* UV Light Source Air Block Quartz Tube Air Cooling AIR AIR AIR AIR UV Intensity Sensor Quartz Window UVT Analyzers * Medium Pressure High Intensity 21
21 Uniform dose distribution Reflective coating (back surface) MPHI* UV Light Source Air Space Quartz Tube UV Intensity Sensor UV Transmittance Analyzer(UVT) * Medium Pressure High Intensity
22 Traditional Reactor: No lamps output measurement No Water transmitttance measurement UV intensity can be measured only on single points (PSS) and does not the reflect the real action of the entire reactor
23 Hydro-Optic Disinfection Lamp output + Water UVT measured => On line Real Dose UV Intensity Sensor UV Transmittance Analyzer(UVT)
24 What You See is What You Get Water receives at least the minimum validated RED (Reduction Equivalent Dose) and not an average dose. Required validated dose (120) + a safety margin Actual delivered dose
25 Third Party Validation assures reliability Typical Validation achieved with Third Party 1. Basic EPA Crypto and Giardia 2. EPA 4 log Adenovirus 3. Pasteurized Equivalent Water under the FDA (Pasteurized Milk Ordinance)
26 log CFU/10ml Post Carbon Bed Results Total count at post GAC sampling point 1.00E E E+03 Total count Regulation <250 CFU/10ml 1.00E E E+00 date GAC OUTLET/ATL IN ATL OUT Sunday GAC CIP Last weekly GAC CIP Accurate monitoring and real-time control
27 Water Safety with MP Hydro-optic Disinfection UV Process water disinfection High microbial inactivation without chemicals validated full scale For rinse, wash down and CIP applications Effective against chlorine-resistant pseudomonas strains Primary product water disinfection Inactivates pathogens and spoilage microorganisms that challenge dairy production: pseudomonas, viruses, cryptosporidium, spore formers, molds, algae Chlorine replacement Chemical-free alternative for treating source water Fully validated to comply with state and federal EPA requirements No carcinogenic or other regulated disinfection by-products Inactivates viruses and heat-resistant spores No residual taste and smell No pipe corrosion issues Post active carbon (placed immediately after carbon filter) Protects against microbe breakthroughs and reduces bio-fouling downstream Reduces demand for frequent and aggressive cleaning
28 Sucrose Solutions UV Transmission through sucrose solutions is critical for effective disinfection. A good example of this is a 67 Brix solution has a UVT of 40%. Most Yeasts are easily disinfected with small doses of UV. Heat resistant molds can also be disinfected with UV. In most cases, since the UVT is low generally continuous recirculation of a tank is most effective. This means with both the tank inlet and outlet going through the UV unit as well. Effective vent filtration is required. Effective UV treatment can extend shelf life of a product by eliminating spoilage by microorganism contamination.
29 Many Thanks for your attention And our partner Questions?
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