Beverage Industry ECA CIP FOR BEVERAGE INDUSTRIES Introduction to - - PowerPoint PPT Presentation

What is ECA and how does it work? Beverage Industry

ECA CIP FOR BEVERAGE INDUSTRIES

Introduction to ECA

• ECA = Electrochemical Activation of water
• Innovation separates & harvests two distinct component streams

converting water into an environmentally friendly disinfectant and cleaning agent

• Anolyte
• Catholyte

ECA: The Technology

Anolyte (+ve) Water In Catholyte (-ve)

Anode Cathode

Catholyte Anolyte

Ceramic membrane splits FEM into 2 chambers Brine flows into both chambers, current is passed between anode & cathode Ceramic membrane is impermeable to non charged compounds

Internal View- Electrolytic cells

Catholyte (-) vs. Anolyte (+)

Catholyte (-) Anolyte (+)

Reducing solution ( gets oxidised) Oxidizing solution (gets reduced) Potent anti-oxidant (ORP> -900mV) Range of natural mixed oxidant radicals (ORP < +1000mV) pH range 9.0 to 12.0 pH range 2.0 to 9.0 Cleaning / Detergent Microbiocidal / disinfectant Activated products: Na+,OH-, H3

• O2
• , H2, HO2
• , O2
• Activated products: ClO2, Cl2O, Cl-, ClO,

HClO, O2, O3, H2O2, OH-, HO2 Properties: Emulsification, Peptisation , Saponification, Dispersant, Free rinsing, Non-corrosive, Buffering Capacity Properties: Diverse range of disinfecting applications, Eliminates microbes “electrically”, No resistance capacity, Broadspectrum, Safe, Non-staining, Easy to use, Removal of biofilms.

ECA: Mode of Action

• The Anolyte water molecule (high +ve

ORP) scavenges the electrons from the microbe surface.

• Alters the cell wall structure (proteins)
• Ineffective cell regulation
• Resulting in cell death through leakage

and eventual lysis.

• Dual mechanism – also chemical (HOCl)

ECA Microbial Efficacy

Biofilm control with ECA

• Initial clean with Catholyte

– Strip existing biofilm effectively

• Sterilization of piping with Anolyte

– Ongoing control of biofilm due to addition of Anolyte – Constant reduction of micro-organisms

• Affects ability of organisms to adhere due to electrostatic

interactions

• MINIMISED BIOFILM FORMATION & REDUCED

DOWNTIME

Centrifuge funnel –before CIP Centrifuge funnel –after CIP

Biofilm

Safety - Toxicity

• Acute toxicity – LD50 > 20gm/Kg
• Dermal, Ocular, Oral sensitization – Nil
• Occupational exposure limits – Nil
• Health Hazard – Nil
• Specialized handling materials/equipment – Nil
• Non allergenic, non sensitising
• No residues
• Dental applications – root canals
• Human tissue culture in Anolyte & Catholyte

“Essentially a replicate of the mammalian inflammatory response”

Certifications & Approvals

• USA FDA has approved it as an advanced level disinfectant (2002).
• USA FDA approval for use in food processing facilities (1996).
• Kosher & Halaal approved.
• CE Certified – Conforms with European Union manufacturing standards (2008)
• South African Department of Health – solutions have been approved for the treatment of foodstuffs for

human consumption.

• SABS 241:2005 – a 1:10 dilution of the Anolyte solution complies with the requirements for potable/

drinking water standards.

• SABS 1827 & 1828 – Both Anolyte and Catholyte meet the requirements for use in food processing

facilities.

• SABS 1853 – meets the requirements for the use as a detergent-disinfectant (Act

29GNR529/212843/072/769) – Bactericidal, Fungicidal & Virucidal.

• SGS South Africa (Pty) Ltd – Complies with the requirements of a safe organic disinfectant with no

harmful residues.

• Coca-Cola protocols for Concentrate Plants, Carbonated Soft drink and Water as a replacement of

traditional chemicals by RW ECA – variously applied in 21 countries to date

• Successful trials completed in March 2010 with SABMiller for use in CIP of brewing bottling plant

Radical Waters Devices Sold

• First RW international installation was 4 years ago
• Roll out has accelerated since 2010
• Installed on 6 continents & greater than 50 sites = market leader

Radical Waters Distribution Expansion

• Distribution network initialized in 2009 to facilitate service enhancement
• Currently finalizing in Canada, Kenya , Australia & Philippines

85°C

65°C 85°C

>65 °C

Pre-Rinse Caustic 2% Rinse Hot water 85°c Final rinse 20°C 5min 15 min 5min 15min + 30 min

