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Effective and Reliable Disinfection for Food & Beverage Processes fumaGen LS®
Effective and reliable non chemical disinfectant / fumaGen® LSseries | | 3 2
The new innovative fumaGen® LS – A “green technology”
All of the classical ECA devices offered in the market are using a brine solution (NaCl) in order to produce a disin fectant material via cathodic and anodic reactions. In such electrolysis only 20 % max. of the brine solution are going to be converted into a disinfectant (HOCl).
The significant downside and threats whilst operating such devices are obviously high corrosion risks, because of the carryover of chlorides. This effect is relevant to all commercial offered devices. Due to the material used, particular in the Food & Beverage Industry such a disinfectant was not applicable for the industry because of the risks.
Electrochemical Activation with FumaGen®:
The fumaGen® generator is an advanced electrolysis proc-ess whilst using water only for the products. The necessary and needed salt is provided from a third chamber which is hydraulic separated from product compartments. With the process there are two different water based products generated:
Hypochlorous Acid (HOCl) > Anolyte Diluted Caustic Soda (NaOH) > Catholyte
The difference to the conventional electrolysis system is the unique and patented chlorinestable Anion exchange Mem-brane from FuMATeCH. The membrane results in a solu-tion with the lowest amount possible of chloride impurities in the disinfection solution.
In addition to the described membrane the special and innovative design of the anode guarantees the excellent and stand alone conversion rate of 1:1 (salt: chlorides).
This result is remarkable as with such a system almost any user is able to produce a highly effective and reliable disin-fectant (pure HOCl) on-site. Based on this any usage of the fumaGen® Anolyte will not increase the corrosion potential of the SIP/CIP cycle medium.
The standard warranty specifications of the Food & Bever-age manufactures with respect to the acceptable chloride levels to use with their equipment will not be exceeded whilst using the fumaGen disinfectant at a concentration of 40 mg/l FAC.
With the unique and stand alone 3 chamber system and the patented cell design of the fumaGen® LS device the amount of chloride impurities in the disinfectant solution is the lowest possible and close to the theoretical limits. Any usage of the fumaGen® Anolyte will not have an effect to the corrosion potential in the system.
The demand for improved and excellent water quality has been a fundamental need since time immemorial and is also a prediction for optimal results in various aspects of world and life. The technological and legal requirements for an optimal water treatment are constantly rising.
In most of the industrial processes water is an essential raw material. Particular in the Food & Beverage Industry most of the production activities require good water quality. As the microbiological contamination of the process water is a critical issue a reliable and optimal control of all biological parameter is indispensable.
In many operation the water quality is currently control-led whilst using halogen-based chemical disinfectants and cleaning agents. Those chemicals used (Chlorine and its chemical compounds) are acting as effective disinfectants in order to ensure the microbiological quality of the water. There are some remarkable disadvantages with operating chemicals such as the handling (e.g Chlorine Gas) and the environmental impact.
The electrochemical activation technology (eCA) is the gen-eration of activated solutions (Anolyte & Catolyte) whilst using a diluted salt solution (sodium chloride NaCl). This electrolysis process is an applicable alternative in the area of disinfection to the dosage of conventional chemicals in case the technology is able to produce a disinfectant without critical by-products.
Based on its well known core competence in electrochemi-cal technologies FuMATeCH in cooperation with the BWT R&D department has developed an advanced electrolysis process for producing an effective and reliable disinfectant on demand.
With the newly developed “fumaGen®LS HC” generator series BWT and FuMATeCH offer a new innovative system for the on-site production of a highly effective disinfectant, which meets all the requested criteria due to its unique and stand alone design. The device is generating Hypochlo-rous Acid, which is well known as a real strong disinfection agent.
C A
T H
O D
E
A N
O D
E
‐+Na+
OH‐
H2
Cl‐
NaOHHOCl
H2O
0,05 – 5,00 %
Pure
H2O
Saturated Brine
Saturated Brine
minimum salt impurities
H2
anode reaction: 2Cl‐ + H2O → HOCl + H+ + 2e‐
cathode reaction: 2Na+ + 2 H2O + 2e‐ → 2 NaOH + H2
anolyte catholyte
O2
HOCl
Effective and reliable non chemical disinfectant / fumaGen® LSseries | | 5 4 effective and reliable non chemical disinfectant / fumaGen® LSseries
fumaGen® is a patented electrolysis technology manufactured by BWT. As various unit capacities are available it is ensured that the amount of on-site produced disinfectants is equivalent to the individual plant requirements.
