the use of eca in the soft drink and bottled water industry

Jürgen Löhrke GmbH ● Firmensitz Lübeck ● Handelregister Lübeck HRB 6360 HL ● Geschäftsführer Jürgen Löhrke, Martin Löhrke

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The use of ECA in the soft drink and bottled water industry. What is ECA?

ECA is the Electro-Chemically Activation of water, an electrochemical process that by the use of

electricity, water and salt generates in-situ (on site where it is used) anolyte and catholyte

anolyte = hypochlorous acid (HClO), a powerful disinfectant at correct pH and dosage

catholyte = sodium hydroxide (NaOH), a chemical base = caustic acid

How does the ECA process work?

process: electro-diaphragmalysis

standard ECA cell: two chambers with anode and cathode

separated by a membrane that allow selective exchange of

ions

cell design and membrane engineering are different at each

generator manufacturer

different philosophies on process details (feeding NaCl, H20,

pH settings, catholyte use, membrane, ion selection,…)

different claims on additional effects (oxidation, …)

Why is the use ECA so attractive?

ECA is used for its image of sustainability: using only water and salt it presents an ecological

alternative to cleaning and disinfection by conventional chemicals.

ECA is said to be economical as it should offer big savings potentials in energy, chemicals and water

consumption

What are the benefits?

In certain applications ECA can save a substantial amount of caustic, acid and disinfectant – always

depending on the starting point and benchmarking before the introduction of ECA.

As the operating costs of an ECA generator are indeed very low (electrical energy, water,

conventional salt pellets) it's use can offer interesting savings

ECA is safe as it required no handling of hazardous chemicals inside food or beverage production

areas.


2013-10-18 ECA in softdrink and bottled water plants.docx www.LOEHRKE.com

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What are the limits?

ECA is a 'mild' alternative to conventional cleaning and disinfection. The surrounding conditions need

to be ideal for good overall results of ECA use. Non-hygienic circumstances can't be compensated by

'over-dosing' chemicals. Temperature and time are the only variables.

Only in some applications ECA can be used as the 'sole' cleaning method. In many cases it is advisable

to combine ECA with regularly used conventional cleaning for best long-term results.

ECA produces a larger amount of disinfectant and only little caustic soda. Therefore in most ECA

applications, the actual caustic cleaning is secondary to the disinfection achieved.

Where are the savings potentials?

Energy savings, mainly from saved heating energy as the majority of ECA applications are ambient

temperature

Chemical savings. You will optimize the hygiene efficiency, use fewer chemicals and generate on-site

most of what you need.

Water savings can be achieved by optimized circuit volumes, shorter rinse cycles in combination with

frequency controlled flow pumps

Time savings from shorter CIPs, shorter rinse times, smaller circuit volumes

The actual amount of these savings will largely depend on the engineering and degree of integration.

What are the risks?

If applied without respecting the industrial limits for dosage, pH and by-products, ECA can be

corrosive. Special attention must be paid to the quality and reliability of metrology.

Satisfactory microbiological and sensory results will only be achieved if all relevant process

parameters are known, understood and reproducible.

With ECA, more than anything else, integration is the key to success!

ECA integration is

Understanding the relevant parameters of the individual process hygiene

Understanding the benefits, the limits and the potential risks of applying ECA



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Taking an unemotional look at the sometimes 'mystified' technology of ECA, 'disenchanting' it,

reducing it to the manageable and reproducible parameters.

Knowledge over assumptions

Rather than assuming how ECA could work in hygiene applications, we at LOEHRKE prefer to actually know what we do. As an independent integrator of ECA technology into the process hygiene of food and beverage plants, we maintain a wide database of the ECA generators commonly used in the industry. With the help of evaluations done by third party laboratories, this database is permanently updated with up-to-date information from ECA installations and applications worldwide.

Integration: Generating, storing, dosing and monitoring of ECA

While the generator remains the 'heart' of your ECA system, integrating ECA in your plant is much more. It includes the selection of the right generator for your applications, the adequate storage system for anolyte and catholyte, the selection and dimensioning of the dosing method and engineering the right measurement system. In addition, your installation of CIP or filler hygiene must be suitable for the use of ECA.



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ECAGuard – stay in control of ECA

Over many years of experience and dozens of applications we have learned that dependable and on-time measurements are crucial to success when integrating ECA. Not all methods are adequate and not all sensors are suitable. So we developed our own range of metrology, monitoring all relevant parameters: pH, flow, temperature, free chlorine and chlorides in one compact and economical system.

ECAGuard consists of the ControlPanel to which up to 4 SensorBoards can be connected. The SensorBoards are of a compact design and can be installed close to the ideal point of measurement. The ControlPanel collects all measured data and is connected to the CIP control via Ethernet or optional ProfiBus connection.

FAC measurement: LOEHRKE ECAGuard uses especially developed probes that measure the occurrence and increase of FAC correctly and without delay. Besides the type also the actual position of the probes in the process is crucial for response time.

pH measurement: The microbiological efficiency of ECA anolyte depends on its pH to a large extend as well as the pH related corrosion risk. Keeping the anolyte's pH within the optimum window is crucial for a successful yet efficient usage of ECA. LOEHRKE ECAGuard was design to do just this. Chloride Measurement: The high chloride content of many ECA anolytes in the market is a substantial risk for corrosion on both, the CIP system as well as the cleaned objects like tanks or fillers. ECAGuard continuously monitors the chloride content of the anolyte dilution tank and will notify the user if critical values are exceeded.



