Acoustic sensing and signal processing techniques for monitoring milk fouling cleaning operations

Large resource investments are necessary in order to minimize the limiting problems arising from food industrial intensive productivity. One of the most challenging concerns is the cleaning status uncertainty among heat transfer areas in dairy heat exchangers, since the effectiveness of this process cannot be easily validated. The present study aimed to develop a low‐power ultrasound sensing method for monitoring the removal of milk fouling deposits along cleaning processes inside an experimental plate heat exchanger structure, connected to a milk piping unit. For that purpose, signal processing, namely acoustic feature extraction, over different wave patterns combined with artificial neural network techniques was used. Measurements were taken in pulse‐echo mode with a handmade 4 MHz ultrasound transducer. While fouling deposits having initial average thickness values of 250 μm (34.5 ± 4.5 mg/cm²) were removed, the acoustic transmissivity increased. Results showed that the signal features follow the expected trends in both, clean and fouled cases, within right guess detection accuracies above 80%. Therefore, when calibrated well, this could be a very sensitive and noninvasive technique for material characterization, as well as a suitable validation method for industrial cleaning cycle operation optimization that could significantly reduce the associated costs.     

Methodology for a comparative evaluation of sensitivity to fouling and cleanability of floor materials used in the food industry

Samples of floor materials used at present in different types of food plants were studied for their sensitivity to fouling and for their cleaning properties. A cleaning procedure close to that used in industry was carried out on seven different floor samples fouled with six industrial soils (e.g. green salad soil, reconstituted milk, and meat) and inoculated with spores of Bacillus stearothermophilus var. calidolactis as tracer. Sensitivity to fouling and the cleanability of the different floor materials were measured, and the results showed a significant difference between them. These differences were dependent upon the type of soil. Sensitivity to fouling and cleanability were not correlated with their slipping resistance characteristics.     

A comparison of two fouling‐resistant heat exchangers

Fouling cannot always be prevented; it is important to consider the design of fouling‐resistant heat exchangers. To examine these exchangers, a test fluid whose fouling behaviour is understood should be used. Experiments have been conducted to examine the response of two model systems, a pulsatile flow and a fluid bed heat exchanger, to fouling from whey protein concentrates. Both systems are effective in certain cases, although the enhanced mass transfer possible in the pulsatile flow exchanger can increase fouling when mass transfer controls deposition. This demonstrates the possible danger in installing “antifouling”; systems. The possible mechanisms by which antifouling exchangers operate is discussed; they may work both by slowing the kinetics of fouling or enhancing the heat transfer coefficient. A simple model to demonstrate the design of antifouling exchangers is presented.     

Comparative Study on Caustic and Enzymatic Cleanings of Stainless Steel Surface Fouled with β-Lactoglobulin

Desorption behavior of β-lactoglobulin (β-Lg), one of the main constituents of fouling deposits in milk processing, from stainless steel surfaces during caustic and enzymatic cleanings was studied by using a glass column packed with stainless steel particles fouled with β-Lg. Both in caustic and enzymatic cleanings, the amount of β-Lg remaining on the stainless steel particles decreased according to first-order kinetics at the initial stage, and gradually reached a constant value. The desorption rate constant at the initial stage and the residual amount of β-Lg after 2 h of cleaning were evaluated as the measures of cleaning efficiency under various conditions. In caustic cleaning, these two values were strongly affected by the concentration of NaOH. The initial desorption rate increased with increasing flow rate of the caustic solution, suggesting a mass transfer effect. In enzymatic cleaning, the maximum desorption rate constant was obtained at around the optimum pH for the enzyme reaction. The temperature dependence of the initial desorption rate constant was stronger in caustic cleaning than in enzymatic cleaning.     

Life cycle assessment of a detailed dairy processing model and recommendations for the allocation to single products

Purpose

This study analyses the environmental impacts referring to dairy products and to the operation of a dairy. The study aims to better understand different process stages in a dairy operation. This analysis can be used to improve the flows of energy, water, and materials in the dairy operation. The results are also used to suggest an improved allocation model for assigning the impacts of operation to single dairy products.

