Case Study: Used Equipment Decontamination

Our Decontamination Service Team recently completed a decontamination of a used bacon slicing line for a food company.  Because it was a used piece of equipment, the company did not want to bring it into the facility without being decontaminated first. This was not only to preserve the current sterility of their production area, but also to ensure safe food production once the line was in use. The slicing line was placed within a trailer which provided a sealed chamber for safe decontamination. 10 biological indicators were placed within the trailer and equipment in order to show that a 6-log reduction had been achieved. Once the trailer was sealed, the decontamination started.  The entire setup and decontamination took 4 hours from start to finish, when it was safe to open the trailer and bring the equipment into the production area. All biological indicators came back negative for growth verifying that the decontamination was successful. Production was able to start on the bacon slicing line shortly after being installed within the production area, and the company has been safely producing food since.

Contaminated piece of equipment in your facility? Call ClorDiSys at (908) 236-4100 or email the Decontamination Service Team at service@clordisys.com.

Continuous vs. Pulsed UV-C

Not all ultraviolet disinfection is alike. In fact, not all ultraviolet light is alike. Ultraviolet light is divided into UV-A, UV-B, and UV-C rays. It is the wavelengths in the UV-C spectrum which offer the greatest germicidal potential. Some UV disinfection systems, like xenon pulse UV, use the full spectrum of ultraviolet light to disperse germ-killing energy. It is claimed that the xenon pulse is a more effective way to kill harmful bacteria because of its similarities to punching a wall, more punches will weaken it better than one. However, light is not a fist. It is a form of energy, and continual energy is more effective than turning it on and turning it off. Additionally, bulbs generating UV-A, UV-B, and UV-C wavelengths are inherently less effective in disinfection than continuous UV-C.

The US Veterans Administration commissioned an infection prevention research team led by Curtis Donskey, M.D., to conduct an independent study of continuous ultraviolet disinfection versus xenon pulse UV disinfection. The study tested a continuous UV-C robot which was run for the same length of time from the same point in the room as a pulsed xenon (PU-UV) unit.  The results showed surprisingly low pathogen kill rates for the pulsed xenon device, about .5 log for both C.diff and VRE, even as close as 4 feet.  The continuous UV-C robot demonstrated a much higher CFU reduction for the pathogens C. difficile, MRSA and VRE.  The study states, “PX-UV was less effective than continuous UV-C in reducing pathogen recovery on glass slides with a 10-minute exposure time in similar hospital rooms” and “the UV-C device achieved significantly greater log10 CFU reductions than the PX-UV device”. Not only did the continuous UV-C robot in the study show much stronger disinfectant results, but that it was not run for its entire cycle time. The study calls attention to the dangers of bold claims and trying to complete a disinfectant procedure too quickly.

Chart from VA Donskey study: Study results showing log reductions achieved by a UV-C and pulsed xenon devices
when run for the same time (10 min.) at the same distance from glass microscope slides (4 ft).
(PRNewsFoto/Infection Prevention Technologies)

To read more on the comparison of these two technologies, click here.

Decontamination of Spiral Freezers

The biggest challenge in successfully cleaning spiral freezers is trying to reach all the surfaces.  Spiral freezers are constructed with minimal clearances, making it hard to use traditional cleaning techniques such as the spraying of liquid chemicals.  The interior is too tight to maneuver cleaning equipment properly and operate it effectively.  Cleaning every nook and cranny inside of a spiral freezer is a very difficult task when taking into consideration all of the internal components, all of the hard to reach crevices, the difficulty in maintaining the correct contact time of the chemical being used, and the difficulty in the agent reaching all surfaces.

Chlorine dioxide gas has been proven effective at eliminating listeria from within spiral and tunnel freezers. ClorDiSys’ chlorine dioxide gas is made using a proprietary generation method and is registered with the US EPA as a sterilant providing a 6-log (99.9999%) reduction of all viruses, bacteria, fungi, molds and spores. As a true gas, chlorine dioxide naturally fills the spiral freezer evenly and completely, and with a molecule size smaller than the smallest organism, there’s no surface that is safe for pathogens to hide. Gaseous CD is the only decontaminant that penetrates water and decontaminates both the water and the surface beneath, which is important for spiral freezers that typically have condensation issues.

One facility which produced frozen sausages had a persistent listeria problem, resulting in consistent positive swabs. After one treatment with chlorine dioxide gas, the facility was able to eclipse 16 weeks without a single positive swab after testing 2-3 times per day. CD gas decontamination has been written into a quarterly preventive maintenance schedule.

