Beverage Industry – Improvement of hygiene through filler spraying, tank and bottle disinfection

NADES permanently enhances the quality of well water and brewing water. Process reliability is increased by direct bottle and tank disinfection with NADES – without rinsing – or by germ-free NADES rinsing water (CIP). NADES replaces hot water filler flushing , ensuring that production does not need to be interrupted. It is no longer necessary to heat up the filler flushing water – this reduces energy consumption and protects the environment.

NADES maintains the microbiological quality of pasteurizing water at the level required by the European Drinking Water Ordinance and prevents the retrograde contamination of the final product.

Suitable for use in the filling of sensitive mineral water

At a leading beverage manufacturer, the use of NADES for surface disinfection of a bottling plant of still mineral water was investigated with regard to germ reduction. In the course of the practical application in a beverage plant, the hygiene of the filler surface was significantly improved when NADES was used for permanent spraying. During beverage filling, NADES was permanently sprayed on the filler. At the same time, the conveyor belts were sprayed.

Goal: High output, low costs, perfect hygiene

The declared aim of the beverage industry is to achieve the largest possible production window possible, together with more or less short cleaning times, i.e. filling many bottles in a short time. If the time between the cleaning intervals is extended and the cleaning duration shortened at the same time, the number of filled bottles is significantly increased. Of course, the focus continues to be on material compatibility and employee safety, not forgetting the sterility and shelf life of the filled product.

Task: Permanent spraying during the filling of a natural mineral water according to mineral and table water regulations.

The following parameter were used as the basis: It concerns the filling of non-carbonated (still) mineral water in plastic bottles (PET). The bottle filling machine was an enclosed area, but not suitable for aseptic filling. The capacity of the filler was 20,000 bottles per hour. Daily disinfection and weekly CIP and exterior cleaning of the filler took place before the changeover to NADES spraying.

The customer had the following requirements:

• Daily intermediate disinfection is no longer necessary in order to gain filling times.
• Increase in capacity utilization
• At least 72 hours production of non-carbonated, still mineral water without intermediate disinfection
• Improved microbiological results

NADES was dosed in proportion to quantity with a motor dosing pump. The continuous monitoring of the active substance concentration took place by means of online measurement with reporting to the higher-level control station.

Approx. 30 flat jet nozzles were installed on site at all microbiological critical points (HACCP) together with the customer and optimized during the test run. Particular attention was paid to areas with direct product contact. At places where the NADES solution could get into the open bottle, the spraying was permanently checked very critically.

Legally secure

Upfront, an expert opinion proved that the use of a NADES solution was in line with the Mineral and Table Water Ordinance.

No sensory impairments

The question was whether there would be sensory impairments when using a NADES solution. Therefore, comparative tests of contaminated versus unpolluted reference samples were carried out in two different laboratories with six respectively 20 test persons. No sensory differences were found.

No formation of questionable reaction products

The following reaction products may be important: trihalomethane, chlorate, chlorite, bromate and bromide. Before the use of NADES and during validation, SGS Fresenius continuously performed analytical tests. None of these substances could be detected in the concentrations used. Furthermore, no chlorinated acetic acids were found in connection with the material of the PET bottle.

The permanent spraying of the filler surface with NADES leads to a significant improvement in hygiene.

NADES guarantees

1. perfect hygiene
2. the associated product shelf life
3. material compatibility

The customer’s requirement for a high number of filled bottles was successfully met. Due to the additional savings, the process described above works extremely efficiently and cost-effectively with the aquagroup system.

Conclusion

After acceptance by SGS Fresenius the following can be confirmed:

The use of NADES for filler spraying significantly improves the microbiological situation. It represents a complete replacement of intermediate disinfection. Cleaning takes place once a week, filling 24/7. There is no impairment of the product. In addition, there is a saving of time and personnel as well as savings of disinfectants for daily intermediate disinfection.

The significant increase in capacity utilization led to an increase in production per month: 250,000 bottles and this with the safe filling of sensitive still mineral water. In beverage bottling plants, NADES offers the ideal solution for maintaining the desired hygiene.