Food and beverage manufacturers use compressed air for a variety of processes and functions that are critical to their end products. From cleaning, to sorting, to cutting and shaping, compressed air can impact products either directly or indirectly. Unfortunately, when it comes to the quality of this air, compressed air and gas is an often-overlooked utility. If the air or gas is contaminated or not of adequate purity, then will have a negative impact on the system and the quality of the product.
Because compressed air quality is so essential to the safety and quality of end products, many standards and certification bodies require or recommend regular compressed air testing and monitoring. Whether you are trying to meet SQF, Primus, BRC, or FDA requirements, you can utilize ISO 8573 as a common language and resource for compressed air quality. ISO 8573 is the international standard for compressed air. This standard provides a purity class chart and outlines the testing methods for each type of contaminant that may affect the quality of the compressed air.
Many of these standards and requirements are somewhat vague, so it is generally up to the facility to assess their risks and determine what levels of purity and contaminants are acceptable for their usage.
Download a compressed air risk assessment here
COMMON CONTAMINANTS IN COMPRESSED AIR
The common contaminants in compressed air systems according to ISO 8573 are particles (non viable and viable), water, total oil, and gases. It is essential to conduct a risk assessment of your system to understand which contaminants pose the most risk to your system and product. Understanding your unique requirements and limitations will help you determine the appropriate purity levels for testing.
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Particles
Particles can be introduced into a system from the ambient air or the system itself. Rust or debris from inside the distribution piping can sometimes be found at the end of the line where the point of use is placed. Dust, metal shavings, plastics, and more are all potential risks for a compressed air system.
Look at the piping, tubing, fittings, o-rings and account for any maintenance or line additions that may have impacted the system’s quality. These are all common sources for particle contamination.
Water
Water as a contaminant in food products may not seem like a terribly huge concern, however it can be detrimental to distribution systems causing greater issues like rust and favorable environments for microbial growth.
The main source of water contamination is the ambient air – as air compresses, the water content increases. It can also pool and collect in drops, dead ends, and condensate traps. Permeable tubing can allow water to enter a system as well. If you use a refrigerated or desiccant dryer, it’s important to ensure that your dryer is working as expected.
Total Oil
ISO 8573 defines Total Oil as oil aerosol and oil vapor together. If you are hoping to meet Class 1 or Class 2 requirements, you will need to test for both oil vapor and oil aerosol. Make sure you’re working with a laboratory that can provide these types of results.
Even if you have an oil-free compressor, testing for oil contamination is critical. In addition to the compressor itself, oils can enter a system from ambient air, inadequate or ineffective filtration, and cleaning solvents.
Microorganisms
Microbial contamination is of great concern, especially to food manufacturers. Excess water and oil create optimal breeding grounds for microbes. Bacteria, yeast, and mold are all particularly dangerous to end-products and end-users alike.
Microorganisms are all around us all the time. It is essential to regularly monitor your compressed air lines for microbial contamination to keep products safe. If you have a laboratory on site for microbial needs, be sure to regularly employ third party verification.
Gases
If you use compressed gases in your products, or employ compressed breathing air at your facility, it is essential to test for purity and contaminants. Gases like Nitrogen, Argon, and mixed gases are becoming more commonly used in manufacturing processes. Ensuring that your gases are performing adequately is of the utmost importance. Gas contaminants come from the ambient air or are created by the system itself. Leaks can also have a negative impact on the purity of your gas mixture.
DANGERS OF CONTAMINATED COMPRESSED AIR SYSTEMS
Different types of contamination can have different effects on a system or product. Some types of contaminants are harmful to the system itself (causing rust or build ups) which reduce efficiency, and other types of contaminants put end-products and their consumers at risk (bacteria).
Contaminated end products can result in recalls and can be severely damaging to bottom lines and reputations alike. Regular testing of the compressed air system helps to ensure that the compressed air or gas is not contaminating end products.
HOW TO TEST COMPRESSED AIR
You’ll need to adequately obtain an air sample that is representative of your manufacturing air. Each contaminant requires its own collection media and analysis methods. Make sure you work with an accredited laboratory that provides the necessary kits, media, and training to effectively collect compressed air and gas samples.
When you work with a lab like Trace Analytics, you have access to their compressed air experts who can assist with troubleshooting, sampling technique help, and assist in understanding and working with air analysis reports.
For more information on compressed air testing, please contact the AirCheck experts at Trace Analytics.
