In the rapidly evolving world of regulatory legislation, good manufacturing practice (GMP) and industry compliance for the liquid food, beverage, nutrition and pharmaceutical industries in particular, our products, as well as our strategy and decision making,  adhere to the highest standards of environmental and corporate social responsibility, giving our customers and their employees peace of mind.

Whatever the industry sector, EIT International’s preventative control technology systems can facilitate improved performance and efficiency, delivering a realistic return on investment in a fast turnaround, short time frame.

 

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Bactiscan

Food processors have a common problem in detecting bacteria and bio films that could contaminate the end product. Currently, processors use ATP tests for measuring actively growing microorganisms through detection of adenosine triphosphate, or ATP. Although this process is good, it is not fool proof due to the minute size of physical swab point compared to overall volume of surface, and the physical swab procedure is cumbersome. Other technologies include florescent markers and gels; however, these are not environmentally friendly and, again, due to minute size of physical test area a true result is impossible to gauge.

With Bactiscans’ unique wave alternating UV system, Bactiscan enables food processors to immediately isolate Biofilms, mould and bacteria such as salmonella and E.coli and many other contaminants are easily located and identified with Bactiscan which makes the remediation job much faster and therefore more cost effective.

These contaminants are often undetectable using other methods such as white light and UV lamps. With Bactiscan you can light up the entire surface and get an immediate result, so within seconds you can pick things up that would take hours with any other method.

 

How does the Bactiscan help elimate risk exposure caused by bacteria contaminants?

 
 

Find details for your local Bactiscan Reseller underneath the main 'Contact Us' form:Bactiscan Resellers Map

 

Frequently Asked Questions

Why should we test our surface areas after CIP?
In order to comply with HACCP requirements, processors need to identify CCPs (Critical Control Points), and/or areas within their production plant that may cause product contamination/failure. Examination of surface areas after CIP (Clean in Place) is now possible using the unique Bactiscan system, allowing the processor to comply with due diligence.
How often should we examine the surface areas?
Stainless steel surfaces, some of which are positioned within the production area should be examined regularly, searching for areas of biofilm and bacterial growth caused by poor cleaning systems, spray ball faults for example, defects may occur at any time during production, or when the item is CIP cleaned, these areas may cause product contamination at any time, so examination as frequently as possible is recommended.
I have used traditional methods for validating my CIP, what is the best methodology now?
Scanning in real time using EIT International’s Bactiscan. This equipment enables the processor to clearly see the biofilms in real time, enabling them to take swabs of the area to identify bacteria numbers.
We have seen people using U.V. to try to look for biofilms, why not use U.V. instead of Bactiscan?
Bactiscan works on the fringes of the UV spectrum, it is a system that is designed to detect protein shell around the bacteria and isolate biofilms that are not visible with U.V. and this is proven with validation documentation provided by Campden BRI
Is it correct that biofilms become hardened on the surface and cannot be washed off by CIP?
It is our experience that some biofilms are hidden behind a glass-like surface caused through continuous washing and chemical hardening and when swabs are taken, they are not detected with the swabbing technique. Bactiscan can highlight these regions and abrasive work is needed to remove the film in order to measure bacteria numbers. The danger for processors is that these films may become loose during production and release the biofilm into the product.
Where would your inspector look for these biofilms in my plant?
We would recommend that you isolate a line and scan all areas within that line, so 100% surfaces that are in contact with products. For example, we recently checked a sterile water vessel as this was the final examination when searching for a contamination that had happened. The vessel had serious biofilms that were obviously releasing into the final rinse before the line was filled with product, contaminating the whole line.
What are the environmental issues with testing using Bactiscan?
EIT International’s Bactiscan system has electronic sensors that can be used for many years without any consumables, so extremely environmentally friendly and cost effective.
Can you prove accuracy of the test?
The Bactiscan equipment comprises of real time scanner and test piece to replicate biofilms and bacteria on surfaces, proving accuracy. This process has been validated by Campden BRI
How safe is the equipment that you will use for the tests?
Bactiscan uses lightweight battery operated electronic sensors and transmitters to illuminate a surface.
What safety steps should I take whilst using Bactiscan?
We recommend that the inspector wear adequate eye protection in the form of protective glasses whilst using Bactiscan. Most production facilities will have safety glasses in situ. Safety glass lenses made of polycarbonate will naturally block 99.9% of UV light. So, even clear safety glasses will provide excellent protection. However should you require specific UV protection, a simple on-line search will provide a list of suppliers in their area.
How much downtime is needed for the Bactiscan test?
In most instances downtime is not required as long as the surface can be illuminated by Bactiscan. Bactiscan is able to examine an empty silo for example in approximately 30 minutes.
Would your test method find product residues on my filling machine?
Bactiscan is able to identify poorly cleaned areas of many surfaces including filling machines.