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ECA applications in the soft drink and bottled water industry

CIP – clean-in-place systems for fillers, mixers, tanks, pipes

external filler hygiene (EFH) including conveyor cleaning and preventive spray disinfection (PSD)

water treatment – chlorination of process water for hygiene

ECA in CIP systems

replacing traditional CIP regimes with hot water, hot caustic, acidic steps and disinfection by 3- or 5-

step ECA CIP

focus on time and energy-saving cold CIPs but maintaining the capability of hot CIPs where

necessary

significant savings of chemicals, heating energy, water and time based on analysis

includes hygienic audit of existing CIP, upgrades and process modifications where necessary

validation of cleaning results and efficiency by independent laboratory recommended

additional time savings by running ambient temperature CIP at the same time as external cleaning

CIP analysis

CIP system: hygienic design, minimum requirements, process control

CIP activity: number of lines, number of tanks, number of CIPs/element/year

CIP recipes: starting point, philosophies, recipe design, key parameters

CIP evaluation: How good is the CIP result?

What are the criteria for a CIP evaluation?

short term microbiological cleaning result (rinse water quality)

long term microbiological cleaning result (biofilms, etc.)

sensory cleaning results (pungent flavours)

cycle duration (CIP-time = production down time)

water consumption

chemical consumption

energy consumption

reproducibility



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CIP philosophy

There's hardly any field within process hygiene in the food and beverage industry which is more controversially discussed than CIP. Its long history provides traditional CIP approaches that heavily rely on high temperatures and large tanks volumes. LOEHRKE's CIP philosophy focusses on the saving of valuable resources like water and energy by reducing the circuit volumes to a minimum, thus reducing time and chemical consumption while optimizing reproducible cleaning results.

In ECA-CIP we combine these achievements with the advantage of ECA, offering yet another level of sustainability and economics: LOEHRKE blueCIP.

LOEHRKE ECA-CIP special characteristic:

highly accurate proportional dosing of ECA and conventional detergents or additives

hydrostatic compensation tank for pipe CIP and temperature/volume balance

quick-phase-switch valve-configuration

LOEHRKE CIP for sensitive products:

double-seat-valves

hygienic design: piping, welding, components design, skid frame

sensory carry-over prevention for flavoured beverages by engineering, selection of components,

polymers and research programs

LOEHRKE ECA-CIP:

regular CIP: 3-step ambient

focus disinfection

rely on mechanical cleaning effect

special CIP: 5-step with heated

catholyte/caustic step

used for preventive cleaning effect

add caustic cleaning effect for special

situations by CIP matrix



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ECA in external filler hygiene (EFH)

extending the regular cleaning interval by

adding additional rinse steps

hygiene center supply with ECA treated water

replacing full clean cycles by regular ECA-rinse-

only cycles saves time and chemicals

adding focused preventive spray disinfection in

critical areas during production

process design with selective cleaning zones

External filler hygiene (EFH) analysis

EFH system: pressure, dosing, products, parameter, monitoring

EFH activity: no. of EFCs/line/year

EFH regime: intervals, programs

EFH evaluation: results, swab tests, spray shadow tests

EFH evaluation

process design

cleaning zone selection

mechanical cleaning result (spray shadow

tests)

microbiological cleaning result (swab tests)

cycle duration (= production down time)

water consumption

chemical consumption

reproducibility

ECA in water treatment treat complete process water with ECA within potable water regulations

use treated water for supply of filler hygiene centers

use treated water for supply of conveyor belt lubrication

bottle cooling in blocked PET lines



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The 5 steps to your ECA success:

Step 1. Plant analysis:

In which areas could you use ECA efficiently? CIP, filler hygiene, water treatment? Together with your staff we will explore your potentials by reviewing your equipment, your products, your operations. If you already have ECA in your plant and you feel you don't get the benefits you expected, we will identify the shortcomings and suggest improvements.

Step 2. Hygiene concept development:

The ideal ECA-based CIP matrix and filler hygiene concept - based on your current CIP activities and EFC regime we will develop new ECA routines that will provide you with the benefits of ECA.

Step 3. Generator selection:

In consideration of the results of steps 1 and 2 we will help you select the ideal generator for your needs, both in type and size to meet the estimated consumptions, typically offering some spare capacity for additional future ECA applications.

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Step 4. Cost and savings estimate:

Knowing how to efficiently integrate ECA we will make cost estimates for ECA generator and concentrate storage and handling, possible required hygienic upgrade and system modifications. Having analyzed your current hygiene activities we'll also be able to identify realistic savings potentials from the use of ECA in combination with the suggested optimizations.

Step 5. Turn-key integration: We take care of everything!

Process Design and Engineering: tailored to your application and

hygienic requirements and economical expectations

Mechanical installation: supply of all components to highest

industry standards, qualified welders for complete work, incl.

supply and installation of ECA generator

Electrical installation: complete supply and installation of

electrical components, wiring of new components, probes, etc.,

integration into existing electrical system

Software integration: working closely with your software staff,

your sub-suppliers or the OEM, we'll make sure that the ECA-

related programming will be integrated and that the

visualization is optimized for your system.

Start-Up: full support of CIP operation during start-up period,

on-site adjustments and operator back-up

Training & Support: Operator training, maintenance training,

maintenance contracts , remote access and on-line support

Validation: of microbiological efficincy by independent

laboratories

With LOEHRKE, turn-key integration is your key to success!



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For more information please contact: [email protected]

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the use of eca in the soft drink and bottled water industry

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