Methods

The analysis is based on a detailed, product-specific model calculation for the use of energy, water, and chemicals for more than 40 subprocesses of a dairy operation. This model has been used to elaborate the life cycle inventory for a detailed life cycle assessment study. The environmental impacts are analyzed from cradle to gate including and excluding the raw milk input. The environmental impacts are assessed with the midpoint indicators suggested by the International Reference Life Cycle Data System. Finally, results of this study are compared with an allocation model recommended for life cycle assessment (LCA) studies on milk products.

Results and discussion

The analysis of the model dairy shows that raw milk production has the main impact in all categories. Consumer packaging has the second biggest impact in many categories. The detailed dairy processing model allows the assignment of inputs and outputs for each subprocess to single dairy products and thus avoids allocation largely. The analysis of inputs to different dairy products per kilogram shows that ultra-high-temperature (UHT)-processed milk uses more chemicals for cleaning compared to the other products. Cream uses more electricity and heat compared to UHT milk and to yogurt.

Conclusions

A detailed discussion shows the overlaps and differences found for the allocation of inputs to the milk processing to final dairy products. Allocation models for different types of inputs are partly confirmed by the detailed theoretical model used for this LCA. The allocation of chemicals, steam, and electricity to single products can be improved based on the detailed dairy model developed in this study.

     

Ship hull in-water cleaning and its effects on fouling-control coatings

Abstract

Today, ship hull fouling is managed through fouling-control coatings, complemented with in-water cleaning. During cleaning, coating damage and wear must be avoided, for maximum coating lifetime and reduced antifoulant release. When possible, cleaning should target early stages of fouling, using minimal forces. However, such forces, and their effects on coatings, have not yet been fully quantified. In this one-year study, minimal cleaning forces were determined using a newly-designed immersed waterjet. The results show that bi-monthly/monthly cleaning, with maximum wall shear stress up to ～1.3?kPa and jet stagnation pressure ～0.17?MPa, did not appear to cause damage or wear on either the biocidal antifouling (AF) or the biocide-free foul-release (FR) coatings. The AF coating required bi-monthly cleanings to keep fouling to incipient slime (time-averaged results), while the FR coating had a similar fouling level even without cleaning. The reported forces may be used in matching cleaning parameters to the adhesion strength of the early stages of fouling.     

Effect of Manual Brush Cleaning on Biomass and Community Structure of Microfouling Film Formed on Aluminum and Titanium Surfaces Exposed to Rapidly Flowing Seawater

Metals exposed to rapidly flowing seawater are fouled by microbes that increase heat transfer resistance. In this study, results of biochemical test methods quantitatively relating the biomass and community structure of the microfouling film on aluminum and titanium to heat transfer resistance across the metal surface during three cycles of free fouling and manual brushing showed that cleaning accelerates the rate of fouling measured as the loss of heat transfer efficiency and as microfouling film biomass. The results also showed that the rate of fouling, measured as an increase in heat transfer resistance, is faster on titanium than on aluminum but that the titanium surface is more readily cleaned. In three cycles of free fouling and cleaning with a stiff-bristle nylon brush, the free-fouling communities re-forming on aluminum became enriched in bacteria containing short-branched fatty acids as the cycling progressed. The free-fouling community on titanium revealed an increasingly diverse morphology under scanning electron microscopy that was enriched in a portion of the microeucaryotes. Brushing removed most of the biomass, but left a residual community that was relatively enriched in a portion of the bacterial assembly containing cyclopropane fatty acids on aluminum and in a more diverse community on the titanium surface. The residual communities left after cleaning of titanium revealed an increase in bacteria with short-branched fatty acids and in microeucaryotes as cleaning continued. No significant changes occurred in the residual microbial community structure left on aluminum with cleaning; it was, again, less diverse than that remaining on titanium. The residual communities secreted a twofold-larger amount of extracellular polymer, measured as the ratio of total organic carbon to lipid phosphate, than did the free-fouling community on both surfaces.     