Bactiscope

EIT International’s BactiScope™ inspection cameras give you the freedom to inspect and investigate areas that would normally be inaccessible. Essentially, BactiScope™™ is a miniature camera, or probe, on a flexible cable that can be maneuverer into awkward areas such as piping or behind hard to get too cabinets. They then transmit a video feed via high energy area and camera head that allows you to see a close-up, real time view of inspection areas.

 

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Magnerscan

EIT International is an industry leader in the development and supply of environmentally friendly preventative controls and detection systems for the liquid food processing, nutraceutical, pharma-medical and petrochemical industries.

EIT International’s Magnerscan™ non-invasive testing system, uses ground-breaking technology to provide the fastest and most accurate surface integrity and crack detection results in the market. Cracks, pin-holes and general surface defects in metal are an important indicator reflecting the safety status of your production infrastructure. Magnerscan™ electronic surface integrity detection system utilises an array of close-contact inline sensors which is far superior to eddy current testing (ECT) and dye penetrant inspection (DPI) as it is environmentally friendly and does not require pre-test preparation. The operation of Magnerscan™ also requires limited training for the operator.

GMP (Good Manufacturing Practice), HACCP programmes and pathogen monitoring are essential for effective food safety programmes especially in the most widely used industrial process, spray drying. The importance of regular examination and testing of a spray dryer chamber is paramount in today's industries, cracks and defects have the potential source of microbial contamination that may lead to food spoilage or transmission of diseases.

Cracks/ defects will often emerge from active sites of pitting corrosion within holding, mixing and blending tanks at various regulated manufacturing sites. So-called chloride stress corrosion is a common cause of cracking, as it has the potential to release stored energy in the steel. This can be tensile stress caused by small variations in the thickness of stainless steel plates and residual tensile stress caused by welding, grinding, and bending deformation of the steel plates during fabrication. Temperature variations during cleaning will often promote release of such stress forces and lead to cracking

 

 

