Optimizing Process water – disinfection generated in-situ – microbiological safe

Water is often used as process water (starting or auxiliary material) in the production of pharmaceuticals and cosmetics as well as for cleaning CIP systems. As a result, high demands are placed on its quality, which are, however, difficult to meet, especially with regard to microbial contamination. Water-bearing systems tend to form biofilm and can become a source of dangerous pathogens such as legionella and pseudomonas, which makes it necessary to use effective disinfection methods. However, a lot of germs have already developed resistance to common chemical solutions. Also, thermal disinfection often does not lead to the desired success.

Water systems belong to the essential components of pharmaceutical and cosmetic production. However, since a wide variety of contaminants – such as particles or microorganisms – can occur, suitable treatment processes must be applied. For example, biofilm can form in all systems in which water is used. A symbiotic community of different bacteria that support each other and are protected by a layer of extracellular polymeric substances (EPS). This biofilm ensures, among other things, ideal conditions for the growth of Legionella pneumophila and Pseudomonas aeruginosa, which can pose a serious health risk. Therefore, strict control is essential to ensure a high quality of water and to reduce the risk of microbial contamination of the products.

Application in the cosmetic sector

In the cosmetics sector, NADES 2.0 is used primarily for drinking and process water sanitation, for the disinfection of mixers (CIP) and filling lines. In this context, process water also includes the water used to manufacture cosmetic products. As a result, an increased product safety can be achieved. The application concentrations of NADES 2.0 in the cosmetics industry for drinking water applications are within the scope of the Drinking Water Ordinance. Higher concentrations are used in the disinfection of mixers and filling lines. The objectives are to improve the microbiological situation and potential time savings in cleaning. Thus, it is possible to increase the production volume. Furthermore the use of NADES 2.0 improves the product stability.

No formation of resistance with NADES 2.0

First of all, thermal disinfection is used for this purpose. Also, biocides such as peracetic acid are used to kill the microorganisms and reduce biofilm formation. The bacteria present in the biofilm often form resistances to conventional disinfection methods and agents. NADES 2.0 is one of only a few effective alternatives to these common but increasingly ineffective methods. It is active chlorine generated from sodium chloride by electrolysis (electrolysis-based sodium hypochlorite).

Furthermore, it has been proven to have a bactericidal effect against

• Pseudomonas aeruginosa
• Legionella spp
• Escherichia coli
• Listeria monocytogenes
• Salmonella entercia
• Staphylococcus aureus
• Enterococcus faecium.

NADES 2.0 leads to a reduction of biofilm in water-bearing systems and prevents its rebuilding. In other words, NADES 2.0 degrades EPS through continuous feeding. Because, on contact with organic matter, active chlorine (sodium hypochlorite (NaOCl)) reacts off. The micro-organism finally dies if the concentration or exposure time is appropriate. It has a broad spectrum of activity for which no resistance is currently known to develop. For this reason, it reliably minimizes the risk of the product being affected by contaminated water. The use of the biocide for the disinfection of production lines or CIP systems also prevents cross-contamination. NADES 2.0 is automatically generated on-site from salt, water and electricity. Consequently, the risks and costs associated with the transport, storage and handling of hazardous chemicals in conventional water treatment are eliminated.

Automated dosing and feeding

The integration into the system on site is carried out by an automated, volume-proportional dosing. NADES 2.0 is dosed into the water by means of a pump via an injection point. Dosing is according to the specified set point or flow-controlled. A safety shutdown in case of overdosing is possible in all cases. Monitoring can be carried out via an online measuring system, which can be installed as an option. To monitor the feed and control the dosing of NADES 2.0, aquagroup uses chlorine or redox measuring probes, depending on the project-specific conditions. They constantly measure the active ingredient content. This prevents overdosing or underdosing.

To ensure the microbial quality of pharmaceutical and cosmetic products, NADES 2.0 is suitable for treating drinking and process water. Also, for disinfecting production lines, CIP systems, containers (IBCs or tanks) and plant components. Here, the application concentration can be adjusted according to changes in the microbiological state of the water system or product line.

No canister goods, no manual dosing

In addition to the broad spectrum of activity against microorganisms, a major advantage of NADES 2.0 is that, unlike most other biocides, it is not a hazardous substance.

Measures such as the wearing of protective clothing or the use of specially trained personnel are not necessary with the in-situ production of NADES 2.0. This significantly increases occupational safety. In addition, the typical transport and storage costs that have to be incurred for hazardous substances such as hydrogen peroxide, peracetic acid or alcohol – which are delivered in canisters – are eliminated. The operation of an ECA generator is significantly less cost-intensive, since all three operating resources – salt, water and electricity – are inexpensive and available worldwide. In addition, conventionally produced NaOCl can form harmful chlorate during storage or the concentration of active ingredients can be reduced on site, for example during transport or environmental influences – dangers that also do not exist due to the just-in-time concept of NADES 2.0.

Furthermore, on-site generation and automated feed eliminates the “human factor”, i.e. the risk of errors during mixing and manual dosing. All in all, the automation of the processes enables significant time savings compared to conventional methods.

Since aquagroup manufactures the devices itself, the generators can be designed specifically for the respective application. The messages from the ECA generator, for example, can even be displayed or visualized on the user’s control room.

The very good microbiological effectiveness, the reduction of biofilm and the fact that NADES 2.0 – in contrast to conventional sodium hypochlorite – is neither a hazardous substance nor a dangerous good are just some of the advantages. Furthermore, in-situ production, i.e. on site, avoids the transport, storage and disposal of canisters. We therefore offer clean drinking water and employee safety combined with microbiological safety plus sustainability.