fumaGen LS series fumaGen 30 LS fumaGen 48 LS fumaGen 72 LS fumaGen 96 LS
Number of cells 2 2 4 5
Disinfection Solution Anolyte
Free Chlorine (FAC)* mg/l 150 160 180 200
Flow rate (FAC) l/h 200 300 400 500
Mass flow (FAC) g/h 30 48 72 96
Salt content (Chloride in the Anolyte) mg/l 150 170 190 210
Chlorate mg/l < 3.5 < 3.5 < 3.5 < 3.5
Chlorite mg/l < 0.3 < 0.3 < 0.3 < 0.3
ORP mV > 1000 > 1000 > 1000 > 1000
electricity consumption / kg FAC* KWh/kg 14 13 12 11
ph value 5.5 5.5 5.5 5.5
Salt consumption
NaCl consumption g/h 90 143 215 260
daily salt consumption kg/24h 2.2 3.2 5.2 6.2
effective Disinfection
In the industry it is essential to work with a disinfectant which meets the criteria at all time to ensure an effective microbiological control of all systems. extensive tests are performed out of operating production plant or the F&B industry showing outstanding results:
FAC vs. chloride concentration of different anolyte solutions chlorate concentration of different anolyte solutions in relation to permitted value of TVO (5,4 %m/m related to FAC)
- 50,00
100,00 150,00 200,00
250,00
conc
entra
ion
(mg/
l)
anolyte 1 anolyte 2 anolyte 3 anolyte 4
FAC (ppm)Chloride (mg/l)
-
2,00
4,00
6,00
8,00
10,00
Chl
orat
e (m
g/l)
anolyte 1 anolyte 2 anolyte 3 anolyte 4 TVOpermitted
killing ratio of more than log 4 proven for different anolyte solutions
-
10.000,00
20.000,00
30.000,00
40.000,00
Bac
illus
sub
tilis
(S
p./m
l)
0 min. 10 min.
anolyte 1
anolyte 2
anolyte 3
stability of oxidation-reduction potential during disinfection degradation of FAC during disinfection and persistence of FAC for deposit effect
- 200,00 400,00 600,00 800,00
1.000,00
OR
P
anolyte 1 anolyte 2 anolyte 3
ORP (mV) startORP (mV) after 10 min.
- 5,00
10,00 15,00 20,00
FAC
anolyte 1 anolyte 2 anolyte 3
FAC (ppm) start
FAC (ppm) afer 10 min
source: report VLB october 2009, september 2010, report SGS october 2010
summery average concentration FAC 180 ppm average ORP of 1:10 dilution > 1000 mV killing ratio > log4 stability of anolyte > 2 weeks FAC to chloride 1 : 1 chlorate < 3,6 mg/l
As the fumaGen generator produces pure HOCl of the requested high quality, the disinfection is ensured whilst there are no safety issues to be considered. The anolyte is non-toxic against oral toxicity, skin sensitization, eye or skin irritation or bacterial assay.
The “new” innovative ECA technology results in high performing components
Feed solution softened water *
Active specie hypochlorous acid (HOCl)
Mechanism diffusion into the cell osmotic effects & degradation
Disinfectant 100 – 500 ppm FAC
Purities sodium chloride (low quantities)
* Due to the unique design and stand-alone FumaTech technology, there will be no transfer of salt solutions into the anolyte compartment.
Effective and reliable non chemical disinfectant / fumaGen® LSseries | | 7 6
Schematic view of onsite production
Cold Short CIP:CIP cleaning with electrochemical activated water eCA is known as “Cold cleaning”:
Replacement of hot water cleaning (85 °C) Replacement of hot caustic detergent (1.5 wt.%) Replacement of chlorinated alkaline detergents
Significant Savings Reduced cleaning time Decreased energy & water consumption Decreased chemical usage
The cold CIP procedure could be implemented successfully for carbonated non-sensitive products (e.g. the syrup tank, the mixer, the filler and pipe lines)
Cold Short CIP Cleaning Procedures:
Step 1 Rinsing with cold water
Step 2 Cleaning with anolyte 10 – 20 ppm FACTotal cleaning time appr. 20 minutesControlled by RedOx potential ORP > 900 mV
Step 3 Cold water rinse 0.3 – 1.2 ppm FACFAC given by e.g. TVO Almost no waste water. The entire amount of the cleaning solution is recirculated.
Work methode ECA production:
Potable Water supplymin. 3 to max. 6 bar
Anolyte Concentrate 200 ppm FAC
Dilute 1:20
Catholyte Concentrate 2 wt% NaOH
Buffer TankCatholyte
Concentrate
CIP Tank10ppm FAC
Buffer TankAnolyte
Concentrate
It is essential, that every installed device should cover all safety features to ensure a smooth and user friendly op-eration. Every fumaGen generator provides – apart from its outstanding technical performances all necessary safety features.
