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E-BEAM,Fast and reliable,
chemical-free decontamination technology
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
It is because industrialists in the agricultural food
sector are increasingly faced with this difficulty,
that manufacturers such as Serac have developed
decontamination solutions based on E-Beam
technology.
The capability of the electron beams to efficiently
destroy micro-organisms has been well known
for decades and its reliability when used in a
high-speed industrial production context has
been confirmed in numerous applications, in
particular for surface cross-linking of plastic
materials.
Their use for the decontamination of pac-
kaging lines is however far more recent.
It is associated with the development of
a new generation of emitters, which are
more compact and longer lasting, as
well as the ground work undertaken by equip-
ment manufacturers in the qualification of pro-
cesses specific to this field of activity.
Without water or chemical products, E-Beam
decontamination has a very low environmental
impact. Once the process has been validated, this
technology is far easier to control than the deconta-
mination processes using hydrogen peroxide (H2O2)
or peracetic acid. It is also a lot faster which enables
a reduction in the space required for the decontami-
nation module.
It thus offers all the advantages necessary to meet the
needs and expectations of industrialists.
How can we meet the ever-increasing health and safety requi-
rements both with regard to consumers as well as operators,
while at the same time reducing the environmental impact and
space requirements for packaging production lines?
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
CONTENT
01E-Beam: Scope and
principle of application
02An emerging technology
in the packaging sector
03The key advantages
of E-Beam decontamination
A technology based on the emission of a beam of electrons
The future of ionising treatment processes
A double action on micro-organisms		
Proven treatment already used in numerous sectors
04
Incorporation of E-Beam
decontamination in the
production line
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
01A technology based
on the emission of a beam of electrons
E-Beam stands for "electron beam"
E-beam treatment consists of exposing the products
to be decontaminated to a beam of accelerated elec-
trons.
This technology is nothing new to the industrial
sector; it has been perfectly mastered and used
for over fifty years for the sterilisation of medical
equipment, cross-linking of plastic materials or
drying of resins or inks
Creation of the beam
The beams are generated in an ultra-vacuum*
chamber by heating a cathode* under the effect
of an electrical current. Subjected to a very
high electrical voltage, they are then accelera-
ted and directed towards a "window" through
which they leave the emitter.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
Interaction with the surrounding
environment
When they leave the emitter, the electrons pass
through the air before entering into contact with the
material to be treated.
The impact of the electron beam on the molecules
of the material they hit modifies the latter by
means of an ionisation* reaction.
The ionisation process draws away electrons
from the material which, due to this, is no lon-
ger electrically neutral and it reacts in turn to
create new stable molecules.
It is the consequences of these ionisation
reactions which enable us to destroy the mi-
cro-organisms, dry the monomers or cross-
link the plastic materials depending on the
use made of the E-Beam technology.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
01A technology based
on the emission of a beam of electrons
High and low energy electron beams
An electron beam is characterised by its energy, ex-
pressed in electron-volts*, and its power, expressed in
watts.
The energy of the beam characterises its capacity to
penetrate the materials it encounters, whereas the
power defines its treatment capacity.
It is common these days to separate the elec-
tron beams in two main categories: High-energy
beams (several million electron-volts*) and low
energy beams, which do not exceed a few hun-
dred kilo electron-volts* (keV).
For packaging decontamination applications,
some solutions require high energy beams,
whereas other systems function perfectly
well with low energy beams depending on
the shape of the product and the way it is
placed in the radiation field.
The choice of energy and power levels of a beam are
defined according to the intended application and pro-
cess to ensure the electrons arrive at the correct point
and in sufficient quantity to destroy the micro-orga-
nisms present. This quantity is expressed in the absor-
bed dose, the unit value of which is the Grey (Gy), repre-
senting the unit of energy in relation to the mass of the
material irradiated.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
E-Beam and gamma rays are today the
two main ionisation* treatment methods
used in industry.
But the trend is clearly leaning towards the
development of E-Beam technology which
offers advantages both from an environmen-
tal as well as an industrial viewpoint.
A solution without a radioactive
source
The electron beams are produced from a neutral
material (generally tungsten) whereas gamma
rays are produced from a radioactive isotope* of
cobalt (cobalt 60).
