How to Avoid Interruptions in the Food and Beverage Sterilization Process

What is your cost in the event of an interruption in the sterilization process? Our clients inform us that losses can result in an additional cost of up to 1 euro per package. Understanding the causes behind these interruptions is essential to take appropriate actions and make timely decisions to prevent such a significant impact on profit margins.

First Cause: Supply Failures

Among the most common causes is the failure of essential supplies necessary for the operation of the process, which includes steam, air, water, or the most frequent issue, power outages.

• What to Do: Before starting the sterilization process, it is crucial to confirm that the facility is equipped with the necessary resources and that these are within the optimal supply parameters. Utilizing measuring instruments at the entrance of the autoclave will help detect these deviations. Additionally, Surdry autoclaves come with an external uninterruptible power supply (UPS) to continue operating in the event of a power failure, and their control system is designed to record process data and resend it to the central PC as soon as the power supply is restored.
  
  

Second Cause: Component Failures

Another important aspect to consider is the deterioration and wear of the most critical components of an autoclave.

Having mechanical and electrical components, positioning sensors, or instrumentation in poor condition is one of the main causes of interruptions faced by our clients, necessitating urgent replacement. Without proper stock forecasting, lead times can often be long, resulting in significant losses in most cases.

Additionally, special attention should also be paid to potential leaks in the sealing elements, particularly the gasket that allows the door to close, which is considered the most worn component of the autoclave.

The successful operation of the equipment and its components largely depends on the efficiency of the periodic inspection method, as timely detection of any issues can prevent greater consequences later on.

• What to Do: Establish periodic review routines to monitor the wear of components and the performance of detection and isolation mechanisms. Additionally, it is important to maintain an accessible stock of spare parts. In the case of temperature sensors, this inspection should be conducted daily to check with a reference thermometer for any deviation of +/- 0.5°C.
  
  

  Third Cause: Ineffective Maintenance Processes

  As we have observed, maintenance tasks are crucial for limiting unexpected interruptions and ensuring the constant operation of an autoclave and all its components.

  If this process is carried out inadequately due to a lack of periodic reviews supervised by the manufacturer or the absence of training and education for the team and operational staff who will work with the equipment, it is another common cause of productive downtime.

  These causes can result in a reduction in machine availability for companies in the food industry by up to 80% annually, which is equivalent to being out of production for 10 weeks each year.

  • What to Do: Work with a reputable and reliable autoclave manufacturer and adhere to their recommended follow-up procedures.

    Surdry, your ally in overcoming these challenges.
    
    At Surdry, we offer various solutions to address the issues that can affect a sterilization process while ensuring 98% machine availability throughout the year, especially in our batch autoclaves.
    
    

    In addition, we work with top brands as suppliers of all autoclave components, ensuring continuous and trouble-free operation over extended periods.

    For the regular monitoring of the supply measurements of steam, water, compressed air, and electricity, as well as the condition of the air and water outlets, we install flow and pressure measurement devices at the inlet connections to the autoclave.

    Additionally, our machines come with a two-year warranty against possible unexpected incidents with autoclave components, and we offer agreements to our clients to ensure access to a minimum stock of spare parts, as well as preventive maintenance for the entire sterilization system.

    These solutions are complemented by an annual technical assistance service available 24/7, which supports our clients at all times in case of any failure or error in the equipment.

    And, through training and guidance for the operators of the companies we work with, we facilitate the integration and implementation of our machines into their production lines, ensuring maximum efficiency in sterilization.

    Clients who have trusted Surdry's products and have access to all these resources and services confirm improvements in their productivity due to the high availability of their autoclaves.