Disinfection of process water & drinking water systems | Case Study

An introduction to the case study

Water pollution has escalated due to the growing population, improper water management and environmental changes caused by human activity making most of our water sources unsafe for consumption. The inefficiency of many current disinfectants to eliminate all pathogens in the water treatment and distribution systems requires a new approach.

The properties of an effective disinfectant are as follows:

Broad anti-microbial ability at ambient temperature within a short contact time.
It should not generate any harmful by-products during or after use.
The disinfectant itself should not affect human health.
Inexpensive and easily applicable for the intended use.
Easy to store, highly soluble in water and must not be corrosive for any equipment or surface.
Amenable to safe disposal.

Sinowatek offers the INNOWATECH Aquadron® system which provides a very powerful disinfectant INNOWATECH Anolyte® tradename Sulafect^TM which has the above-mentioned properties.

Sulafect^TM is a disinfectant where the concentrate is produced exclusively from drinking water, electricity, and high purity salt and therefore it is safe to handle, easy to store and have no harmful by-products.

The active ingredient in Sulafect^TM, hypochlorous acid (HOCL), kills a multitude of pathogens which are harmful to humans, animals, and plants. The HOCL tear down the pathogens cell membranes and envelope their proteins in a very short time.

INNOWATECH Anolyte® is manufactured in an electrolysis cell in the neutral pH range of 6.7 to 7.2 preventing the formation of Cl2 micro bubbles and therefore it is non-corrosive to water supply or production equipment.

We can install a cost-effective Innowatech Aquadron® station for a client as part of a process or Sulafect^TM disinfectant can be supplied as a liquid product to disinfect drinking water, treat waste / process water for release or re-use.

Technologies used

Water disinfection technology

Service used

Water disinfection services

Look at how we deal with the followingchallenges:

CIP system water treatment

Clean-In-Place (CIP) systems are automated systems used to clean the interior surfaces of food and beverage process equipment, without disassembling the equipment. During the sanitizing rinse of the cleaning process disinfectants are used to kill germs in the system.

The cleaning and disinfectant agents in conventional CIP stations are expensive and the CIP process requires a significant time and effort. The cleaning and disinfectant materials are subject to rigid safety regulations for storage, handling, and disposal.

These agents kill germs aggressively while impacting the life of pipes and valves. Proactive thermal disinfection as an alternative to chemicals is also time-consuming, energy intensive and not always effective.

Sinowatek offers the INNOWATECH Anolyte® tradename Sulafect^TM as an efficient disinfectant for CIP systems.

Using the Sulafect^TM disinfectant in CIP plants give rise to high disinfection activity. Individual programme steps such as acid treatment after the main cleaning step and the freshwater rinse after disinfection can be eliminated.

The Aquadron® systems and the active agent, INNOWATECH Anolyte® (hypochlorous acid), have already proven reliable in a variety of industries over an extended period.

Disinfection of hydroponic water

Hydroponics is the practice of growing plants using only water, nutrients, and a growing medium. Automated nutrient solution systems form part of the hydroponics to enable controlled dosing of water and nutrients for each plant. Unfortunately, these systems are susceptible to fungal and root diseases caused by microbial growth.

Applying a disinfectant to the nutrient solution can combat the microbial growth significantly, however most effective disinfectants for hydroponics can also be toxic to the plants used for the hydroculture.

Another problem is biofilm that form which can block parts of the irrigation system while sheltering pathogens and cause crop failure. It Is known that biofilm are excellent reservoirs for bacteria and fungi that can harm the root systems of the plants.

INNOWATECH Anolyte® (tradename Sulafect^TM) is a very powerful disinfectant where the concentrate is produced exclusively from drinking water, electricity, and high purity salt. Sulafect^TM possess very high bactericidal, virucidal and fungicidal activity (about 10 times stronger than chlorine dioxide).

The most important advantage of the disinfectant is that it is manufactured within an electrolysis cell in the neutral pH range of 6.7 to 7.2. In this pH range, the proportion of hypochlorous acid, the substance necessary to kill germs, is over 85% while preventing the formation of Cl2 micro bubbles.

The active ingredient in Sulafect^TM, hypochlorous acid (HOCL), kills a multitude of pathogens. For example, pythium infested hydroponic systems can effectively be treated by using Sulafect^TM in the nutrient solution.

Bacteria find a well-protected habitat in the slimy biofilm deposits in the pipe systems of hydroponics. By using Sulafect^TM in the irrigation system, the biofilm is destroyed along with the bacteria that might be harboured by the biofilm. This wholly “organic”, disinfectant, not harmful to plants, will ensure healthy hydroponic systems.