Attend our Food Facility Decontamination Services webinar on June 7^th to learn more or stop by Booth #10 at the North American Food Safety and Quality 2018 on June 5-6^th to further discuss.

How Ultraviolet Light Help Prevent The Spread Of Ebola

While combating the highly infectious Ebola virus disease (EVD) outbreak in West Africa, aid workers and other visitors have been inadvertently exposed and contracting the virus. In 2014, a number of infected individuals were evacuated from Africa and returned to the United States for treatment. The Nebraska Biocontainment Unit (NBU) was one of the several receiving hospitals for these patients. The NBU and Omaha Fire Department’s emergency medical services coordinated patient transportation from the airport to the high-level isolation unit. Following patient admission into this unit, biocontainment staff members relocated the ambulance to an isolated, controlled-access area to be decontaminated. All surfaces in the cab and patient compartment were thoroughly wiped with bleach solution. Then, as a final disinfection step, the back of the ambulance was exposed to ultraviolet light.

Ultraviolet light is a specific part of the electromagnetic spectrum of light that offers bactericidal effects. It is the wavelengths in the UV-C spectrum, which offer the greatest germicidal potential. UV-C provides a dry, chemical-free, and residue-free method of disinfection effective against bacteria, viruses, fungi and spores. For this reason, ultraviolet light disinfection was not only used in the ambulances, but as the final step in decontaminating medical equipment, patients’ rooms, and bathrooms after patients were discharged. Acknowledging the known limitations that UV-C only disinfects the areas light can reach, the Nebraska Biocontainment Unit used four ClorDiSys Torch systems in tandem to ensure the proper exposure was achieved to inactivate the Ebola virus.

Read more about the effective use of ultraviolet lightdisinfection against Ebola here.

Learn more about ClorDiSys Solutions’ Torch here.

How Often You Should Schedule Preventative Decontamination

Over the past couple of years, we've noticed a shift within our decontamination services projects.  At first, all projects were in response to active contaminations.  More recently however, we've noticed a shift as more of our decontamination service projects have been scheduled as part of a preventive sanitation effort, aimed at providing a more thorough kill than traditional sanitation can achieve.  One of the more frequent questions we get when discussing preventive decontamination is, 'how often should we decontaminate?'  It's a great question, and its one that doesn't have a simple answer as every situation is different.

When discussing the frequency and scheduling of preventive decontamination, the best first step is to review your environmental monitoring data.  Sometimes, there's a trend within the data that can help guide the process along.  In these situations, we would propose to undercut that trend so that the decontamination takes place before the next positive "is expected."

Example:
A processing area shows positive environmental monitoring swabs approximately every 6-8 months. 

Proposed Preventive Schedule:
Decontamination every 5 months

For areas where there is no easy to determine a trend in positive environmental swabs, another approach must be taken.  In these situations, the following factors should be considered:

• The environment itself (a room, spiral freezer, entire processing area, etc...)
• The risk level of the product and environment (raw meat vs. canned foods vs. produce vs...)
• Historical environmental monitoring data
• Downtime / Availability of the space (24/7 production, 24/5 production, yearly shutdown, etc...)

We've seen preventive decontamination schedules ranging from daily (for the decontamination of brushes and dry cleaning tools within a Decon Chamber) to quarterly (Spiral Freezers and Aseptic Fill Rooms) to Annual (Processing Areas and Production Rooms).

If you're interested in learning more about Preventive Decontamination as a supplement to your sanitation program, contact us at 908-236-4100 or visit www.clordisys.com/foodsafetyapp

Chlorine Dioxide vs. Chlorine Dioxide: Choosing the Right Provider

ClorDiSys Solutions approaches decontamination differently than other chlorine dioxide gas companies. We strive for excellent process control, high quality, and outstanding safety. Our chlorine dioxide gas is registered with the US EPA as a sterilant. It is proven capable of providing a 6-log (99.9999% reduction) of all viruses, bacteria, fungi, molds and spores. Our chlorine dioxide gas is the only one registered at this highest antimicrobial level.

The ClorDiSys method of generating chlorine dioxide produces a 100% pure gas. Other methods of generating chlorine dioxide mix an acid and a base which forms a chlorine dioxide solution which is then off-gassed to fumigate a space. That generation method produces two acidic components, acidified sodium chlorite and chlorous acid, alongside chlorine dioxide which makes these methods more corrosive. Our method of generating pure chlorine dioxide gas is accomplished by passing a low concentration chlorine gas through a proprietary sodium chlorite cartridge to convert the chlorine gas into pure chlorine dioxide gas. This allows our process to be safe when decontaminating stainless steel, galvanized metals, anodized aluminum, epoxy surfaces, electronics, and the most common materials of construction. Typically, if water will not corrode an item, neither will our CD. ClorDiSys’ chlorine dioxide gas has been proven to the FDA to leave behind no measurable residue. Once the gas has been removed, the area is safe and does not require additional cleanup.

