Compressed air is critical to many food and beverage manufacturing processes, from packaging to bottling to conveying ingredients. However, if not properly maintained and monitored, it can become a source of contamination, posing significant risks to food safety. Brett Greenlee, Sales and Key Accounts Manager at Trace Analytics, shares the key takeaways from the webinar hosted on IFSQN, offering a roadmap for food safety professionals to ensure their compressed air systems meet the facility’s required safety standards.

Understanding the Importance of Compressed Air Quality

Compressed air can harbor contaminants such as particles, water, oil, and microorganisms, which, if introduced into food products, can compromise safety and quality. Regulatory bodies and food safety standards, including ISO 8573, outline specific purity classes to mitigate these risks. Understanding and adhering to these standards is crucial for maintaining product integrity and consumer trust.

Conducting a Thorough Risk Assessment

Before implementing a testing and monitoring program, it’s essential to perform a comprehensive risk assessment of your compressed air system.
This involves:

  • Identifying Points of Use: Determine where compressed air interacts with food products or contact surfaces.
  • Assessing Potential Contaminants: Evaluate the likelihood of oil, water, or particulate ingress at each point.
  • Evaluating System Design: Consider how system components, such as filters and dryers, influence air quality.

By systematically analyzing these factors, organizations can tailor their testing protocols to address specific vulnerabilities within their systems.

Deciphering ISO 8573 Purity Classes

ISO 8573 is the international standard that specifies the testing requirements and purity class limits for compressed air quality. It categorizes compressed air purity into classes based on three primary contaminants:

  • Particulates: Solid particles that can originate from pipe corrosion or ambient air.
  • Water: Even present as a vapor, water can promote microbial growth or rust within the system.
  • Oil: Total Oil includes both aerosol and vapor forms, which can stem from lubricated compressors.

Each class within ISO 8573 sets maximum allowable concentrations for these contaminants. For instance, Class 1 represents the highest purity, suitable for critical applications, while Class 5 allows for higher contaminant levels. Selecting the appropriate purity class based on the specific requirements of your food processing operations is an essential part of successful routine monitoring.

Establishing a Testing Schedule

Regular monitoring is vital to ensure ongoing compliance with air quality standards. Trace Analytics can support manufacturers through a variety of testing schedules:

  • Baseline Testing: Conduct initial tests to establish a reference point for system performance.
  • Periodic Testing: Schedule routine assessments, with frequency determined by risk assessment outcomes and regulatory requirements.
  • Event-Driven Testing: Perform additional tests following system modifications, maintenance, or contamination incidents.

Adhering to a structured testing schedule enables early detection of potential issues and facilitates prompt corrective actions.

Interpreting Test Results and Taking Action

Understanding test results is critical for maintaining air quality. Key considerations include:

  • Analyzing Data Trends: Monitor changes over time to identify emerging issues.
  • Comparing Against Standards: Ensure contaminant levels remain within the specified purity class limits.
  • Implementing Corrective Measures: If tests reveal non-compliance, investigate root causes and adjust system components or maintenance practices accordingly.

Documentation of all findings and actions taken is critical because thorough records support compliance efforts and continuous improvement initiatives.

Integrating Air Quality Management into Food Safety Systems

Effective compressed air quality management should be an integral part of a facility’s overall food safety strategy. This involves:

  • Training Personnel: Educate staff on the significance of air quality and proper system operation.
  • Maintaining Equipment: Regularly service compressors, filters, and dryers to prevent contamination.
  • Reviewing Procedures: Periodically assess and update protocols to align with evolving standards and technologies.

By embedding air quality considerations into the broader food safety culture, organizations can enhance their resilience against contamination risks.

Conclusion

Compressed air, while essential to food manufacturing, can pose significant contamination risks if not properly monitored. Through diligent risk assessment, adherence to ISO 8573 standards, regular testing, and proactive system management, food safety professionals can safeguard product integrity and protect consumer health. Save this webinar serves as a valuable resource, with guidance on navigating the complexities of compressed air quality testing.

For those interested in a deeper exploration of this topic, the full webinar is available on the IFSQN website, providing comprehensive insights into best practices and regulatory considerations.

Note: This blog post is based on the IFSQN webinar “Compressed Air Quality Testing – What You Need to Know,” presented by Brett Greenlee of Trace Analytics.