Frequently Asked Questions

Why should I test my vessels regularly?
In order to comply with HACCP requirements, processors need to identify Critical Control Points, and/or areas within their production facilities that may cause contamination of the product. Examination of internal surface areas in sprayer dryer chambers, processing and holding tanks, and silo’s has now become common practice in the liquid food industry.
How often should I examine my vessels?
Vessels, some of which are positioned within the production area, are regularly checked for cracks. Normally this is undertaken every six months, searching for pinholes, cracks and other defects inherent in this equipment. Defects may occur at any time during production, or when the vessel is opened for servicing or cleaning. Some defects are even detected when the vessel is new, either from the manufacturing process when cracks emanate from welding or from fitting attachments. These defects may cause product contamination in the form of bacteria or chemical leak into the product via the coolant jacket or proliferation in cracks, pinholes or insulation around the outer surfaces.
I have used traditional methods for testing my vessels, what is the best methodology now?
As vessels have inherent defects that can cause product contamination, there has been one method developed over the years to help prevent this; dye testing. This test method has shown inconsistencies that will be described in the following questions. EIT International has developed Magnerscan to address these inconsistencies.
What are the environmental issues with testing?
Traditional methods have many environmental issues. Chemicals and dyes have to be manufactured for tests and disposed of afterwards, mainly into the plant effluent system and then into a watercourse. The Magnerscan test system uses battery powered, electronic sensors that can be used for many years without consumables, addressing environmental concerns.
I would like to detect cracks before they leak; is it possible to know how deep these cracks are?
Using traditional dye-test methods, this would not be possible as the test reveals dyes that hold in all types of discontinuities, including scratches. When viewing fluorescent dyes in UV light, it is impossible to correctly assess these defects or determine their depth. The Magnerscan test method is able to accurately measure the size of the defect depth. This means that the processor can assess the seriousness of the defect before it will become a problem and the vessel fails. Determining the depth of a defect is particularly important in spray dryers where the vessel is working under pressure and deep cracks may allow contaminates to be sucked in from the exterior of the vessel.
Can you prove the accuracy of the test?
Dye testers may say that their method has been used for many years, so it must work, even though the procedure used is not a qualified test method normally used for dye testing in the aerospace and nuclear industries. Magnerscan uses a laser drilled test block with verified cracks at different depths to calibrate it crack depth detection. Additionally, Magnerscan can check for cracks in all directions at the same time.
How safe is the equipment that you will use for the tests?
Dye testers will mostly be carrying electrically operated equipment, either 110v, 240v or 415v while spraying dyes and water around vessels; electric shock is always a possibility. Additionally, the dyes and water have a viscous quality and create a risk of slipping or falling inside of the vessel. When spraying dyes, there is also an issue with inhalation. Magnerscan is a dry test, operating with battery power, involves no viscous liquid and eliminates the above risks.
How much production downtime is needed for the test?
Dye testing requires the vessel to be thoroughly cleaned, then dyes applied using a spray gun, wait for approximately one hour, wash off dye and another half an hour to view. So, a considerable time is involved, 4-6hrs. Magnerscan testing is carried out very quickly by simply scanning or ‘swiping’ over the vessel surface. It has been shown that Magerscan is 200 times faster than eddy current testing.
Would your test method find defects that are closed or filled with product residue?
Dye testing will not normally penetrate a closed defect due to surface tension. Also, any residual product, especially if greasy, will stop the dye from registering the defect. Magnerscan will definitely find these defects as it penetrates any residual product or closed crack defect. This can be proven by placing insulation tape over the pre drilled test block and scanning across it’s surface, where a defect will then be highlighted.
Will your Inspector be trained and qualified?
In accordance with our Quality Manual, all Inspectors are trained in the use of the relevent test equipment and methodology, by way of annual training and qualification certification.
Is your equipment calibrated and serviced regularly?
In accordance with EIT International’s ISO 9001 accreditation, all test equipment has unique numbering and is returned for annual upgrading when necessary, servicing and calibration. When calibrated, the equipment will stop working automatically after twelve months if not returned for it’s annual check-up. This ensures that calibration of the equipment is keep fully updated.
Traceability is very important to the producer, how can this be done with a vessel test?
Traditionally, a certificate will follow a dye test. EIT International has introduced full traceability for condition monitoring of vessels. This includes GPS location, date and time stamp, defect location via our defect mapping system with laser technology. This is imperative for ISO accredited organisations.

Gappscan

EIT International is an industry leader in the development and supply of environmentally friendly preventative controls and detection systems for the liquid food processing, nutraceutical, pharma-medical and petrochemical industries.

Gappscan™ is the most advanced and eco-friendly integrity testing solution for heat exchangers to the dairy, food, brewery and pharmaceutical industries. Heat exchanger testing is an important procedure for the early detection of internal leaks inside the equipment. If not found in good time, the product can become contaminated and spoilt, leading to waste and potential expensive recall of finished product.

Most cracked heat exchanger plates will show no symptoms of defect. Gappscan™ has been developed specifically to detect cross contaminating defects as low as a few microns in size, and is the only test system that can accurately measure defect size which allows processors to predict when a heat exchanger may fail, preventing unnecessary shutdown of an exchanger.