The use of E-Beam technology therefore avoids
the presence of a radioactive source inside the fac-
tory, presence which is particularly restrictive from a
health and safety viewpoint, has a serious environmen-
tal impact (waste) and is increasingly frowned upon in
terms of company image.
Shorter treatment times
The dose rate* based on is a key notion in ionising treatment
methods It corresponds to the time required by the product
to absorb a defined dose of radiation.
Furthermore, electron beams have a far greater dose rate*
than gamma rays (in the order of kiloGray per second for
the first and up to 10,000 times less for the second).
This means that with E-Beam technology it is pos-
sible to considerably reduce the time the product is
exposed to the radiation. A positive point with regard
to productivity most certainly, but also for quality as
over-exposure may in certain applications cause
oxidation with a subsequent drop in the organolep-
tic properties of foodstuffs as well as the physical
properties of some materials.
The future of ionising
treatment processes
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
01The future of ionising
treatment processes
Unavoidable for individual treatment
in a production line
Gamma rays have a far greater material penetra-
tion capacity as opposed to electron beams; They
are therefore often used for the decontamination
of products in their packaging by complete pallet
load.
On the other hand, however, their low dose rate *
excludes their use for high speed treatment;
This explains why in most industrial applica-
tions for the cross-linking of plastic mate-
rials E-Beam technology is used and why this
technology is being used today for individual
decontamination in a production line.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
01Breaking of the DNA chains
The ionisation* reactions caused by the electron beams have an
influence on the DNA of the micro-organisms and cause them
to break (single or double strand) at the chain link points.
These breaks are irreparable and have an immediate and
fatal effect on single-cell organisms (bacteria, yeast, mould).
Dissociation of water
Micro-organisms contain a large quantity of water.
The collision between the electron and a water molecule
results in the dissociation* of the latter in extremely
active free radicals (OH, H, O2). These free radicals,
in the same way as ozone which is created by their
re-combination, participate in the oxidation reactions
which also damage the DNA of the micro-organisms.
They prevent, in particular, the pairing of nucleo-
tides* affected with those of the other strand.
A double action
on micro-organisms
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
01Proven treatment already
used in numerous sectors
Sterilisation of medical equipment
E-beam treatment has been used for almost 50 years
in the medical sector for the sterilisation of textiles,
plastic elements (syringes, tubes, pouches) or
implants.
Often contracted out to specialised service compa-
nies equipped with large-scale installations,
E-beam decontamination is in this particu-
lar case usually carried out with high energy
beams. This enables the electrons to pass
through packaging in order to sterilise the
product contained therein. However, mini-
sterilisers using a low energy beam are also
now becoming available on the market.
These sterilisers are used for individual ste-
rilisation of products in a packaging line.
E-beam treatment is recognised by the
AAMI (Association for the Advancement
of Medical Instrumentation)
Sterilisation of pharmaceutical
products and reactive substances
Sterilisation of active substances is a delicate matter;
The process must be perfectly mastered in order to
deliver a sufficient dose of electrons without modifying
the properties of the product. Electron beam sterilisation
is also used for this type of application (sterilisation of
freeze-dried vaccines, syringes filled with vaccine or blood
sampling tubes containing a reactive agent).
It is incorporated into the good manufacturing practice guide
in the pharmaceutical industry (GMP) and it is particularly
interesting for heat-sensitive substances; Indeed, when per-
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
01fectly controlled, the exposure to this radiation
does not significantly increase the temperature
inside the product.
Reduction of microbial content in
foodstuffs
On the international stage, E-beam technology also
replaces gamma rays in more and more foodstuff
or phytosanitary applications (decontamination of
meat, or fruits and vegetable, disinsectisation of
cereals…).
The primary arguments in favour of this change of
technology are the elimination of a radioactive source
and reduction of the footprint of decontamination units.
However, the use of E-Beam technology often requires
redesigning of the processing line in order to incorporate
the decontamination unit upstream of the packaging line.
E-beam treatment is recognised and approved by the FDA
(Food and Drugs Administration).
Decontamination of water and effluents
E-Beam technology has also been used for around
twenty years in pilot projects for the treatment of
industrial water and effluents as well as slurry
from waste water treatment plants (reduction
of chemical contaminants in the drinking water
in Austria, treatment of effluents from dying
processes in Brazil or, more recently in China,
treatment of slurry and waste water in South
Africa and USA…).
