Dairy Uses bioeXile® with the Get Clean, Keep Clean™ Approach to Save Energy and  Solve Quality Problems

GoalRestore cooling system efficiency through improved microbiological control and biofilm removal.

<p><!-- wp:acf/two-cols-text {"name":"acf/two-cols-text","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"blue","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a1b96b768f","block_title":"Overview","_block_title":"field_6629f36ac5d6b","block_content_clone":"","_block_content_clone":"field_662a1b96b76fb","text_list_0_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eIndustry: \u003c/b\u003eDairy Manufacturing\u003c/li\u003e\r\n\u003c/ul\u003e\r\n\u0026nbsp;\r\n\r\n\u0026nbsp;","_text_list_0_text_item":"field_662a1bf77d245","text_list_1_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eApplication: \u003c/b\u003eClosed chilled system, evaporative condenser heat exchange loop\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_1_text_item":"field_662a1bf77d245","text_list_2_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eProblem: \u003c/b\u003eMicrobiological fouling in cooling and heat exchanger systems causing energy and product losses\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_2_text_item":"field_662a1bf77d245","text_list_3_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eSolution\u003c/b\u003e: \u003ci\u003eGet Clean, Keep Clean \u003c/i\u003eapproach including bioeXile technology\u003c/li\u003e\r\n\u003c/ul\u003e\r\n\u0026nbsp;","_text_list_3_text_item":"field_662a1bf77d245","text_list_4_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eResults\u003c/b\u003e: 27% reduction in energy consumption (i.e. $92K energy savings in less than 9 months) and elimination of the temperature induced product quality issues and losses.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_4_text_item":"field_662a1bf77d245","text_list":5,"_text_list":"field_662a1bb97d244"},"mode":"edit"} /--><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Customer Challenge</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>A large European dairy manufacturer produces enriched powdered milk and bulk butter for export to over 50 countries globally. The cooling system was not meeting design efficiency, resulting in excessive energy consumption and costs. The inefficient cooling was also having a negative impact on production.</p> <p><!-- /wp:paragraph --><!-- wp:paragraph --></p> <p>The facility leadership suspected a cooling water management issue may be involved. So, Chem-Aqua was contacted to assess the program and recommend improvements.</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Recommended Solution</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>Chem-Aqua determined the problem was microbiological contamination and biofouling in the process cooling water systems. The biofilm and biofouling deposits common in these systems reduce both heat transfer and flow, which prevents the cooling systems from operating at design efficiency. To address this challenging issue, Chem-Aqua recommended the Get Clean, Keep Clean&trade; program - the 360&deg; Total System Approach.</p> <p data-start="1321" data-end="1457">The Get Clean, Keep Clean&trade; approach involves an initial deep cleaning of the system followed by a rigorous Keep Clean treatment program.</p> <p data-start="1321" data-end="1457"><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/01b39fb3a60f4e5f918591d4ac01df87.aspx" alt="" width="400" height="389" /></p> <p><!-- /wp:paragraph --><!-- wp:image {"id":7139,"sizeSlug":"full","linkDestination":"none","align":"center"} --><!-- /wp:image --><!-- wp:heading {"level":5} --><!-- /wp:heading --><!-- wp:paragraph --><!-- /wp:paragraph --><!-- wp:paragraph --></p> <h6>Get Clean</h6> <p>The&nbsp;<em>Get Clean </em>phase was started just prior to the beginning of the busy dairy season and included adding bioeXile-L, a powerful biofilm cleaning product. By effectively removing the biofilm deposits, heat transfer efficiency is restored to provide better cooling, reduced energy cost, and improved production. Deep cleaning also reduced the seed material for future microbial regrowth.</p> <p class="PDq2pG_selectionAnchorContainer" data-start="1865" data-end="2230">Chem-Aqua performed a 24-hour bioeXile&trade;-L clean and flush procedure on the entire chilled water system including the chilled and hot water tanks, pipework into the factory, and numerous cooling jackets and heat exchangers (~40k gal system volume). Water samples were taken for on-site analysis and bacteria testing at regular intervals throughout the procedure.