There are many other types of test procedures including dyes, chemicals, pressure and gas, but all of these test sensitivities are reduced with volume and therefore unreliable when testing large heat exchangers. Traditional test methods can only pass or fail a heat exchanger, they cannot determine the size of the defect or the leakage rate.

Benefits of Gappscan™ compared to other technologies:
  • Increase business project effectiveness of preventative maintenance programmes to your third party customers
  • Increase efficiency of your servicing teams allowing for multiple tests over shorter time frame.
  • Ability to monitor changes in heat exchanger behaviour and performance through regular on-site testing, avoiding the expense of prophylactic change.
  • Adheres to your food and beverage customers Sustainability Programme through environmentally friendly technology that does not require any harmful dyes, chemicals, gases or gels.
  • 100% accuracy in surface integrity and crack detection down to (1 micron) 30 microns (30um). Actual defect size can be gauged and measured against subsequent tests.
  • Gappscan™ identifies and reports numerous cracks and defects, alternative technologies will detect these as a single isolated fail only.
  • Deployed on all types of heat exchangers including plate and tubular
  • Non-invasive integrity testing technology, no requirement to disassemble heat exchanger
  • Minimal downtime, full on-site test carried out within 2 hours.
  • Full test equipment contained in a single suitcase size holdall and operated by a single person.

Hexteq

EIT International is an industry leader in the development and supply of environmentally friendly preventative controls and detection systems for the liquid food processing, nutraceutical, pharma-medical and petrochemical industries.

HEXTEQ™ is the most advanced and eco-friendly integrity testing solution for heat exchangers to the dairy, food, brewery and pharmaceutical industries. Heat exchanger testing is an important procedure for the early detection of internal leaks inside the equipment. If not found in good time, the product can become contaminated and spoilt, leading to waste and potential expensive recall of finished product.

Most cracked heat exchanger plates will show no symptoms of defect. HEXTEQ™ has been developed specifically to detect cross contaminating defects as low as a few microns in size, and is the only test system that can accurately measure defect size which allows processors to predict when a heat exchanger may fail, preventing unnecessary shutdown of an exchanger.

There are many other types of test procedures including dyes, chemicals, pressure and gas, but all of these test sensitivities are reduced with volume and therefore unreliable when testing large heat exchangers. Traditional test methods can only pass or fail a heat exchanger, they cannot determine the size of the defect or the leakage rate.

Benefits of HEXTEQ™ compared to other technologies:
  • Increase business project effectiveness of preventative maintenance programmes to your third party customers
  • Increase efficiency of your servicing teams allowing for multiple tests over shorter time frame.
  • Ability to monitor changes in heat exchanger behaviour and performance through regular on-site testing, avoiding the expense of prophylactic change.
  • Adheres to your food and beverage customers Sustainability Programme through environmentally friendly technology that does not require any harmful dyes, chemicals, gases or gels.
  • 100% accuracy in surface integrity and crack detection down to (1 micron) 30 microns (30um). Actual defect size can be gauged and measured against subsequent tests.
  • HEXTEQ™ identifies and reports numerous cracks and defects, alternative technologies will detect these as a single isolated fail only.
  • Deployed on all types of heat exchangers including plate and tubular
  • Non-invasive integrity testing technology, no requirement to disassemble heat exchanger
  • Minimal downtime, full on-site test carried out within 2 hours.
  • Full test equipment contained in a single suitcase size holdall and operated by a single person.
  • For a demonstration or further information on
 
 

