Pressure loss in pipes: how can disinfection help?

In many production environments, process piping is only given a second thought when things go wrong: a blocked water pipe, for instance. Suddenly, production comes to a standstill and emergency cleaning is required. This is often more than just a technical issue. It may indicate the presence of biofilm in the pipe, which undermines product quality and microbiological safety, carrying the risk of non-conforming samples, additional cleaning rounds or, in the worst-case scenario, production losses and product recalls.

What signs indicate a blockage caused by biofilm?

Biofilm does not form overnight, but builds up gradually into an increasingly thick layer that can eventually block pipes.

There are a number of typical signs that biofilm is becoming a problem:

• Gradual loss of pressure: reduced pressure in certain sections of pipes or across filters and membranes.
• Irregular flow: some pipes clearly deliver less water than others, despite identical settings.
• Recurring microbiological abnormalities: fluctuating peaks in bacterial counts, indicator organisms or pathogens such as E. coli and Salmonella, despite regular disinfection.
• Slimy or discoloured inner walls: visible colour difference upon inspection or when dismantling pipe sections.
• Increase in odour or taste abnormalities in process or drinking water: you notice that an abnormal or unpleasant odour and taste occur more frequently, which may indicate microbial activity and biofilm formation in the pipework system.
• Shorter cleaning intervals: filters and cartridges become clogged more quickly and CIP must be carried out more frequently.

How much does a blocked process pipe cost your business?

A blocked process water pipe is rarely an isolated problem and can lead to the following consequences, amongst others:

• Product loss/shutdowns: in the event of blockages, lines often need to be drained or flushed, resulting in the disposal of semi-finished or finished products. The production shutdowns themselves also lead to lower output and additional cleaning and restart costs, particularly if the issues are not addressed in a timely manner.
• Extra labour and maintenance: engineers, external plumbers or cleaning teams must suddenly be called in for emergency repairs and intensive pipe cleaning.
• Accelerated wear: biofilm causes pipe systems to become narrowed and leads to microbiologically induced corrosion (MIC), resulting in the premature replacement of pipes, fittings and membranes.
• Quality and food safety risks: biofilm provides a hiding place for pathogens; if the biofilm erodes, large numbers of microorganisms can enter the water within a short period of time.
• Energy efficiency: in heat exchangers, cooling and heating circuits, blockages caused by biofilm result in poor heat transfer and higher energy consumption.

These costs are often hidden within various budgets (production, maintenance, energy, quality rejections), but they all stem from a single cause: inadequate control of biofilm in the process pipes.

Why is the Watter system a proven better solution for disinfecting pipes?

Hypochlorous acid (HOCl) is a powerful, broad-spectrum disinfectant that can be generated by the electrolysis of water and salt, in a process known as electrochemical activation (ECA).

An in-situ HOCl solution, such as that offered by Watter, provides significant benefits for disinfection and the prevention of biofilm in pipework systems:

• Highly effective against biofilm: HOCl can penetrate biofilm and rapidly and effectively eliminate the bacteria, fungi and algae present within it, causing the slimy layer to break down and thereby reducing the risk of blockages.
• Continuous and controlled dosing: as HOCl is produced on-site, it can be added to the water in low doses 24/7, thereby continuously controlling biofilm formation rather than combating it periodically.
• Sustainable production process: production requires only water, salt and electricity, with no need for the storage or transport of hazardous chemicals.
• Lower operating costs: thanks to on-site production, the company is less reliant on external suppliers and transport, meaning that once the initial investment has been made, additional costs (transport/storage) are low.