SAFEXPERT® da GEA

Sabemos que a aparência, sabor, textura e prazo de validade de seus produtos representam as qualidades da marca que seus clientes esperam e exigem. Atingir esse padrão mantendo os mais altos níveis de higiene e minimizando o tempo de inatividade é um desafio constante para si. É aí que o SAFEXPERT® ajudará, aplicando nosso know-how de processo para diagnosticar a causa raiz de qualquer problema de processamento existente e eliminá-lo, evitando qualquer contaminação no futuro.

O SAFEXPERT® é um programa de serviço de consultoria e diagnóstico de processamento completo para garantir a segurança do produto, otimizar seus processos e proteger a qualidade do produto contra qualquer contaminação. Com a GEA como sua parceira, você pode ficar à frente da concorrência, obter um rápido retorno do investimento e manter a satisfação do cliente e a lealdade à marca pela alta qualidade e o prazo de validade mais longo.

O SAFEXPERT® é um programa de serviço vitalício da GEA que cuida da sua planta hoje e no futuro, garantindo que você atinja seus KPIs de qualidade e segurança do produto, desempenho e higiene da planta em tudo o que faz. Combinando o diagnóstico da planta com o tratamento higiênico e as ações preventivas em curso, seremos os vigilantes da qualidade e segurança do seu produto.

• Processo e diagnóstico CIP e COP 

• Verificação do processo de limpeza 

• Inspeção da contaminação e identificação da causa raiz 

• Detecção microbiana, escaneamento de resíduos orgânicos e biofilme

• Ajuste e otimização do CIP 

• Serviço de referência do processo e CIP e verificação de KPI do processo 

• Relatório de integridade e desempenho da planta

No setor de pesquisa e fabricação farmacêutica, garantir a segurança e a qualidade das formas de dosagem líquidas é fundamental.

O GEA Safexpert® oferece o serviço que você precisa para manter os mais altos padrões de higiene, controle microbiano e eficiência do processo. Aperfeiçoe seus procedimentos e otimize o desempenho de sua planta e seu equipamento com esta oferta ecologicamente correta e compatível com GMP. Desde a prevenção de biofilmes até a identificação de espécies bacteriológicas em suas máquinas, o Safexpert® ajuda-o a proteger a saúde de suas instalações, seus produtos... e seus pacientes.

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.