Frequently Asked Questions

Why should I test my heat exchanger?
In order to comply with HACCP requirements, processors need to identify Critical Control Points and/or areas within their production facilities that may cause product contamination. Examination of internal surface areas in plate and tubular heat exchangers, coolers and pasteurisers has become common practice in the liquid food processing industry in order to comply with Due Diligence.
How often should I examine my heat exchanger?
Heat exchangers, most positioned within the production area, are regularly checked for cracks, normally six monthly, searching for pinholes, cracks and other defects inherent in this equipment. Defects may occur ay any time during production, or when the machine is opened for servicing; some defects can be detected even when the equipment is new, either from the manufacturing process when cracks emanate from the pressed areas, or from poor fitting. These defects may cause product contamination in the form of bacteria or chemical leakage into the product via the adjacent service/regeneration side of the exchanger.
I have used traditional methods to test heat exchangers, what is the best methodology now?
As heat exchangers have inherent defects that can contaminate the product, there have been may test methods developed over the years to help prevent this. These include; pressure testing, gas testing (Helium), conductivity testing, and dye testing. Inconsistencies in some of these methods will be described shortly. EIT International has developed Hexteq to address these inconsistencies.
I would like to detect cracks before they leak, is it possible?
Traditional test methods can only Pass or Fail a heat exchanger; they cannot determine the size of the defect or the leakage rate. The Hexteq test method is able to accurately measure the size of a defect. EIT International has determined that with a defect size of less than 20 microns and under a defined pressure, there will be no leakage or cross-contamination of the product. With this information, the processor is able to predict when a heat exchanger may fail and prevents unnecessary shut-down of an exchanger.
Can you prove the accuracy of the test?
Traditional methods have been used for many years and not normally validated for accuracy under processing conditions, Hexteq has proven University validation using laser drilled test holes in an industry standard heat exchanger, independently verified with a Scanning Electron Microscope.
How safe is the equipment that you will use for the tests?
Traditional methods use electrically operated equipment, either 110v, 240v or 415v; chemicals and gases are also used. Some of the common risks involved include, electric shock, chemical contamination, heavy lifting injuries. Hexteq uses lightweight, battery operated electronic sensors and transmitters only.
How much downtime is needed for the test?
Traditional methods may take many hours for one heat exchanger test, given the amount of equipment needed and the methodology used. Hexteq is able to examine a heat exchanger from both sides in approximately one hour.
Would the size of my heat exchanger affect test sensitivity?
All traditional methods are volume dependent and the larger the heat exchanger, the less sensitive the test will be. With Hexteq, the size of the heat exchanger is not a factor for this methodology as the sensors are searching for defect size and leakage volume in micro-litres. This is a critical improvement from traditional test techniques.
I have been told that if the test is carried out from one side only, it is possible to miss major defects; is that correct?
It has been proven that some cracks or defects may ‘close’ when pressurised from one side, making them undetectable and then ‘open’ when pressurised from the other side. This is due to plates either pushing together at critical defect areas, or cracks open like a door from one side, then close from the other side. Traditional methods cannot normally check from both sides as it is too time consuming to remove the donor gas or chemical from the recipient side. Hexteq is able to do this by simply switching pressure from one side to the other.
Traceability is very important to me, how can this be done with a heat exchanger test?
Traditionally, a certificate will follow the test. Hexteq introduces full traceability for the condition monitoring of heat exchangers. This includes GPS location of the test, date and time stamp, graph showing leakage rate and size of any holes inside the heat exchanger. For ISO approved production facilities this enables clear and concise auditing.

Pasflo

EIT International is an industry leader in the development and supply of environmentally friendly preventative controls and detection systems for the liquid food processing, nutraceutical, pharma-medical and petrochemical industries.

EIT International’s Pasflo™ system allows for non-intrusive pasteurisation validation to the liquid dairy, ice cream, brewery (cider) and juices industries without the need to stop production. Pasflo™ validates pasteurisation residents and flow rate during production.

The pasteurisation cycles devised for milk and juices often involve exposing the liquid to relatively high temperatures for very short lengths of time, the so-called high temperature, short time (HTST) pasteurisation we are most familiar with. The main advantage of Pasflo™ compared to other systems such as the conductivity test, is that it is completely non-intrusive and checks the holding time of the finished product, and not water.

