GEA SAFEXPERT®

Wij weten dat het uiterlijk, de smaak, de textuur en de houdbaarheid van uw producten de merkeigenschappen representeren die uw klanten verwachten en eisen. Aan u de constante uitdaging om aan deze verwachtingen te blijven voldoen, terwijl tegelijkertijd de beste hygiëne en de geringste stilstand moeten worden gerealiseerd. SAFEXPERT® helpt u hierbij, door onze knowhow van processen te gebruiken om de onderliggende oorzaak van alle bestaande verwerkingsproblemen op te sporen en te elimineren, en iedere vorm van verontreiniging in de toekomst te voorkomen.

GEA SAFEXPERT® is een end-to-end procesdiagnose- en consultingserviceprogramma dat bedoeld is om de veiligheid van uw producten te waarborgen, uw processen te optimaliseren en uw producten te behoeden voor verontreiniging. Met GEA als partner loopt u voor op uw concurrenten, krijgt u snel rendement op de investering, en behoudt u de tevredenheid en merkloyaliteit van uw klanten dankzij de hoge kwaliteit en lange houdbaarheid van uw producten.

SAFEXPERT® is een lifetime serviceprogramma van GEA voor uw fabriek of installatie, waarmee u zich verzekert van het behalen van uw KPI’s op het gebied van productkwaliteit en veiligheid, prestaties en hygiëne van de installatie, vandaag en morgen. Door de diagnose van de installatie te combineren met hygiënische behandeling en voortdurende preventieve acties, zijn we de bewakers van uw productkwaliteit en veiligheid.

• Proces- en CIP & COP-diagnose 

• Verificatie van schone processen 

• Inspectie op verontreiniging en identificatie van onderliggende oorzaken 

• Microbiologische detectie en scan van organische residuen en biofilm

• CIP-aanpassing en optimalisatie 

• Proces- en CIP-benchmarkservice en controle van de proces-KPI’s 

• Plant health en performance rapportage

In de farmaceutische onderzoeks- en productie-industrie is het waarborgen van de veiligheid en kwaliteit van vloeibare dosisvormen een topprioriteit.

GEA Safexpert® levert de service die u nodig heeft om de hoogste hygiënestandaards, microbiologische controle en procesefficiëntie te handhaven. Dring de risico’s in uw procedures terug en optimaliseer de prestaties van uw installatie en apparatuur met deze milieuvriendelijke, GMP-conforme aanbieding. Van de preventie van biofilms tot de identificatie van bacteriologische soorten in uw machines, Safexpert® helpt u om de gezondheid van uw faciliteit, uw producten.... en van uw patiënten te beschermen.

GEA Solution:

1. Performance audit: Identify the major contamination areas and diagnose the root cause of contamination with ‘mapping life flora’ and ‘process mapping’.
2. Hygiene service: Restore plant initial hygiene conditions with cocktail treatment methods on the CIP system and open surface area. GEA recommend adjustment on current CIP and COP protocols.
3. Performance service: Establish adapted detection KPIs with QA team  to eliminate contamination risk before exceeding QC standard. Monthly preventive microbial and biofilm treatment.

Customer Gain:

• A deeper understanding of the production process, the weak spots: where and why.
• A drastic reduction in the incidence of non-compliant products.
• 100% contamination-controlled equipment with specific preventive maintenance actions
• Restore 11% of total production, equal to 6.8M EUR/year.
• Significant reduction in use of hot water and detergents.

GEA Solution:

1. Performance audit: Review customer QC process and perform ‘process mapping’ together with the production team to diagnose the root cause of end-product quality change.
2. Hygiene service: Modify current batch culture condition, storage time and adjust CIP protocol. Optimize QC sampling and measurement methods of incoming raw milk.
3. Performance service: Establish a specific weekly QC system for the fermentation process.

Customer Gain:

• Great learning of the production process, the critical steps of production: why and how.
• Superior raw material quality, more than 99% passed the stress test.
• A consumer satisfied end-product with good appearance, texture and flavor.

GEA Solution:

1. Performance audit: Identify water wastage and bottleneck areas on process lines.
2. Process service: Adjust and improve the cleaning system and re-design the CIP system to improve mechanical action during cleaning. Introduce RO (Reverse Osmosis) to recover water from whey.
3. Performance service: Implement additional sensors to manage the control system. Implement Water Pinch methods on control areas and a new process to recover wastewater.

Customer Gain:

• Reduced water consumption by 6% which represents 95KEUR/year.
• Established an alternative water supply system generated from whey that can provide nearly 35% of the plant’s required production water.

GEA Solution:

1. Performance audit:Troubleshoot the source of contamination by analyzing raw material quality, processing water quality, and performing a hygiene inspection on processing equipment and valves.
2. Process service:Modify existing CIP programme for both filtration system and process line and replace all valve gaskets.
3. Performance service: Benchmark system hygienic performance KPIs and establish a periodic preventive maintenance plan with GEA service.

Customer Gain:

• Saved 2M EUR on product loss, prevented further product recall. Rescued the company brand credibility and retained its consumer loyalty.
• Updated QC KPIs for better product monitoring, significantly limited the risk of contamination and fully controlled process hygiene.

GEA Solution:

1. Performance audit:Diagnose the root cause of the contamination, microbial distribution scan and metagenetic analysis were performed to identify contaminated surface area.
2. Hygiene service:5-day microbial treatment with GEA recommend cleaning program and bioactive detergent. Aging tests done before and after treatment to confirm shelf life extension.
3. Performance service:Quarterly microbial treatment and performance audit at production area and storage room.

Customer Gain:

• A deeper undersetting of the operation process, the sources of contamination: what and how.
• Clear microbiological trend showing full control of plant contamination
• Extend shelf life after treatment, from 7 days to 9 days.

GEA Solution:

1. Performance Audit:Diagnose source of contamination with a surface inspection and metagenetic test to identify the organism.
2. Hygiene service:Treat the plant with a GEA-recommended sanitizer and bioactive detergents according to SOP-defined cleaning protocols. Perform swab test and analyze both wash and rinse water using GMP- and ATMP- approved methodologies.
3. Performance service:Results suggested that redesigning the process water system and optimizing the manual cleaning process would solve the problem.

Customer Gain:

• A clear understanding of the root cause, source and location of the contamination.
• A safe and robust process that operates in a controlled microbiological environment.
• Best practice guidelines to maintain optimum plant performance and control.
• Eliminate downtime production/OPEX losses of €230k/day.