Chiller Water Microbial Control via PAA Injection
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Solution Overview
Problem
Current food processing methods, particularly in large-scale poultry processing, face challenges in efficiently extending the time between filling and draining of chiller water tanks while maintaining microbial control and compliance with USDA regulations, leading to high operational costs and environmental impact.
Innovation Solution
The use of a Peracetic Acid (PAA)/Hydrogen Peroxide blend, injected at specific points in the chiller recirculation loop and dosed through specialized systems, allows for the extension of chiller water usage from two shifts to up to seven days, maintaining effective microbial control and compliance with USDA guidelines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chiller water tanks are drained and refilled frequently to maintain microbial control, then microbial safety is improved, but water consumption and operational costs increase
Solution Approach 1:
Peracetic acid is introduced as an intermediary substance that mediates between the conflicting requirements of microbial control and water conservation. The chemical agent allows water to be retained in the system longer by providing continuous microbial inhibition, thereby reducing the frequency of drainage and refilling operations while maintaining sanitation standards
Solution Approach 2:
The invention changes the chemical parameter of the water by adding peracetic acid, which fundamentally alters the water's properties from a simple cooling medium to an active antimicrobial solution. This parameter change enables the water to maintain microbial control over extended periods, allowing the system to operate with less frequent water replacement
2Loss of substance
If chiller water is retained longer in tanks to reduce water consumption, then water conservation is improved, but microbial control effectiveness deteriorates
Solution Approach 1:
The peracetic acid provides continuous antimicrobial action throughout the extended water retention period. Rather than relying on periodic water replacement to maintain sanitation, the chemical agent ensures uninterrupted microbial inhibition, allowing the water to remain in the system for extended periods (up to 7 days as mentioned in the patent) while maintaining effective microbial control
Solution Approach 2:
The peracetic acid acts as a mediator that enables the contradiction between water conservation and microbial control to be resolved. It allows the system to achieve both goals simultaneously by providing the microbial control function that would otherwise require frequent water replacement
3Reliability
If traditional chlorination methods are used for microbial control, then microbial safety is maintained, but operational complexity and chemical intervention requirements increase
Solution Approach 1:
The invention changes the chemical composition parameter by substituting peracetic acid for traditional chlorine-based sanitizers. This parameter change simplifies the overall system by reducing the need for complex chemical intervention infrastructure, multiple chemical storage systems, and extensive safety protocols associated with chlorine handling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces operational costs, electrical consumption, and environmental impact by extending the usable time of chiller water, while ensuring compliance with USDA regulations and improving microbial control, resulting in substantial water and refrigeration cost savings.
Implementation Method 1
The use of a Peracetic Acid (PAA)/Hydrogen Peroxide blend, injected at specific points in the chiller recirculation loop
Data Source
AI summary
A method for extending the use of water during the production of products for human consumption in food production facilities for an extended period of time of at least two production days and up to seven production days by delivering an initial chemical charge at the beginning of each production day to return the process water to the desired antimicrobial solution concentration to provide acceptable antimicrobial control of the process water over the extended period of time. The method providing acceptable antimicrobial control in the processing of any protein or non-protein based food products that require batch or continuous chilling as part of the production process. The length of time that the water may be used in a processing tank may be dramatically and safely increased before the processing tank is emptied for cleaning, sanitizing and refilling.