PETpla.net Insider 01+02 / 2014

BOTTLING / FILLING 39 PET planet insider Vol. 15 No. 01+02/14 www.petpla.net Wet sterilisation Dr Diana Wolf, KHS, spoke at the conference about the use of chlorine dioxide in “wet“ processes. Compared to peracetic acid and ECA, in tests the medium proved to be the most effective in deactivating large num- bers of germs. Chlorine dioxide, said Wolf, emphasising the advantages of the substance, offers a wide range of usages, it is extremely economi- cal – generally speaking only very little liquid is required to achieve the desired sterilisation effect – and is suitable for sterilising packaging media for carbonated products. She recommended using chlorine dioxide in the entire line as a microbiologically safe bottling process can be guaran- teed by using it, providing it is used properly. 4-stage validation approach Matthias Hickstein, Coca Cola soft drinks, presented a 4-stage approach used by the Coca-Cola Company to validate new bottling plants. This approach is derived from a stage gate process. A pre-condition for validation is, alongside adaptation to the HACCP risk analysis, to take into account the applicable requirements and to define the criteria for success. This involves creating a project team consisting of representatives of various sectors including Engineering, Production, Health and Safety at Work as well as Quality Assurance. Each of the four In the subsequent operational validation (OV) the key element is to prove the function and process capa- bility of the units within the context of the relevant process stages. The focus of evaluation lies here on the features directly characteristic of prod- ucts and productions and the results of the peripheral processes (cleanli- ness and sanitation). Finally, performance validation forms the basis for the final registra- tion for the process change or instal- lation. For this all results and informa- tion are assessed by reference to the success criteria of the OV. In addition, routine tests are car- ried out during production and a final report is compiled. The 4-stage approach has so far proved itself, especially as regards the cross-func- tional collaborative work carried out within the project team, the utilisa- tion of a central data base for com- munication and documentation, the “customising” of the test plans on the basis of existing protocols and in the integration of central resources during the OV, said Hickstein, taking stock. There were further advantages to be identified in the evaluation of process stages over and above the require- ments of the Coca-Cola Company and in the utilisation of the data derived for technical acceptance purposes. www.akademie-fresenius.de steps to validation must be formally signed off by the team before going forward with the project (Gate func- tion), explained Hickstein. In order, the four steps comprise the following:  Design,  Installation,  Operational and  Performance Validation. Each of the stages is built up simultaneously one directly on top of the other, but the design validation (DV) is at its heart and the installation, operational and performance valida- tion is always based on the founda- tion stone of design validation. The method to be adopted for selecting new equipment or the desired technol- ogy is considered, i.e. the decision- making processes are set out and documented. To this end a risk analy- sis is carried out in which the relevant aspects of quality, food safety and Health & Safety at Work as well as Environmental and Energy Manage- ment are included. The next stage, the installation val- idation (IV), deals with the actual reali- sation compared to the specification established in the DV. The hardware supplied and/or the technology is syn- chronised with the DV specification and the order specification and rele- vant parameters of the actual installa- tion (e.g. measurements, dimensions, compatibility of the materials used etc.) documented. BHSJOUM DPN t 5FM t & NBJM TBMFT!BHSJOUM DPN Want the real secret to bottle light weighting? Measurement and process control systems for the packaging industry Process Pilot ® automated blowmolder control system can make the difference between a modest attempt at light weighting and a truly successful program. Process Pilot works with your blowmolder to continually monitor and maintain material distribution on every bottle to an unmatched degree of accuracy. Featuring automatic adjustment and 24/7 control , Process Pilot can facilitate even the most aggressive light weighting program while ensuring the highest quality and performance! Not convinced? Contact us to set up an in-house seminar to learn more about what Process Pilot offers or a free in-plant trial to experience the difference first hand.