Detection of dairy fouling: Combining ultrasonic measurements and classification methods

Fouling and cleaning in heat exchangers are severe and costly (up to 0.3% of gross national product) issues in dairy and food processing. Therefore, reducing cleaning time and cost is urgently needed. In this study, two classification methods [artificial neural network (ANN) and support vector machine (SVM)] for detecting protein and mineral fouling presence and absence based on ultrasonic measurements were presented and compared. ANN is based on a multilayer perceptron feed forward neural network, whereas SVM is based on clustering between fouling and no fouling using a hyperplane. When both fouling types (1239 datasets) were combined, ANN showed an accuracy of 71.9% while SVM displayed an accuracy of 97.6%. Separate fouling detection of mineral/protein fouling by ANN/SVM was comparable: dependent on fouling type detection accuracies of 100% (protein fouling, ANN and SVM), and 98.2% (SVM), and 93.5% (ANN) for mineral fouling was reached. It was shown that it was possible to detect fouling presence and absence offline in a static setup using ultrasonic measurements in combination with a classification method. This study proved the applicability of combining classification methods and fouling measurements to take a step toward reducing cleaning costs and time.     

Efficacy of different antifouling treatments for seawater cooling systems

In an industrial seawater cooling system, the effects of three different antifouling treatments, viz. sodium hypochlorite (NaClO), aliphatic amines (Mexel®432) and UV radiation, on the characteristics of the fouling formed were evaluated. For this study a portable pilot plant, as a side-stream monitoring system and seawater cooling system, was employed. The pilot plant simulated a power plant steam condenser, having four titanium tubes under different treatment patterns, where fouling progression could be monitored. The nature of the fouling obtained was chiefly inorganic, showing a clear dependence on the antifouling treatment employed. After 72 days the tubes under treatment showed a reduction in the heat transfer resistance (R) of around 70% for NaClO, 48% for aliphatic amines and 55% for UV, with respect to the untreated tube. The use of a logistic model was very useful for predicting the fouling progression and the maximum asymptotic value of the increment in the heat transfer resistance (ΔR _max). The apparent thermal conductivity (λ) of the fouling layer showed a direct relationship with the percentage of organic matter in the collected fouling. The characteristics and mode of action of the different treatments used led to fouling with diverse physicochemical properties.     

The impact of body condition after calving on metabolism and milk progesterone profiles in two breeds of dairy cows

Background

Optimal body condition in early lactation is generally accepted as a prerequisite for good reproductive performance. Examination of milk progesterone profiles offers an objective method for characterization of postpartum ovarian activity in dairy cows. The present study investigated the relationship between body condition after calving, some metabolic parameters in blood plasma, and fertility, as reflected by milk progesterone profiles in the two dairy breeds Swedish Red (SR) and Swedish Holstein (SH).

Results

Multiparous dairy cows (n = 73) of SR and SH breeds were selected and divided into three groups based on their body condition score (BCS) after parturition. Selected plasma metabolites were determined, milk progesterone profiles were identified and body condition was scored. Over-conditioned cows and atypical progesterone profiles were more common among SR cows. Insulin sensitivity was lower and IGF 1 higher among SR cows. Insulin was positively related to body condition, but not related to breed.

Conclusions

Atypical progesterone profiles were more common and insulin sensitivity lower in SR than in SH cows, but the SR breed had a higher proportion of over-conditioned SR cows. It is reasonable to assume that breed differences in body condition contributed to these results.

     

Rhamnolipid as new bio‐agent for cleaning of ultrafiltration membrane fouled by whey

In this work, rhamnolipid biosurfactant as an eco‐friendly and biodegradable cleaning agent was produced by Pseudomonas aeruginosa bacteria and was used to evaluate the chemical cleaning efficiency of whey fouled ultrafiltration membranes. Thin layer chromatography (TLC) and Fourier transform infrared spectroscopy (FTIR) confirmed the successful synthesis of rhamnolipid. The produced rhamnolipid was compared to chemical cleaners including sodium hydroxide (NaOH), sodium dodecyl sulfate (SDS) and Tween 20. Ultrafiltration membranes used for fouling and cleaning analysis were prepared using phase inversion via immersion precipitation technique. For studying the fouling mechanisms, Hermia's model adapted to cross‐flow was used. From the fouling mechanism experiments, it was found that the complete blocking and cake formation were the dominant fouling mechanisms. The highest values of cleaning efficiency were achieved using rhamnolipid and NaOH as cleaning agents with the flux recovery of 100%, but with considering the low concentration of the rhamnolipid used in the cleaning solution compared to NaOH (0.3 versus 4 g/L for NaOH), its application is preferred.     

