The Challenge
A poultry processing plant was struggling to maintain efficient control of bacterial growth measured in water samples collected from their potable water supply. Despite carrying out twice monthly cleaning procedures using an acid detergent followed by peracetic acid/hydrogen peroxide sanitiser, weekly water screening was regularly returning out-of-spec results.
TVC
Out of Spec
Coliforms
Out of Spec
E.coli
Out of Spec
Enterococci
Out of Spec
This meant constant remedial actions were required to maintain safe operation and prevent production downtime.
Additional Problems
- Manual handling hazards: Chemical addition involved handling 1000L of product in 25kg drums with risk of vast foaming when added
- Corrosion damage: Due to the amount of chlorine used, heavy corrosion to stainless steel equipment was an identified issue
- Biofilm build-up: Large accumulation of biofilm affected control in tanks and throughout the factory
The Solution: ChloroKlean Plus
To address issues stemming from excessive chlorine use, ChloroKlean Plus was introduced and trialled for constant low-level dosing in the borehole water supply. ChloroKlean Plus was dosed at 5ppm with a 5-hour contact time.
ChloroKlean Plus proved effective in mitigating microbial concerns and reducing corrosion, providing an effective water treatment solution. Following the successful trial, ChloroKlean Plus was adopted as the primary solution for process disinfection across the site.
The Results
99% Chemical Reduction
Volume reduced from 1000L to just 10L, offering massive cost savings and simplified storage.
Improved Safety
Eliminated manual handling of 1000L chemicals in 25kg drums, reducing workplace hazards.
Zero Bacterial Issues
All sample points now passing with zero counts for TVC, Coliforms, E.coli and Enterococci.
Before & After Comparison
Before: September 2023
10 sample points tested - All Failed
- TVC at 22°C: Up to >300 CFU
- TVC at 37°C: Up to >300 CFU
- Coliforms: Up to >201 CFU
- E.coli: Up to 165 CFU
- Enterococci: Up to >200 CFU
After: October 2023
10 sample points tested - All Passed
- TVC at 22°C: 0 CFU
- TVC at 37°C: 0 CFU
- Coliforms: 0 CFU
- E.coli: 0 CFU
- Enterococci: 0 CFU
Operational Improvements
- Eliminated cleaning regime: Abandoned twice monthly acid detergent and peracetic acid cleaning. Now disinfects based on bacterial results only
- Reduced remedial actions: Site has significantly reduced their reliance on emergency interventions
- Simplified dosing: ChloroKlean Plus is dosed volumetrically from a single 25kg drum, eliminating complex manual handling
- Reduced corrosion: Less aggressive on stainless steel equipment compared to high chlorine dosing
Conclusion
Since ChloroKlean Plus has been used as the primary disinfectant, the results have been consistently clear and immediate improvements were observed. The site continues to use ChloroKlean Plus for constant dosing and disinfection, with bacterial results remaining excellent and reduced risk of product contamination or plant stoppages.