</p> <p data-start="2232" data-end="2793">The cleaner, bioeXile-L, was selected due to its neutral pH, low toxicity, and rating for use in cooling systems in food processing facilities. This product disrupts the non-living protective layer of a biofilm, exposing the living bacteria underneath. Bacteria testing proved a large amount of bacteria was released during the bioeXile flush (including <em data-start="2590" data-end="2603">Pseudomonas</em> species, which are a clear indicator of biofilm presence). The subsequent chlorination procedure with registered biocide killed the exposed bacteria. The tanks were then physically cleaned.</p> <h6>Keep Clean</h6> <p><!-- /wp:paragraph --><!-- wp:paragraph --></p> <p>Next, a comprehensive <em>Keep Clean&nbsp;</em> program with effective biocide and corrosion/scale inhibitor additions and frequent testing was initiated to protect the system metallurgy and mitigate the return of biofouling problems.&nbsp;</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --><!-- /wp:heading --><!-- wp:paragraph --><!-- /wp:paragraph --><!-- wp:paragraph --><!-- /wp:paragraph --><!-- wp:heading {"level":5} --><!-- /wp:heading --><!-- wp:paragraph --></p> <p>The cooling water system was put back into service and treated with a customized inhibitor and biocide program, along with improved monitoring and control. According to customer energy readings depicted in the graph below, the <em>Get Clean, Keep Clean</em> approach resulted in substantial energy savings throughout the peak production season from March to October<br />(week 9 to week 38 in the graph below):</p> <p><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/c4f6e77ffce44ea4bfcccbbc2a2b59ee.aspx" alt="" width="1024" height="481" /></p> <p><!-- /wp:paragraph --><!-- wp:image {"id":7138,"sizeSlug":"large","linkDestination":"none"} --><!-- /wp:image --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Results Achieved</h5> <p><!-- /wp:heading --><!-- wp:list --></p> <ul class="wp-block-list"><!-- wp:list-item --> <li>27% energy savings / $92K saved during the high production season and hottest summer on record</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Sustainability and carbon footprint improvements from the energy savings</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Cooling efficiency restored</li> <!-- /wp:list-item --></ul> <p><!-- /wp:list --><!-- wp:paragraph --></p> <p><em>CS2-015</em></p> <p><!-- /wp:paragraph --><!-- wp:acf/one-col-wysiwyg {"name":"acf/one-col-wysiwyg","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-none","_padding_options":"field_6629e0d2860af","background_colour":"white","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_6629f2331ce27","block_title_type":"h2","_block_title_type":"field_664b18d38a3b7","block_title":"","_block_title":"field_6629f36ac5d6b","block_excerpt":"","_block_excerpt":"field_6629f37dc5d6c","show_cta_button":"0","_show_cta_button":"field_6629f386c5d6d","use_special_button":"0","_use_special_button":"field_663af6cb5a467","block_content_clone":"","_block_content_clone":"field_6629f3c76b783"},"mode":"edit"} /--><!-- wp:acf/testimonials {"name":"acf/testimonials","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"light-grey","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_6635ed062a3cb","block_title":"Customer Testimonial","_block_title":"field_6629f36ac5d6b","block_excerpt":"\u003ci\u003e\u0022The clean carried out [by Chem-Aqua] greatly reduced the energy usage of the refrigeration system and reduced the cooling load on the same system. In turn we had less downgraded product as the plant was able to reach the desired temperature. I would recommend a [\u003c/i\u003e\u003ci\u003ebioeXile\u003c/i\u003e\u003ci\u003e-L] clean every year.\u0022\u003c/i\u003e ~ Site Engineering Manager\u003ci\u003e\r\n\u003c/i\u003e","_block_excerpt":"field_6629f37dc5d6c","block_content_clone":"","_block_content_clone":"field_6635f15899325","testimonials_controls":"0","_testimonials_controls":"field_6635ed8b9c247"},"mode":"edit"} /--><!-- wp:acf/two-cols-text-ctas {"name":"acf/two-cols-text-ctas","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"white","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a2539a7d03","block_text_list_0_block_title":"","_block_text_list_0_block_title":"field_662a2573bc047_field_6629f36ac5d6b","block_text_list_0_block_excerpt":"","_block_text_list_0_block_excerpt":"field_662a2573bc047_field_6629f37dc5d6c","block_text_list_0_show_cta_button":"1","_block_text_list_0_show_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f386c5d6d","block_text_list_0_block_cta_button":{"title":"Download PDF","url":"https://www.chemaqua.com/en-us/wp-content/uploads/sites/6/2024/07/CS2-015.pdf","target":""},"_block_text_list_0_block_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f39cc5d6e","block_text_list_0_use_special_button":"0","_block_text_list_0_use_special_button":"field_662a2573bc047_field_663af6cb5a467","block_text_list":1,"_block_text_list":"field_662a2550bc046"},"mode":"edit"} /--></p>