ClorDiSys uses a highly accurate UV-vis spectrophotometer to measure the concentration. Photometers are able to measure precise locations, such as hot spots, in order to provide greater confidence (and data for regulators) that those locations underwent a specific exposure dosage. Our Decon Service team measures the concentration of chlorine dioxide gas throughout the entire process at multiple locations in order to ensure that all locations reach the proper dosage necessary to achieve a 6-log sporicidal reduction. Other chlorine dioxide gas decontamination processes monitor one location using a less accurate chemical sensor, making the process less repeatable and reliable.

Click here to learn more about our process or join us online May 15^th at 1:00pm EST for CD Gas 101 webinar.

Choose Prevention over Recall Apprehension

A recall can be extremely detrimental to a company both at the time of recall and well into the future. Avoid major consequences like production stoppages, adverse media attention, loss of consumer trust, and civil suits or federal investigations by being prepared and investing in routine preventive decontamination. Traditional sanitation methods have difficulty truly eliminating pathogens from hard-to-reach areas.  This is what allows growth niches and harborage sites to become established and create “resident strains” in your facility.  Supplementing your routine sanitation program with a high-level decontamination method can eliminate the pathogens within niches and harborage sites to provide a cleaner and safer environment.

ClorDiSys offers an all-encompassing Preventive Food Safety Program which brings together industry experts from complimentary organizations to help lead the way towards safer food manufacturing. Get an outsider’s perspective on your current Food Safety Program to gain insight and eliminate possible issues that are currently being overlooked. Through a single purchasing source, you can select from a variety of services not offered by a single organization to help find and address the gaps in your food safety program and ensure that your reputation stays in high regard among consumers.

Stop by to chat and learn more at the 20^th Annual Food Safety Summit next week or log in to our Preventive Food Safety Program webinar on May 22^nd.

Fighting Biofilms in Food Processing Facilities

A biofilm is defined as a “microbially-derived sessile community which is characterized cells that are irreversibly attached to a substratum or interface, or to each other” are embedded in a matrix of extracellular polymeric substances (EPS). More simply put, microorganisms attach to surfaces and develop biofilms. Biofilms can be found in natural environments, on surfaces around the home, but more alarmingly, they can be found in food processing facilities.

Cells in a biofilm have the ability to survive cleaning and sanitization. The resistance to sanitizers increases with the maturity of the biofilm. In the last decade, a number of studies have been conducted to determine a variety of sanitizers’ efficacy against biofilms. In 2010, the Department of Food Science at Purdue University compared the effect of chlorine dioxide gas, aqueous chlorine dioxide, and aqueous sodium hypochlorite treatments on the inactivation of listeria monocytogenes containing biofilms. Listeria monocytogenes is a food-borne pathogen with the highest mortality rate. It has the ability to adhere to and grow on a variety of surfaces found in food processing plants. The study proved that the biofilm developed from the five-strain mixture was more resistant to the sodium hypochlorite treatment than either chlorine dioxide (CD) option. Aqueous CD resulted in significantly greater log reduction of biofilm cells for shorter treatment times as compared to CD gas treatment. However, once the CD gas dissolved in the water present, it was similar in effectiveness.

This comparison of chlorine dioxide’s efficacy against biofilms in both the gaseous or aqueous state was taken a step further by the Republic of Korea’s Department of Biotechnology and University of Georgia’s Center for Food Safety in 2014. This team evaluated chlorine dioxide’s ability to kill Bacillus cereus spores in biofilm formed on a stainless steel surface. Bacillus cereus is a spore-forming bacterium that can cause foodborne diseases. The study pointed out that while aqueous CD has “the advantage of being easy to produce and handle compared to gaseous ClO₂,” its residual moisture may promote the growth of molds after treatment of food-contact surfaces. It was determined that the antimicrobial activity of chlorine dioxide gas was higher than that of the aqueous, and spores were inactivated within one hour.

Interested in reading more? You can view the published articles here:

Comparison of inactivation of Listeria monocytogenes within a biofilmmatrix

Efficacy of gaseous chlorine dioxide in inactivating Bacillus cereus spores

Concerned about biofilms in your facility? Call (908) 236-4100 today!