Conventional 5 step procedure - Beverage

65°C 85°C 20°C Final rinse 5min Pre- rinse 5 min 45°C Catholyte 10 min Anolyte 10 min

Radical Waters ECA 4 step procedure - Beverage

65°C 85°C 20°C 45°C Energy Time saving (+60min) Water saving Chemical saving

Radical Waters ECA vs 5 step procedure

CIP Steps and Time

• Standard 5-Step CIP with reclaim - 27 Minutes

– Treated Water rinse 2 minutes Dump to drain – 20% Catholyte 2 minute Dump to drain 8 minutes Recovery – 20% Anolyte 2 minutes Dump to drain 8 minutes Recovery – 3% Anolyte rinse 5 minutes Dump to drain

• Standard 3-Step CIP with reclaim - 17 Minutes
• Treated Water rinse

2 minutes Dump to drain

• 20% Anolyte

2 minutes Dump to drain 8 minutes Recovery

• 3% Anolyte rinse

5 minutes Dump to drain

Results – total saving of 95%*

• Substitution of chemicals without adverse effect or efficiency sacrifice
• Overall reduction in CIP time by 47% compared with approved chemical

CIP protocol

• Reduction in water usage by 83%
• Reduction in chemical costs by 95%
• Reduction in energy usage by 98%
• Consistent broad spectrum high level microbial control
• Rapid and consistent residual flavour neutralisation
• Enhanced biofilm control
• Improved effluent management

* - site dependent – above figures from existing site as determined in post implementation review

ECA from Radical Waters

• System integrates completely in any plant
• Production on site:

– Required space ≈ 60 to 80 m2 depending on the size

• f the concentrate and mixing tanks
• A Complete Solution:

– Production unit – Mixing system – Pumps – Integration with existing CIP system

• Solution as a service:

– All the above plus support and maintenance including reactor replacement every 5000 hours.

Industrial Device Models

• IND 12 S1
• 200 L/H Anolyte - 40 G/H FAC
• 50 L/H Catholyte
• IND 24 S1
• 400 L/H Anolyte - 80 G/H FAC
• 100 L/H Catholyte
• IND 36 S1
• 600 L/H Anolyte - 120 G/H FAC
• 150 L/H Catholyte
• IND 48 S1
• 800 L/H Anolyte - 160 G/H FAC
• 200 L/H Catholyte
• IND 60 S1
• 1000 L/H Anolyte - 200 G/H FAC
• 250 L/H Catholyte
• IND 72 S1
• 1200 L/H Anolyte - 240 G/H FAC
• 300 L/H Catholyte

Intermediate (Small) Device Models

• SML 8 S1
• 135 L/H Anolyte - 26 G/H FAC
• 35 L/H Catholyte
• SML 10 S1
• 165 L/H Anolyte - 33 G/H FAC
• 40 L/H Catholyte
• SML 12 S1
• 200 L/H Anolyte - 40 G/H FAC
• 50 L/H Catholyte
• SML 24 S1
• 400 L/H Anolyte - 80 G/H FAC
• 100 L/H Catholyte

Radical Waters Mix System

• Automatic mixing system, using concentrate Anolyte &

Catholyte and combines with treated water to dilute solutions into any ratio (%) required

• On-site ready to use CIP solutions
• Volumetric mixing system with optional conductivity

reference

• PLC Interface – Programmable Logic Control
• Model 1 - RWM 20/20
• 20% Anolyte
• 20% Catholyte
• Model 2 - RWM 20/20/3
• 20% Anolyte
• 20% Catholyte
• 3% Anolyte (CIP Final Rinse)

ECA from Radical Waters

• RW IND device
• Concentrate

tanks

• Self contained

salt & water tank

• Mix system to

supply from Concentrate tanks to Dilute tanks

• One of the Dilute

tanks

Protocol for 3 Step

• Both ECA 3 step and ECA 4 step has been tested on both

tanks and the filler and the final cycles are:

– ECA 3 step:

• Rinse with treated water: 5 min
• Blow: 90 sec
• Drain: 60 sec
• Wash with Anolyte: 10 min from EC>0,8mS on drain
• Blow: 90 sec
• Drain: 60 sec
• Final rinse: 3 minutes from EC < 0,6 mS on drain
• Blow: 90 sec
• Drain until flow < 10 g/min

Protocol for 4 step

– ECA 4 Step:

• Rinse with treated water: 5 min
• Blow: 90 sec
• Drain: 60 sec
• Wash with Catholyte: 10 min from EC>0,8mS on drain
• Wash with Anolyte: 10 min from EC>0,8mS on drain
• Blow: 90 sec
• Drain: 60 sec
• Final rinse: 3 minutes from EC < 0,6 mS
• Blow: 90 sec
• Drain until flow < 10 g/min