Disinfection of drinking water systems

INNOWATECH GmbH has a well proven experience in drinking water treatment and already installed more than 200 Aquadron® systems (membrane cell electrolysis systems) in hospitals, retirement- and nursing homes, schools, sport centres and hotels.

The INNOWATECH Aquadron® systems provide a reliable solution for the removal of all kinds of microbiological pollution and a protects against re-contamination.

Particularly noted is the control of “Legionella pneumophila" appearing in water tubes, fittings, air conditioning systems, air washers, hot water systems, cooling towers, water reservoirs and cooling circuits as a key application.

Sinowatek offers this disinfectant technology for clients in South Africa and Africa because of the following advantages:

No storage and transport of hazardous chemicals is necessary because INNOWATECH Anolyte® tradename Sulafect^TM concentrate is produced exclusively from drinking water, electricity, and high purity salt.
On site production of the concentrate with the INNOWATECH Aquadron® system ensure low stored volumes in storage tanks. Thus, the stored Sulafect^TM solution in the buffer tank is not regarded as water hazardous.
The active ingredient < 0,1 % (w/w) needs not to be labelled as eco toxic. There is no danger of storing toxic substances close to food products.
Disinfection application and drinking water treatment can be done in parallel with other systems.
Hazards for personnel handling dangerous substances can be avoided.

1. Brewer’s spent yeast (BSY) drying

CIP system water treatment

2. Brewer’s spent grain

Brewer’s spent grain

The challenge:‍

Brewer’s spent grain is most often sold as animal feed due to its properties and content of essential nitrogen-containing nutrients. The high moisture content (80%-90%) of this process waste makes it susceptible to microbial growth in the usual environmental conditions prevailing on farms. Within a few days after production, wet grain can undergo molding and spoiling. Therefore, dewatering and treatment for mold prevention are key factors in the utilization of this process waste.

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The solution:‍

Sinowatek offers the Fournier Rotary Press^TM dewatering technology for reducing the moisture content from the spent grain slurry. The rotary press produces a high level of cake dryness and competitive production rates.

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Benefit for the client:

The dewatering can preserve the BSG and is a key factor in the utilization of the by-product as animal feed.
The dryer waste has a lighter weight, resulting in lower transport costs.

3. Spent Kieselguhr slurry

Spent Kieselguhr slurry

The challenge:‍

Kieselguhr (Diatomaceous Earth) is a chalk-like sedimentary mineral derived from fossilized shell-like remains of marine algae called diatoms. The shells are extremely fine and generally range in length from 40 to 160 μm and in width from 2 to 5 μm, the latter being roughly the diameter of most yeast cells. Because of their microscopic size and porous nature, Kieselguhr has been used extensively in the brewing industry as a filtering medium.
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Due to the retention of organic material, especially yeast, proteins, and polyphenols by the end of the filtration, cake mass can be increased three times or more. Kieselguhr is a single-use product before being discarded due to its saturation.
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The used kieselguhr is a slurry with a water content of 80-90 % creating a process waste that requires environmentally conscience disposal or recycling.

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The solution: ‍

Discarded kieselguhr is stored in a tank capable of keeping the slurry (TS around 3%) in suspension before being routed through a Fournier Rotary Press^TM where it is dewatered to a cake dryness of 35% TS, ready for disposal or recycling.

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Benefit for the client:‍

The Fournier Rotary Press^TM ensures high consistency and good cake dryness using very little electrical power while operating unsupervised.
The high capture rate of suspended solids reduces the BOD of water going to the wastewater treatment plant.
The dryer waste has a lighter weight, resulting in lower transport costs.
The Rotary Press is an expandable technology, allowing channels to be added to the unit to accommodate future increases in sludge quantities. Provision can be made to expand a rotary press to 8 channels as demand increases.

4. Bottle washing and filling plant

Bottle washing and filling plant

The challenge:‍

Filling is the last step of the beer brewing process and the first step of the packaging. Sanitary conditions at this stage have a direct impact on the shelf life of bottled beer.
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The beer producers endeavour to deliver pure, fresh, tasty, and natural beverages with a long minimum shelf life with no preservatives or additional thermal treatment. Other marketing challenges are the variety of containment materials (glassware, PET, tinplate/aluminium, or the inside coated cardboard boxes) and long distribution paths.
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Industrial sanitation (washing and disinfection) of the whole filling line is therefore a top priority in the industrial hygiene of beverage production.
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With the conventional cleaning operating technology, the filler is emptied and flushed, disinfected, flushed again and afterwards re-filled. The complete cleaning procedure is therefore very time-consuming, cost-intensive and reduces the plant productivity.
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An assortment of chemicals is used for aseptic filling or traditional custom filling. These chemicals cause high wear and corrosion of the filling equipment.