Case Study: Listeria Decontamination Service

Our Decontamination Service Team has been busy, recently working on multiple projects in Massachusetts, California, Connecticut, and Washington State. One of our more recent projects was helping a company eliminate a listeria problem in the customer's produce blend room. This facility was not in production and was finishing a punch list of installations, upgrades, and maintenance activities. Our Decontamination Team slid in alongside the customer's schedule in order to limit the disruption and enable production to begin as soon as possible.

The almost 500,000 ft³ Blend Room was turned over to our team at 4pm.  At this time, gas injection tubing was run to 10 different locations in order to speed up the natural distribution of the gas.  Gas sample tubing was run to 6 different locations within the Blend Room in order to measure gas concentrations throughout the decontamination process.  This enables our team to confidently control the process, making sure that the entire room has been subjected to the proper dosage of chlorine dioxide gas necessary to achieve a 6-log sporicidal reduction.  Biological Indicators were placed in 20 different locations throughout the space, including placement under trash cans, as well as beneath and behind equipment.  Conveyors, doors, and the HVAC system handling the room were then sealed.  At approximately 11:15pm, gassing started.  At 3:15 am, all areas within the room reached the appropriate dosage, and aeration began.  Upon completion, equipment was removed from the space along with biological indicators.  The next day, Biological Indicators were dropped in growth media and incubated for 36 hours to check if any of the million bacterial spores contained on the indicator were left viable to grow and multiply.  After 36 hours, none of the 20 biological indicators showed any growth, proving that a 6-log sporicidal reduction took place within the Blend Room.  The project was successful and the company was able to start production shortly after.

Visit the ClorDiSys website to learn more about our decontamination services for all industries.

Biological Indicators: Testing a Cycle's Success

ClorDiSys uses Biological Indicators (BIs) to verify the efficacy of our decontamination cycles. Also known as spore strips, the BIs we use consist of over a million (1 x 10⁶) Geobacillus stearothermophilus spores inoculated on a paper substrate and wrapped in Tyvek. The chlorine dioxide gas molecule is small enough to permeate the Tyvek and kill the spores inside. To challenge the decontamination/sterilization cycle, BIs are placed in hard to reach areas throughout the space being decontaminated. Once the decontamination has been completed, the BIs are dropped into growth media using aseptic technique. If the biological indicator does not produce growth within the media tube after the incubation period (we have validated a 36 hour incubation time with the BI manufacturer Crosstex), the process is deemed to be successful.

Below are some of the more challenging locations where Biological Indicators have been placed during chlorine dioxide gas decontaminations. All of these locations’ BIs exhibited 6-log sterilization level kill using our standard cycle.

Inside Packed Isolators

(Over 30 BIs were placed inside)

In Stacks of Filtered Cage Lids

(Blue tape on right corresponds to BIs shown in left image)

Underneath Dust

(Comparable to that of HEPA filters)

In HEPA Filters

(BI between the filter's pleats)

In Packed Storage Rooms

(BI placed at the bottom of the closest trash can)

Contract Sterilization Services

ClorDiSys offers Contract Sterilization Services where we can decontaminate your items, equipment, supplies, and products at our facility, then ship them back to your facility or onward to a 3rd party facility. ClorDiSys uses chlorine dioxide gas for sterilization of components instead of gamma irradiation, ethylene oxide gas, or electron beam methods. ClorDiSys’ chlorine dioxide gas is registered with the US EPA (Reg. # 80802-1) as a sterilant capable of killing all viruses, bacteria, fungi, and spores. Turnaround time is traditionally 24 hours, with items typically being shipped back the day after they arrive. In some cases, turnaround time can be hours, with the items arriving, being treated, and shipped on the same day. Upon completion, a Certification Sheet is issued describing the process and showing the sterilization cycle data.

COMMON APPLICATIONS

• Sterilization of components, instruments, or other items before entering a clean facility

• Equipment contaminated with amplicons or beta lactams

• Computers, printers, keyboards, and routers

• Electronics (RFID tags, monitoring instruments, microscopes)

• Supplies (Shoes, safety glasses, clothing, animal cages)

• Sterile products manufactured in non-sterile facility

• Medical items

• HEPA or Sterilizing Filters

• Contaminated items due to mold, pinworms, or user-site returns

CD Gas Decontamination: A Residue-Free Process

ClorDiSys Solutions’ chlorine dioxide gas is one of the most gentle decontaminating agents available. Our proprietary method of generation produces a dry, 100% pure chlorine dioxide gas which leaves no residue after treatment. There is no need to rinse, wipe, or clean surfaces afterward. One of the first commercial uses for this method of chlorine dioxide gas was the sterilization of implantable contact lenses. In order for the process to be approved by the FDA, it had to be proven that pure chlorine dioxide gas left behind no measurable residue.