Another differential highlight of the fumaGen device is the catalytic destruction of the produced hydrogen (installed hydrogen sensor in the cabinet). Because of this the generator can be installed in closed room and integrated in almost all existing processes. This is validated with a certificate from TÜV South West.
Safety features:Catalytic hydrogen destruction plus hydrogen sensor in the cabinet
Effective and reliable non chemical disinfectant / fumaGen® LSseries | | 9 8
Advantages & Benefits
Safety Because of the replacement of traditional halogen based chemicals no additional equipment required No health issues with the produced disinfectantNo eye or skin irritation
Microbiological EfficacyHOCl as a strong disinfectant effectively destroys phenols, which could influence the tasteAn on-site produced disinfectant which controls all kind of bacteria as well as virusesThe Anolyte is effective against LegionellaIt prevents and removes biofilm
Return on InvestmentReplacement of the traditional used chemicals and reduction of operational cost
As the generator is not producing any critcal by-products (such as chlorate) and the corrosion potential is extremely low the advantage is having a reliable and strong disinfectant available at any time. This results in significant reduction of water and hot water usage.Energy saving and increased production availability are generating significant higher profitability.
Our Customer Service Cares for Ongoing Partnership
even after the handover and the start-up of the fumaGen® generator BWT remains at your side as a reliable partner. Our customer service offers various support and mainte-nance packages with different levels of support. In addi-tion to the technical advantages and therefore commercial benefits the offered service capabilities of the BWT group are outstanding and unique. International experienced and practically orientated staff members are going to ensure
that the installed units are delivering the necessary and requested results. Amongst the annual maintenance and service of the units an on-line monitoring of the cells is pos-sible if desired. During the evaluation of the needed capacity of the gen-erator and engineering task for a successful integration our staff will work out together with you an individual service and maintenance plan in order to ensure the success.
As BWT/FuMA-Tech are partnering with the leading CIP and system integrators in the industry the FuMA-Tech® Generator will be integrated and installed in almost each different plant design. Together with our partners we offer the entire integration project:
Survey and validation of all current plant data Project Management Process engineering and design Installation Start- up and training of the plant staff Documentation On-going Support and Service
For further information:
Dru
ck: 1
6101
0GM
www.fumatech.com
Best Water Technology Group (BWT) is Europe’s leading water technology company. Our water partner network comprises the group’s 3,300 employees and thousands of plumbers, planners, architects and hygiene experts. Our Research & Development teams, using state-of-the-art methods, work on new processes and materials to create products that are both ecological and economical. Looking ahead, a key development issue is a reduc-tion in the products’ use of operating resources and energy consumption and the resulting minimisation of CO2 emissions.
Whether at the place where the wa-ter pipe enters the building (‘point of entry’) or at the tap-ping point (‘point of use’), BWT’s trend-setting ‘Made in Europe’ products have proved their quality millions of times over in the treatment of: drink-ing water, mineral water and ultrapure water for the pharma-ceutical industry; water for swim-ming pools; heating and process water; boiler and cooling water; and water for air-conditioning. BWT’s wide-ranging innovations guarantee
maximum safety, hygiene and health in the daily use of water – that precious elixir of life. These innovations, among others, include: SEPTRON®, the world’s first electrode ionisation module (EDI) with spiral wrap; manganese oxide activation (MDA) – a method for effective manganese removal; AQA total bipolar technology for chemical-free limescale protection; SANISAL – the world’s first regeneration salt for softening water systems, which al- so works as a disinfectant; and the new, revolutionary
Mg2+ technology that improves the taste of fil-tered water, coffee and tea. Through its
unique, high efficiency membranes for fuel cells and batteries, BWT is cre-ating a cleaner, more sustainable energy supply for the 21st century.
BWT – For You and Planet Blue signifies that our mission is to take ecological, economical and social responsibility, to provide our customers and partners with the best products, systems, technolo-gies and services in all areas
of water treatment and, at the same time, to make a valuable
contribution to preserving the global resources of our blue planet.
BWT – The Company
BWT AktiengesellschaftWalter-Simmer-Straße 4A-5310 MondseeTel.: +43/6232/5011-0Fax: +43/6232/4058E-Mail: [email protected]
FUMATECH BWT GmbHCarl-Benz-Straße 4D-74321 Bietigheim-BissingenTel.: +49/7142/3737-900Fax: +49/7142/3737-999E-Mail: [email protected]
