Microbial contamination in the food, health, and consumer product industries has become a critical issue for manufacturers, consumers, and regulators.  Aseptic manufacturing approaches aim to ensure everything is sterile at the the time the final package is sealed to the outide world - ensuring that at the time the package is opened, there is no microbial contamination on the product.  This approach relies on reliable and cost effective technologies for sterilizing the incoming product, the incoming packaging material, the incoming ambient air, as well as critical sufaces of machinery.  AEB has active solutions for sterilizing packaging components as we have discussed in past blog entries (Aseptic Drug Manufacturing, EB sterilization for Beverage Industry).  We see signficant opportunity to address the challenges of critical surface sterilization as well.

The challenge arises from the difficult nature of controlling and ensuring sterility on all pieces of equipment that come in contact with the products.  While some surfaces are easily accessible for sterilization, others may be out of reach or difficult to access.  For instance, last year, a Massachusetts listeria outbreak was traced to a key piece of equipment used in the filling process.

The conditions in processing facilities, especially ones carrying out wet processes, are favorable environments for bacteria growth and attachment.  The complexity of processing equipment creates difficult-to-clean nooks and crannies that are perfect spots for bacteria growth that can escape sanitizing treatments.  Once bacteria attaches to surfaces, it is often very difficult to remove it completely using normal cleaning and sanitation procedures.

Currently, high temperature chlorinated water or various chemical sterilants are used to sanitize processing and aseptic packaging equipment.  Although effective, the practice has some significant disadvantages, including: the potential for the formation of toxic or carcinogenic compounds; the energy intensive nature of the process due to heat requirements; the persistence of chlorine in the environment after usage; and the requirement for special containers for transportation and storage of chlorine compounds. 

Electron beam technology has proven to be a safe and effective method for sterilization.  Novel configurations of electron beams can be leveraged to ensure sterility of problem areas of equipment.

 Let us know if you have specific ideas for critical surface sterilization you would like to discuss.