Notes on Compressed Air Contaminants and Testing

Introduction to Compressed Air Contaminants

In this session of Food Safety Fridays, Simon Templin and Maria Sandoval from Trace Analytics discussed critical points regarding compressed air testing in the context of food safety. Maria Sandoval, the lab director at Trace Analytics, described their role in providing compressed air testing services and emphasized the importance of identifying contaminants that could affect food products. Compressed air is vital in various industries, especially in food manufacturing, hence ensuring its purity is essential to prevent contamination.

Overview of Trace Analytics

Founded in 1989, Trace Analytics is a laboratory specializing in compressed air testing and ensuring compliance with international standards (ISO 17025). They are involved in various regulatory standards including SQF, BRCGS, and ISO 8573. The lab emphasizes collaboration and learning in the field of compressed air testing to refine and improve standards and methodologies.

Understanding Compressed Air Contaminants

The primary focus of the presentation was to discuss various contaminants found in compressed air, which include:

  • Particulates: These are solid particles generated from the wear of equipment or environmental exposure.

  • Water: Moisture in the air can lead to corrosion of pipes and equipment.

  • Oil: Comes from the lubricants used in the compressor system, which can contaminate the air.

  • Microorganisms: These can be introduced through the ambient air intake and can affect food safety if not monitored.

Maria explained that it is necessary to both identify and mitigate these contaminants to prevent harm to products and staff within the food industry.

Importance of Compressed Air Testing

Compressed air is often referred to as the "fourth utility" next to electricity and water due to its widespread use in various industrial applications. Testing is essential not only to comply with regulations but also to ensure that air quality does not contaminate food products. Maria presented shocking images depicting how contamination could lead to catastrophic failures in product safety if proper tests are not performed regularly.

Standards and Regulatory Guidelines

Maria discussed ISO 8573, a crucial standard that helps facilities define their air purity requirements. ISO 8573 provides purity classes for airborne particulates, water vapor, and oil that can guide companies in determining necessary filtration and testing needs. Regulatory bodies such as SQF and BRCGS also have specific requirements for maintaining air quality to ensure the safety of food products.

Analyzing Test Results

Once testing is completed, understanding the results is crucial. Reports will provide details about the levels of particles, water, and oil contaminants but may indicate simple pass/fail outcomes without deeper insights. Companies are encouraged to dive deeper into what these results mean, determining the effectiveness of their air quality controls and identifying the sources of contamination.

Example of Test Results

A specific example discussed was the structure of a compressed air report which includes:

  • Purity Class: Indicates the acceptable contamination levels for the tested air.

  • Sample Results: Comparative values that indicate if there was a pass or failure.

  • Viable Microorganism Counts: Important for understanding the microbiological safety of the air.

Troubleshooting Contamination Causes

Maria stressed the importance of regularly analyzing and interpreting testing results to identify failure sources. These can include:

  • Ambient air quality

  • Condition of the compressor

  • Quality of the filtration systems

Regular quarterly testing is recommended to maintain compliance and ensure air quality over time and to be proactive against potential contamination incidents. Trend analysis helps anticipate maintenance needs and improvements in air quality control.

Advanced Testing and Analysis

The session also elaborated on advanced methodologies for identifying and troubleshooting contaminants, including:

  • Gas Chromatography Mass Spectrometry (GCMS): For identifying hydrocarbons and oil vapors.

  • Scanning Electron Microscopy (SEM): To analyze the composition of particles found in the air.

  • Phenotypic Identification: With systems like Biolog for determining the genus and species of microorganisms present.

Conclusion and Importance of Regular Testing

At the end of the session, Maria highlighted that regular and accurate testing is non-negotiable for ensuring the safety of products, particularly in food manufacturing. Test reports should not be regarded simply as bureaucratic tasks but as invaluable tools for informing operational protocols and ensuring product safety.

Maria encouraged attendees to leverage the power of data from testing and to consider real-time testing technologies in their facilities for better management of air quality.

Q&A Session

The session concluded with a Q&A segment where Maria answered various questions regarding microbiological standards, gas testing, filter replacements, and challenges with oil-free compressors. She provided insights into best practices, emphasizing the need for a risk-based approach to air quality and contamination management.