The myth that chlorine dioxide leaves a residue is one that originates from the generalization of all chlorine dioxide products. Other methods of generating chlorine dioxide gas are not as pure, generating the gas using liquids. This method introduces acidic byproducts into the area which can cause corrosion and leave residues. These residues require a post-treatment rinse. After a decontamination is completed and our CD gas has been removed, the area is safe and does not require additional cleanup.

Visit our company's exhibit at one of these upcoming events to learn more:

April 10-11, 2018 IDFA Ice Cream Technology Conference

April 13, 2018 Southern Biosafety Association Spring 2018 Symposium

April 15-18, 2018 CETA Annual Meeting and Tradeshow

April 24, 2018 PDA Metro Chapter Day

April 25-26, 2018 17th Annual QUAD AALAS Symposium

An Effective Decontamination Requires Excellent Distribution

Chlorine dioxide is a sterilant that is a true gas at room temperatures, meaning it naturally distributes uniformly and completely within the space being decontaminated. It distributes the same way that oxygen does in a room, with the level of oxygen being the same throughout. This level of distribution is excellent when compared to vapor phase hydrogen peroxide, mists or fogs. 

Chlorine Dioxide Gas: Example of Even Distribution & Penetration vs. Thermal Image of a Vapor Phase Hydrogen Peroxide Cycle: Example of Poor Distribution

Hydrogen peroxide has been labeled as a “lazy gas” which doesn’t distribute readily. VPHP will start condensing back to the liquid state upon exiting the generator, and it is distributed throughout the chamber/room through line of sight injection. The vapor can be blocked by objects in its way, leaving the surfaces behind or underneath uncontacted or under-contacted. As such, the back side, underside, and internal portions of components may not be contacted by VPHP for a long enough period of time, at the proper concentration, to achieve the correct level of kill. If the decontaminating agent cannot reach ALL of the dangerous organisms in a critical environment, such as a BSL-3/4 facility, at the proper concentration, for the prescribed amount of time, then a complete decontamination will not occur and worker safety is compromised.

Learn more about the process and benefits of chlorine dioxide gas on April 10^th at our CD 101 webinar or attend one of our upcoming workshops. Click here to see when we will be in your area!

Stethoscope Disinfection

Next week, we will be in New Orleans attending the AORN Expo 2018! We hope to see everyone there and work together to prevent infections within the healthcare industry. 

As mentioned in the Fall 2017 issue of Healthcare Environmental Solutions News, stethoscope cleaning has a compliance rate near 0%. Frightening! More specifically, after a one second long use, contamination rates equalize to that of the physician's hand. With HAI's of utmost concern, every source of possible infection must be addressed. Stethoscopes have been known to host potentially pathogenic organisms including, but not limited to, Staphylococcus aureus, Pseudomonas aeruginosa, Vancomycin-resistant Enterococcus, and Clostridium difficile (C. diff).

A solution that is quick and easy is the Flashbox-mini, a tabletop UV-C chamber disinfecting at a 99% kill rate of harmful organisms in mere minutes. UV-C provides a dry, chemical-free, and residue-free method of disinfection effective against bacteria, viruses, fungi, and spores. When micro-organisms are exposed to UV-C, the nuclei of the cells alter due to photolytic processes, preventing further replication, and causing cell death. The Flashbox-mini is a simple resolution to the complexity of HAI's and patient well-being.

Visit ClorDiSys Solutions at Booth #2018 at the AORN Expo March 25-27th! In the meantime, click here to learn more about ultraviolet light disinfection.

Best Method to Disinfect Phones as Rated by MIT

Cell phones are in everyone’s hands, all day long. Our hands come in contact with many not so pleasant things, with harmful germs and organisms being of particular concern.  To try to mitigate any risks, MIT decided to determine how best to actually clean cell phones.  Researchers tested wipes, sprays, and ultraviolet light disinfection systems, namely the Flashbox-mini and PhoneSoap.  After various studies, they crowned the most effective to be ClorDiSys' Flashbox-mini.  We are proud to hold the title and thrilled that our company's device is able to provide a fast, easy, and chemical free method to disinfect our much-used and much-loved phones. Click here to read the full article!

Ultraviolet light disinfection works by utilizing the UV-C spectrum; the killing range of the ultraviolet spectrum.  When light is emitted onto the surface, the DNA of bacteria, viruses, and spores is altered to prevent replication and causes cell death. To use the Flashbox-mini, simply place a phone, or any other item, onto the high-quality quartz glass shelf, close the door, turn on the timer, and watch the glow.  After just 1 minute, 99% or higher of harmful organisms will be gone.

Click here to learn more about the Flashbox-mini.