The next generation of Pasflo™ will include verification to inline system as well as date and time stamp as well as on-line records for audit validation.

 
 

Frequently Asked Questions

Why should I test my Residence times?
In order to comply with HACCP requirements, processors need to identify CCPs (Critical Control Points), and/or areas within their production plant that may cause product contamination/failure. Examination of pasteurisation holding time by validating regularly has become common practice in the liquid food processing business in order to comply with Due Diligence.
How often should I validate my Holding Time?
Pasteuriser holding tube times are normally checked every 6 months, as any slight variation due to product fouling, pump reliability, valve performance etc. may affect the holding time, if the said time is reduced high bacteria counts may be evident, if the time is increased there may be product quality issues (taste for example). These problems may not be detected by simply checking phosphatase, as with skimmed milk for example most of the enzyme clings to cream .
I have used traditional methods for testing my Holding times, what is the best methodology now?
Many years ago, a system was developed in USA to carry out holding time tests, this involved stopping production, removing the holding tube, fitting conductivity sensors, then filling the system with water and injecting salts for time checks from beginning to end. EIT International has launched Pasflo WSN to address the inconsistencies. Pasflo has been introduced to test the holding time of product during production. It involves placing 4 sensors outside of the holding tube (none intrusive), then slightly raising product temp by a couple of degrees for a few seconds, then using a clever superimposing technique, calculating the time in minutes.
If the Pasflo test simply measures a temperature variation against time, why can’t I do this myself?
EIT International has researched this in detail, and when taking into account laminar and turbulent flows and relevant flow laws, it is important to superimpose images at both ends of the conduit to conclude a correct residence time. Hardware modules and software calculations are necessary to make the test accurate. Technical detail is therefore prohibited.
What are the environmental issues with testing?
Traditional methods have many environmental issues as the chemicals need to be manufactured for the test, then disposed of after test. EIT International’s systems are all electronic sensors that can be used for many years without any consumables, so the most environmentally friendly.
I would like to also calibrate or validate my flow meter, is it possible?
Using traditional methods this would not be possible as the test will show a time from beginning of tube to end of tube only. The Pasflo WSN method is able to accurately measure the Pasteurisation holding time of the tube and also during production, measure the flow rates at varying velocities. A big advantage over all other systems.
Can you prove accuracy of the test?
Traditional methods have been used for many years and not normally validated for accuracy under processing conditions. Pasflo has a proven validation using known holding tubes and an industry standard heat exchanger, independently verified with an industry standard and independently calibrated flow meter.
How safe is the equipment that you will use for the tests?
Traditional methods use electrically operated equipment, either 110v, 240v, or 415v, and also chemicals. Some of the many risks include electric shock, chemical contamination, heavy lifting injuries. Pasflo uses lightweight battery operated electronic sensors and transmitters only, therefore no risk.
How much downtime is needed for the test?
Traditional methods may take many hours to test 1 holding tube due to inconsistent results, this is all down time for production. The test should take an average from 3 checks within 0.5 seconds of each other, this is very difficult to do with inconsistent readings. Pasflo WSN can be done during production and has proven accuracy, requiring minutes to carry out successfully, and no loss of production.
Will your Inspector be trained and qualified?
In accordance with our Quality manual, all Inspectors shall be trained in the use of the relevant Test equipment and methodology, by way of annual training and Qualification certification. Ask to see the Inspector’s Qualification Certificate at any time.
Is your equipment calibrated and serviced regularly?
In accordance with EIT International’s ISO 9001 Accreditation, all test equipment has unique numbering and is returned to base annually for upgrading when necessary, servicing and calibration. When calibrated, the said equipment will expire and stop working after 12 months, this assures annual calibration.
Traceability is very important to me, how can this be done with a holding time test?
Traditionally, a Report will follow the test, that is it! Pasflo has introduced full traceability for the condition monitoring of Holding times, this includes GPS location, date and time stamp, graph showing test details, and for ISO approved organisations this is imperative.

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