A combination of paper industry and microbiology is rare.
The last textbook about this topic was published in U.S.A. - the year was something like 1955 (when I was a small boy).
After that, a lot of things have happened. It is a most interesting issue. Have you heard about
* "ecocatastrophe" in process microbiology during the change from acidic to neutral/alcalic process?
* the role of bacteria in this new situation - all environmental conditions in a paper machine have changed?
* the role of calcium carbonate and kaolin in the microbiology of paper machines?
* ever increasing recirculation of process waters give more growth period for selected process bacteria?
* sporulation of bacteria is stimulated by longer recirculation periods - what does it mean?
* biocides may be dosed in TOO LOW levels - in opposite to opinions that all kind of microbiological control of process water automatically lead to lower consumption of biocides?
These are issues which I have dealed with over 20 years. I am therefore asking your opinions!
Thursday, March 20, 2008
Tuesday, March 18, 2008
Benefits of microbiological process control - in money?
There are several ways to calculate economical benefits of a proper mb control system. Mind-mapping technique can be used first to detect all aspects included:
TOTAL ECONOMY
An active, problem-preventing microbiological control of raw materials and processes is a most important activity of a paper mill to prevent costs, connected to poor process managements and product faults. We can calculate this value in many ways:
* how much money is spent every second when the production is delayed? 10 euros/s?
* what is the price of a lost jumbo roll, 10...30 metric tons? 5000 € to 30 000 €?
* what are the costs of ineffective / too low / wrongly distributed biocide dosage?
* how much money is spent when a lot of mineral filler or starch is spoiled in a storage tank?
* how much working time of the mill employers is spent for corrective measures after a microbiological problem situation?
* comparison of proper HACCP, based on rapid mb methods and an old-fashioned microbiological control, activated only in hazardous situations?
Different points of view....please think over and refer!
TOTAL ECONOMY
- ECONOMY OF PRODUCTION
- SAVINGS CONNECTED TO SECURED PRODUCT QUALITY
- OTHER ISSUES...?
- COST OF SPOILED RAW MATERIALS
- OPTIMAL BIOCIDE PROGRAMS
- MINIMIZED WASHING & BOILOUT PERIODS
- PREVENTION OF DRIVE DELAYS
- OTHER ISSUES...?
- CUSTOMER CLAIMS....
- FLUENT CONVERTING ACTIONS
- IMAGE OF THE PRODUCT BRAND
- OTHER ISSUES...?
An active, problem-preventing microbiological control of raw materials and processes is a most important activity of a paper mill to prevent costs, connected to poor process managements and product faults. We can calculate this value in many ways:
* how much money is spent every second when the production is delayed? 10 euros/s?
* what is the price of a lost jumbo roll, 10...30 metric tons? 5000 € to 30 000 €?
* what are the costs of ineffective / too low / wrongly distributed biocide dosage?
* how much money is spent when a lot of mineral filler or starch is spoiled in a storage tank?
* how much working time of the mill employers is spent for corrective measures after a microbiological problem situation?
* comparison of proper HACCP, based on rapid mb methods and an old-fashioned microbiological control, activated only in hazardous situations?
Different points of view....please think over and refer!
Monday, March 17, 2008
Rapid control of microbiological status of a paper machine.
Paper industry trust on traditional, proven microbiological methods. Customer claims force the paper mills to use them for end-product QC.
Fast detection - and forecasts - of mb problems cannot be performed by these methods. Some promising progress has taken place since 90's, however:
* optical detection of attachements in paper machine water systems (usually based on IR techniques)
* collection & microscopy of test coupons from processes
* luminometric methods for the evaluation of microbial activity in raw materials and processes
Unfortunately there seems to be no "rapid method" for the estimation of product hygiene yet. Methods of molecular biology may help in future?
Luminometric methods, connected with the examionation of real ("ecologic") process samples is the best alternative for specific assays of microbial counts and activities. Combination of rapid incubation and luminometric assays of process samples is available today ("BIOTOUCH" concept, see figure in right marginal below).
Several calculations and estimations about spare of money has been done. All of them indicate significant reduction of costs which are caused by poor-acting biocide programs (ref. inadequate antibiotic treatment of patients!), problems in machine drive and decreased quality of paper and board product.
Fast detection - and forecasts - of mb problems cannot be performed by these methods. Some promising progress has taken place since 90's, however:
* optical detection of attachements in paper machine water systems (usually based on IR techniques)
* collection & microscopy of test coupons from processes
* luminometric methods for the evaluation of microbial activity in raw materials and processes
Unfortunately there seems to be no "rapid method" for the estimation of product hygiene yet. Methods of molecular biology may help in future?
Luminometric methods, connected with the examionation of real ("ecologic") process samples is the best alternative for specific assays of microbial counts and activities. Combination of rapid incubation and luminometric assays of process samples is available today ("BIOTOUCH" concept, see figure in right marginal below).
Several calculations and estimations about spare of money has been done. All of them indicate significant reduction of costs which are caused by poor-acting biocide programs (ref. inadequate antibiotic treatment of patients!), problems in machine drive and decreased quality of paper and board product.
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