Modeling heat stress effects on dairy cattle milk production in a tropical environment using test-day records and random regression models

In tropical environments, dairy cattle production is constrained by several factors, including climate. The seasonal loss of milk due to heat stress is a recurring challenge for many dairy producers. The objective of this study was to detect heat stress thresholds, milk yield loss and individual animal variations using random regression models for dairy cattle from test-day milk records. Data were obtained from the Kenya Livestock Breeders Organization for the years 2000–2017 and merged with weather data. The weather parameters were grid-interpolated solar and meteorological data obtained from the National Aeronautics and Space Administration/Prediction Of Worldwide Energy Resources (NASA/POWER). After editing, the records comprised 49 993, 45 251 and 36 136 test-day records for first, second, and third lactations, respectively, for the four main dairy breeds: Friesian (68.0%), Ayrshire (21.1%), Jersey (7.6%) and Guernsey (3.3%). Variance components were estimated using Restricted Maximum Likelihood in ASReml software. Random regression models with third-order Legendre polynomials were fitted to the average and individual lactation curves and the reaction norms. An extended factor analytic variance structure for the random cow effects was used to estimate (co)variances between days in milk and thermal load. The daily average temperature (TA) and temperature humidity index (THI) were identified as the most suitable thermal load indicators for assessing milk yield losses. Considering a one day lag, the estimated heat stress thresholds were about 22 °C and 69 index units for TA and THI, respectively. Almost no differences were observed for estimated residual variances between the thermal load indicators, indicating there was no better model fit by TA or THI. The heat stress thresholds and milk loss patterns are important for management of dairy production systems in the tropics with climatic conditions similar to this study. Data recording should be improved as a tool to monitor the expected impacts of climate change and mitigation measures.     

Abiotic and Microbiotic Factors Controlling Biofilm Formation by Thermophilic Sporeformers

One of the major concerns in the production of dairy concentrates is the risk of contamination by heat-resistant spores from thermophilic bacteria. In order to acquire more insight in the composition of microbial communities occurring in the dairy concentrate industry, a bar-coded 16S amplicon sequencing analysis was carried out on milk, final products, and fouling samples taken from dairy concentrate production lines. The analysis of these samples revealed the presence of DNA from a broad range of bacterial taxa, including a majority of mesophiles and a minority of (thermophilic) spore-forming bacteria. Enrichments of fouling samples at 55°C showed the accumulation of predominantly Brevibacillus and Bacillus, whereas enrichments at 65°C led to the accumulation of Anoxybacillus and Geobacillus species. Bacterial population analysis of biofilms grown using fouling samples as an inoculum indicated that both Anoxybacillus and Geobacillus preferentially form biofilms on surfaces at air-liquid interfaces rather than on submerged surfaces. Three of the most potent biofilm-forming strains isolated from the dairy factory industrial samples, including Geobacillus thermoglucosidans, Geobacillus stearothermophilus, and Anoxybacillus flavithermus, have been characterized in detail with respect to their growth conditions and spore resistance. Strikingly, Geobacillus thermoglucosidans, which forms the most thermostable spores of these three species, is not able to grow in dairy intermediates as a pure culture but appears to be dependent for growth on other spoilage organisms present, probably as a result of their proteolytic activity. These results underscore the importance of abiotic and microbiotic factors in niche colonization in dairy factories, where the presence of thermophilic sporeformers can affect the quality of end products.     

Ecological interactions between invasive and native fouling species in the reservoir of a hydroelectric plant

In this study, we investigate the main ecological interactions between fouling aquatic organisms (both invasive and native) present in the reservoir of the Governador José Richa hydroelectric plant, located in southern Brazil, and to identify the most suitable period for the interruption of machinery operation for cleaning and maintenance of the hydraulic systems of this plant. A total of 32 experimental plates were fixed to a metallic structure positioned close to the plant's water intake. Three species of invasive fouling were identified in our samples (Limnoperna fortunei [Mollusca], Cordylophora sp., and Hydra sp. [Cnidaria]) and six native taxa belonging to the phyla Protozoa, Ciliophora, Amoebozoa, and Arthropoda. Spring and summer were the seasons with the highest fouling rates, as well as densities of fouling organisms. The highest levels of diversity were recorded during the colder seasons. Several interactions between the organisms were identified, such as mutualism, commensalism, competition, epibiosis, cannibalism, and predation. The data obtained suggest that, from the biological point of view, the most suitable period for machine shutdown destined for the removal of biological fouling in the hydraulic systems of the studied plant is between the end of spring and the beginning of summer.