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The solution:‍

Sinowatek offers the INNOWATECH Anolyte® for the disinfection of filler equipment e.g. rinser, filler, bottle washer etc. INNOWATECH Anolyte® tradename Sulafect^TM is produced electrolytically from a high pure aqueous salt solution on-site with the Aquadron® system.
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The disinfectant differs in its physical properties (colour, specific weight, density, viscosity, melting and freezing point) not much from pure water, as it contains only a low concentration of free chlorine. INNOWATECH Anolyte® tradename Sulafect^TMis a pH neutral, bactericidal, virucidal and fungicidal solution. Because of its low application concentration, it is odourless and tasteless, and, unlike traditional chlorine or chlorine dioxide disinfectants, it is gentle on materials it comes into contact with.
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Sulafect^TM operates at lower concentrations but achieves higher germ-killing rates than conventional disinfectants. It effectively kills legionella, pseudomonads, and other germs, which can be especially prevalent in natural drink products. In addition, while preventing the formation of new ones.
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With the bottle shower and Sulafect^TM system, disinfection of the filler table and surrounding areas is performed continuously. Thus, interruptions of production for in-between cleanings and disinfection can be avoided. The productivity of the plant increases, and water consumption is reduced.
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The Aquadron® systems and the active agent Anolyte® (Sulafect^TM) have already proven reliable in the beer brewing industry for years.

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The benefit to the client:

Main advantages of using Sulafect^TM as a disinfectant: ‍

Safe and quick elimination of all germs.
Better microbiological control.
Complete replacement of all chemicals used for conventional disinfection.
Short exposure times (5 min.) for full impact.
No re-contamination by rinse water residues.
Safe application in the production, filling, and packaging department, with no corrosion on stainless steel and no wear on elastomers.

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Main advantages of using the Aquadron® system:‍

Handling and storage of dangerous chemicals or substances is eliminated.
Due to the neutral pH no wastewater pollution.
Reduction of AOX/COD – values in the wastewater plant
Low operation and maintenance costs,
For the operation only high-quality salt and electricity are needed.
Reduced water consumption due to less cleaning and disinfection flushing.
Easy operation with an intuitive user interface.
Minimised storage and logistic costs.
Uncomplicated integration into existing systems.
Short installation and start-up time.
With this technology beverages can be filled in their natural form without adding any preservatives.
Reduction of operating costs while achieving high hygienic standards.

5. CIP system water treatment

CIP system water treatment

The challenge:‍

In the brewing industry, impeccable hygiene is an essential precondition for making final products of consistently high quality and a long shelf life. A highly efficient CIP process in beer breweries is therefore non-negotiable.
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The cleaning and disinfectant agents in conventional CIP stations are expensive and the CIP process requires a lot of time and effort. Materials are subject to rigid safety regulations for storage, handling, and disposal.
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These agents kill germs aggressively while impacting the life of pipes and valves. Proactive thermal disinfection, as an alternative to chemicals, is also time-consuming and not always effective.

‍

The solution:‍

Sinowatek offers the INNOWATECH Anolyte® for the CIP system of a brewery. INNOWATECH Anolyte® tradename Sulafect^TM is produced electrolytically from a high pure aqueous salt solution on-site with the Aquadron® system.
‍

The disinfectant differs in its physical properties (colour, specific weight, density, viscosity, melting and freezing point) not much from pure water, as it contains a very low concentration of free chlorine. INNOWATECH Anolyte® tradename Sulafect^TM is pH neutral, bactericidal, virucidal and fungicidal. Because of its low application concentration, it is odourless and tasteless, and, unlike traditional chlorine or chlorine dioxide disinfectants, it is gentle on materials it comes in contact with.
‍

Although Sulafect^TM operates at lower concentrations it achieves higher germ-killing rates than conventional disinfectants. It effectively kills legionella, pseudomonads, and other germs, which can be especially prevalent in natural drink products.
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Using the INNOWATECH Anolyte® (Sulafect^TM)system in the CIP plant gives rise to high disinfection activity. Individual programme steps such as acid treatment after the main cleaning step or fresh water rinsing after disinfection can be completely eliminated.
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The Aquadron® systems and the active agent Anolyte® have already proven reliable in the beer brewing industry over an extended period.

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Benefit to the client:

Disinfection of CIP plants by INNOWATECH Anolyte® system replaces aggressive disinfection chemicals and saves water.

Reduction of costs for disinfectant.
Savings of rinsing water > 30%
Improved AOX and CSB values in wastewater.
Stack water tanks free of germs
Elimination of acid treatment in the cleaning cycle.
Elimination of annual tank cleaning against residue film formation.
Rinse water tests show no microbiological activity.

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