P.PSH.1273 - Evaluation of an innovative processing technology for production efficiencies and cost savings in food processing including red meat

Summary

To mitigate the potential for harm caused by exposure to SARS-CoV-2 (novel coronavirus) and the resulting disease, COVID-19, and other pathogens, this project evaluated Active Photocatalytic Oxidation (PCO), Puradigm technology to investigate its ability to reduce &/or eliminate airborne and surface pathogens and the potential additional benefits of extending shelf life of red meat, reduce packaging contaminants and reducing HVAC pathogens such as mould.

Objectives

The overall objective is to evaluate air and surface purification technology for packaging material surface pathogen reduction, extended shelf-life and HVAC pathogen reduction in food processing of red meat.
Specifically, the project aims are to:
• Gain an understanding of the efficacy of Active PCO technology in real-world environments against various microbial loads that are possible in red meat processing facilities with the view of continuing to provide leading edge hygiene standards with reduced need for interventionist cleaning regimes which interrupt production.
• Gain an insight into the efficacy of Active PCO technology in reducing intra-day and intra-species cleaning while maintaining shelf-life of food products, including red meat.
• Develop implementation designs for the various real-world environments to manage challenges such as air movements, large scale spaces, fast moving product, wash down procedures, etc.
• Identify use cases for the technology across the facility at RROA and Chef Fresh.

Key findings

1. Microbiological Reductions on Primal Surfaces for various exposure times
- 24hr Exposures – 99% / 2 Log Reductions (35-day aged primals / Extremely high count).
- >24hr Exposures – 99.99% / 4 Log Reductions (35-day aged primals / Extremely high count).
- 5 min Exposures – 90% / 1 Log Reductions (Fresh primals 10 day aged / Low count)
- 10 min Exposures – 100% / >8 Log Reductions (Fresh primals 10 day aged / Low count)

2. Microbiological Reductions on HVAC Air Handling Unit (AHU) Surfaces Black mould is one of the most difficult microbiological pathogens to remove from air and surfaces. Puradigm was able to keep the HVAC’s AHU surfaces clean well beyond the usual 2 month cleaning period.

3. Microbiological Reductions on Packaging Surfaces covered in Water High concentration of staphylococcus submerged in water achieved no reductions.

Benefits to industry

The benefits for the red meat industry are:
• Primary processors - Carcase surface purification over short or long exposure times – reduced reliance on chemical washes or DNA damaging interventions such as UV. Enhanced shelf-life of products. Primary & Secondary processors - Primal surface purification over short exposures prior and
during portioning. Enhanced shelf-life of products.

• Primary & Secondary processors – Cleaning of Air Handling Units, refrigeration coils and surfaces, 24/7 cleaning, reducing chemical clean frequency, usage and cost.

• Primary, Secondary and Supermarkets - reducing air borne & surface pathogens includingSARS-CoV-2, cold, influenza, norovirus and other bacteria and viruses and thereby keeping staff & customers safe, reducing absenteeism and enhancing the well-being of people, plants and animals.

• Primary & Secondary processors – Purification of external packaging surfaces prior to opening within high risk production areas.

• Primary & Secondary processors – Purification of production surfaces between chemical cleaning periods, to minimise the risk of outbreaks such as listeria, and enhance shelf-life of products.

• Puradigm is over 2400x faster than HEPA alone purification, as the air is not required to pass through the Puradigm device, but instead every part of the volume of an indoor space is filled with the natural charged water aerosols, deactivating pathogens in seconds rather than 40 mins or more.

• Safer and more effective than UV which requires slow air flow and close proximity, and requires the air to be brought to the device. UV can also be blocked by shadowing and damages the DNA of products thereby changing its taste and texture.

• Puradigm is safe for continuous operation in occupied spaces.

MLA action

- Release and promote public report.
- Share with other investment agencies including AMIC and NSW DPI.
- Discuss next steps with Coles RROA.

Future research

That depends on strategy and budgets. The project shows a number of benefits across various aspects of primary and tertiary processing from reduction / elimination of pathogens in air-conditioning to sterilizing trays and reductions of pathogens on the surface of meat.

Further research aimed at incorporating the technology into MAP packaging, odour control in waste management, equipment cleaning, transportation of fresh produce, transportation sanitation for mould control, and combined applications with Denba to provide additional microbial reductions/control for enhanced shelf-life of products could be conducted.