     

D-LL-31 in combination with ceftazidime synergistically enhances bactericidal activity and biofilm destruction in Burkholderia pseudomallei

Deposits on surfaces in water-bearing systems, also known as ‘fouling’, can lead to substantial losses in the performance of industrial processes as well as a decreased product quality. Early detection and localization of such deposits can, to a considerable extent, save such losses. However, most of the surfaces that become fouled, for example, in process water pipes, membrane systems, power plants, and food and beverage industries, are difficult to access and analyses conducted on the water phase do not reveal the site or extent of deposits. Furthermore, it is of interest to distinguish biological from non-biological deposits. Although they usually occur together, different countermeasures are necessary. Therefore, sensors are required that indicate the development of surface fouling in real-time, non-destructively, and in situ, preferably allowing for discrimination between chemical and/or biological deposits. In this paper, an optical deposit sensor is presented which fulfills these requirements. Based on multiple fluorescence excitation emission matrix analysis, it detects autofluorescence of amino acids as indicators of biomass. Autofluorescence of nicotinamide adenine dinucleotide?+?hydrogen is interpreted as an indicator of biological activity, thus it acts as a viability marker, making the method suited for assessing the efficacy of disinfection treatments. Scattering signals from abiotic deposits such as calcium carbonate or corrosion products can clearly be distinguished from biotic substances and monitored separately. The sensor provides an early warning of fouling, allowing for timely countermeasures to be deployed. It also provides an assessment of the success of cleaning treatments and is a promising tool for integrated antifouling strategies.     

The resistance to heat of thermo-resistant streptococci attached to stainless steel in the presence of milk

Skim milk residues had a significant impact on the sensitivity to heat of a dairy isolate of the thermo-resistant, Streptococcus thermophilus. Cells of S. thermophilus (H) suspended in water or in milk had D values at 60°C of 2.0 and 14 min, respectively. Cells of S. thermophilus (H) attached to stainless steel in the presence of water or milk had D values at 60°C of 2.2 and 8.1 min, respectively. The attached cells in both experiments were heat-treated in the presence of water. The increase in heat resistance could not be fully attributed to individual components (caseinate or whey) in the milk. The potential for thermo-resistant streptococci to survive heat treatment in a dairy manufacturing plant is therefore greater than may be expected for the organism in less complex environments. Journal of Industrial Microbiology & Biotechnology (2002) 28, 134–136 DOI: 10.1038/sj/jim/7000229 Received 06 September 2001/ Accepted in revised form 17 November 2001     

淡水入侵生物沼蛤的污损机制与防污措施研究进展

沼蛤是一种典型的淡水入侵贝类,能够利用其分泌的足丝牢固黏附在多种水下基质表面,引起严重的生物污损问题。沼蛤污损不但影响水生态系统健康,也给水利工程、交通运输、水产养殖等行业带来经济损失,已成为全球水生态系统安全和国民经济重要行业的潜在威胁,相关防污工作亟待开展。欲从根本上解决沼蛤污损问题,一方面需要加强对其基础生物学特性和污损机制的深入解析,另一方面也需要在此基础上研发更加经济、高效、环境友好的防污措施。本文综述了近年来国内外关于沼蛤污损生物学特性、污损机制和防污措施方面的研究进展,尤其是对沼蛤生物污损发生的主要机制如足探测识别、足丝黏附和环境影响等方面进行了总结,也从物理、化学、生物和防污材料等角度阐述了现有的沼蛤污损控制措施并对未来发展方向进行了展望,以期更加深入地理解沼蛤生物污损现象,为揭示其作用机制、制定科学有效的防污措施、维护水生态系统安全提供数据支撑,综述内容对于水下仿生材料研发也具有重要的参考价值。     

Commensalism or mutualism: conditional outcomes in a branchiobdellid–crayfish symbiosis

