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Ozone cip

Author(s): a tool to reduce the environmental impacts of cleaning and disinfection in food industries
Congress: 2008
Author(s): A. Pascual
A. Canut. Technician of the Quality, food safety and environment departmentof the Research Association on Food Industry (ainia). A.Pascual. Head of the Quality, food safety and environment departmentof the Research Association on Food Industry (ainia)

Keyword(s): ozone, sanitation, cleaning and disinfection, wastewater, food industry, cip
AbstractIntroduction The need to keep high hygienic standards is a main concern in the food processing industry. Most care areas rely on a range of chemicals (chlorine, quaternary ammonium compounds, bromine or iodine products…) to maintain an acceptable hygiene regime. Sanitation in food industries has significant environmental considerations as frequent cleaning is required and this uses water intensively along with chemicals. This will cause a significant environmental impact in terms of water consumption, wastewater production and energy consumption if hot water is required. Some of the most important cleaning tasks are those related to the washing of process vessels, tanks and pipes where Cleaning In Place (CIP) systems are of common use. CIP are characterized by automatic cleaning programs based on a succession of several solutions of water, cleaning chemicals and disinfection agents that are discharged into sewer systems together with large amounts water necessary to rinse out residual chemicals. Typically, cleaning and disinfection wastewaters contain organic material, FOG, SS, nitrate, nitrite, ammonia and phosphate from product remnants and removed deposit soil. Moreover, when chlorine based compounds combine with organic residues the results could potentially be extremely harmful to people. So health and environmental concerns with chemical use on food products or food contact facilities are supporting the need for alternative sanitation technologies. Ozone might play an advantageous role in CIP operations as an alternative to other sanitizers. CIP with ozone-enriched water has the potential of replacing chemicals and hot water rinses with several potential environmental advantages: water saving; faster disinfection; water re-use possibilities; as ozone is not stored it removes the need to store hazardous chemicals; ozone conversion oxygenate wastewater effluents, so its use will improve the performance of aeration tanks and biological wastewater treatment processes; energy saving, as it is used at low temperatures;etc. Objective The project is a demonstration project that aims to contribute to the achievement of a reduction in the environmental impact of the sanitation operations carried out in the food industry through an innovative sanitation technique based on the use of ozone as an alternative sanitizing agent to other sanitation systems commonly used. Methods The project will last for 3 years (December 2005 to December 2008). The demonstration activities will focus on CIP protocols in three key beverage sectors: brewery, winery and dairy. The project tasks are: A. Preliminary actions. Specific studies on ozone technology, CIP techniques and perform environmental diagnosis of cleaning operations. B. Ozonecip prototype. to simulate conventional CIP processes and essay alternative processes based in ozone C. Demonstration activities. Simulation of protocols comparing the environmental results obtained when performed with and without ozone. D. Evaluation. Water and chemicals consumption, hygienic results, wastewaters E. Dissemination Tasks A and B have been already covered and task C is ongoing. Results As a result of task A several thematic studies have been produced (Study of cleaning and disinfection according to theBREFs; Study of Clean in Place (CIP); Study of the ozone technology; Study of non-environmental driving forces and Environmental Industrial diagnosis of sanitation operations in collaborating companies where samples and analysis of in process wastewaters has been performed. The output of Task B consists on the design and installation of the pilot plant where the comparative trials will be performed. The expected results of the ongoing tasks (Tasks C) are related to obtain indicators that show the differences between conventional and ozone based CIP operations in terms of water consumption, energy consumption, pollution in wastewaters, and evaluation of cleaning and disinfection efficiency of alternative systems. Conclusions Sanitation is a key operation within food industries. Actual practice in industry on CIP systems has been analysed in real companies that have collaborated. Environmental data of in-process operations related to sanitation has been collected that confirms that the impact of such operations is significant although the actual practices employed in each particular company plays an important role on the degree of pollution discharged. All companies agree on the need to seek less time consuming protocols along with the need for a reduction in water and chemicals consumption that would mean a reduction in the environmental impacts. The revisions made on CIP techniques and ozone technologies show that an integration of the technologies would be easy and feasible, adopting safety measures to prevent any hazards arisen by the use of ozone and considering material compatibility of installations with ozone, what is not a serious problem as the considered facilities are made of stainless steel 316. Ongoing tasks should demonstrate the extent in which the potential environmental benefits improve the actual impacts of conventional CIP protocols. Project Consortium Ainia - Instituto Tecnologico Agroalimentario (Spain, OZONECIP Project coordinator), Umweltinstitut des Technologie-Transfer-Zentrums Bremerhaven (Germany), Gdansk University of Technology (Poland), Allied Domecq bodegas (Spain, wine processing), InBev. (Germany, beer processing) and Meierei- Genossenschaft e.G. Langernhorn (Germany, dairy processing) Acknowledgements The OZONECIP project is co-funded by the European Union’s Life Environment Programme, EC contribution 394,924.00 € (LIFE 05 ENV/E/000251).
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