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) Catholyte (-ve) Water In

Internal View- Electrolytic cells Ceramic Brine flows into both membrane splits chambers, current is FEM into 2 passed between chambers anode & cathode Ceramic membrane is impermeable to non charged compounds Cathode Anode Anolyte Catholyte

Catholyte (-) vs. Anolyte (+) Catholyte (-) Anolyte (+) Reducing solution ( gets oxidised) Oxidizing solution (gets reduced) Potent anti-oxidant Range of natural mixed oxidant radicals (ORP> -900mV) (ORP < +1000mV) pH range 9.0 to 12.0 pH range 2.0 to 9.0 Cleaning / Detergent Microbiocidal / disinfectant Activated products: Na + ,OH - , H 3 - O 2 - , H 2 , HO 2 - Activated products: ClO 2 , Cl 2 O, Cl - , ClO, - HClO , O 2 , O 3 , H 2 O 2 , OH - , HO 2 , O 2 Properties: Emulsification, Peptisation , Properties: Diverse range of disinfecting Saponification, Dispersant, Free rinsing, applications, Eliminates microbes “electrically”, No resistance capacity, Non-corrosive, Buffering 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

Biofilm Centrifuge funnel – before CIP Centrifuge funnel – after CIP

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

Conventional 5 step procedure - Beverage 85°C 65°C 85°C >65 °C 20°C Pre-Rinse Caustic 2% Rinse Hot water 85 ° c Final rinse 5min 15 min 5min 15min + 30 min

Radical Waters ECA 4 step procedure - Beverage 85°C 65°C 45°C 20°C Anolyte Pre- rinse Catholyte Final rinse 10 min 5 min 10 min 5min

Radical Waters ECA vs 5 step procedure 85°C 65°C Energy Chemical saving 45°C Water saving 20°C Time saving (+60min)

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 m 2 depending on the size – of 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 •