A growing body of evidence suggests that the costs and benefits involved in cleaning interactions can vary over space and time depending on the environmental conditions. However, whether the same cleaners actually induce variable net outcomes in terms of host fitness remains unclear to date. Branchiobdellid annelids are generally regarded as commensals or rarely parasites of their freshwater crayfish hosts, but a recent study suggests that they may also function as cleaning organisms. Under natural conditions, crayfish can experience fouling of the exposed surfaces of their exoskeletons and their gills (e.g., epibiosis) by various epibionts and particles of organic debris, and branchiobdellids graze on these sources of fouling. Here, we examined the extent to which variation in fouling pressure in the environment alters the outcome of the interaction between branchiobdellids and their crayfish host Cambaroide similis. A series of manipulations were performed in artificial environments designed to simulate either high or low fouling pressure. We used crayfish growth rates and mortality as direct measurements of the net costs and benefits of cleaning. Branchiobdellids had no significant effect on crayfish growth or mortality when cultured under low fouling pressure. However, their presence had a significant positive impact on host growth rates when cultured under high fouling pressure. These results suggest that the relationship between crayfish and branchiobdellids can fluctuate between commensalism and mutualism depending mainly on the environmental fouling pressure. We hypothesize that the outcome of cleaning interactions may largely depend on the factors directly related to the need for cleaning, such as parasite loads or fouling pressure.     

Assessment of the potential suitability of selected commercially available enzymes for cleaning-in-place (CIP) in the dairy industry

The potential suitability of 10 commercial protease and lipase products for cleaning-in-place (CIP) application in the dairy industry was investigated on a laboratory scale. Assessment was based primarily on the ability of the enzymes to remove an experimentally generated milk fouling deposit from stainless steel (SS) panels. Three protease products were identified as being most suitable for this application on the basis of their cleaning performance at 40°C, which was comparable to that of the commonly used cleaning agent, 1% NaOH at 60°C. This was judged by quantification of residual organic matter and protein on the SS surface after cleaning and analysis by laser scanning confocal microscopy (LSCM). Enzyme activity was removed/inactivated under conditions simulating those normally undertaken after cleaning (rinsing with water, acid circulation, sanitation). Preliminary process-scale studies strongly suggest that enzyme-based CIP achieves satisfactory cleaning at an industrial scale. Cost analysis indicates that replacing caustic-based cleaning procedures with biodegradable enzymes operating at lower temperatures would be economically viable. Additional potential benefits include decreased energy and water consumption, improved safety, reduced waste generation, greater compatibility with wastewater treatment processes and a reduction in the environmental impact of the cleaning process.     

Countermeasures to Microbiofouling in Simulated Ocean Thermal Energy Conversion Heat Exchangers with Surface and Deep Ocean Waters in Hawaii

Countermeasures to biofouling in simulated ocean thermal energy conversion heat exchangers have been studied in single-pass flow systems, using cold deep and warm surface ocean waters off the island of Hawaii. Manual brushing of the loops after free fouling periods removed most of the biofouling material. However, over a 2-year period a tenacious film formed. Daily free passage of sponge rubber balls through the tubing only removed the loose surface biofouling layer and was inadequate as a countermeasure in both titanium and aluminum alloy tubes. Chlorination at 0.05, 0.07, and 0.10 mg liter^-1 for 1 h day^-1 lowered biofouling rates. Only at 0.10 mg liter^-1 was chlorine adequate over a 1-year period to keep film formation and heat transfer resistance from rising above the maximum tolerated values. Lower chlorination regimens led to the buildup of uneven or patchy films which produced increased flow turbulence. The result was lower heat transfer resistance values which did not correlate with the amount of biofouling. Surfaces which were let foul and then treated with intermittent or continuous chlorination at 0.10 mg of chlorine or less per liter were only partially or unevenly cleaned, although heat transfer measurements did not indicate that fact. It took continuous chlorination at 0.25 mg liter^-1 to bring the heat transfer resistance to zero and eliminate the fouling layer. Biofouling in deep cold seawater was much slower than in the warm surface waters. Tubing in one stainless-steel loop had a barely detectable fouling layer after 1 year in flow. With aluminum alloys sufficient corrosion and biofouling material accumulated to require that some fouling coutermeasure be used in long-term operation of an ocean thermal energy conversion plant.