Its effect destroys the organic pollutants, or
increases their biodegradability in order to
render their elimination in the receiving
medium easier.
It is the environmental aspect of the
E-Beam treatment which gave rise to this
project; Indeed, contrary to conventional
de-pollution systems, E-Beam treatment
requires no chemical product and pro-
duces no toxic by-products.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
CONTENT
01E-Beam: Scope and
principle of application
02An emerging technology
in the packaging sector
03The key advantages
of E-Beam decontamination
A new field of application for a proven technology
Targeted markets and technical approaches
04
Incorporation of E-Beam
decontamination in the
production line
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
02A new field of application
for a proven technology
Conscious of the advantages of E-Beam technology, its environ-
mental impact, user safety and running costs, manufacturers of
aseptic filling and packaging lines have closely examined the
use of this technology in their trade.
The initial operational solutions appeared on the market very
recently and were in particular rendered possible thanks
to the miniaturisation of emitters. They combine the well-
known efficiency of E-Beam technology on micro-orga-
nisms with its capacity to be incorporated into high-speed
industrial processes; It is this aspect which renders them
particularly innovative
High-speed, individual decontamina-
tion on production line
The effectiveness of ionisation* treatment in
decontamination applications has long been
proven; It has been used for this purpose for over
fifty years. Moreover, the electron beams are
often used on high-speed, non-stop production
lines (cars, cables, ducting) and
have therefore proven beyond doubt
their industrial reliability.
Application of this technology in the
decontamination of packaging lines
however is a very new arrival on the
scene. The appearance of these inno-
vative solutions was rendered possible
by recent developments in the design of
ultra-vacuum* chambers and the minia-
turisation of low-energy beam emitters.
Now much more compact, less expensive
and longer lasting, these new generation
emitters may easily be incorporated into a
production line.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
02In-depth groundwork on
the qualification of processes
The main challenge in developing solutions for
decontamination of packaging lines is adapting
the E-Beam treatment process to this use:
- ensuring the wide variety of applications
encountered in this sector (decontamination
of films, pre-formed and formed packaging
elements),
- comply with the hygiene standards required.
This prerequisite demands extensive
groundwork in areas such as size, power,
positioning and the number of emitters,
all of which are validated with dosime-
tric studies which guarantee that each
packaging element has been sufficiently
exposed to the electron beam in a uni-
form manner.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
02Targeted markets
and technical approaches
Primarily for liquids in cartons and bottles
E-Beam decontamination is primarily used for the aseptic
packaging of liquids. Although trials have been carried out
on flexible packaging elements (pouches, bag-in-box),
the units presently in operation are only used for cartons
and bottles.
Where bottles are concerned, the E-Beam deconta-
mination solutions were initially developed for the
treatment of PET. Indeed, with this new technology it
is possible to avoid certain phenomena relative to the
migration of hydrogen peroxide or peracetic acid in
the plastic. This having been said, E-Beam treat-
ment is not limited exclusively to this material and
the treatment of PEHD, PP, aluminium and even
glass is now possible.
Electron beam treatment is used for aseptic
packaging of a wide variety of acidic or basic
products: fruit juices, dairy products, vegetable
milks, waters, teas…
Decontamination of films,
pre-formed packaging or
bottles
Three solutions are currently proposed on the
market, each with its own treatment process.
The simplest case is flat treatment of the sheet
before forming the carton packaging. This is fol-
lowed by the treatment of pre-formed elements
with a small volume and relatively simple shape.
E-Beam treatment of formed bottles is, bearing
in mind the complexity and diversity of shapes
available on the market, more delicate. It is there-
fore this solution which requires the most research
to guarantee the minimum exposure to the electron
beam in every part of the packaging.
E-Beam treatment may also be used for the decontami-
nation of caps when necessary.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
2 methods for interior
decontamination
Presently two methods of E-Beam treatment are pro-
posed for bottles and pre-formed packaging:
Sterilisation from the exterior only, or exterior/interior
sterilisation.
The first method requires an electron beam with an
energy level sufficiently high to pass through the packa-
ging; The second uses ultra-miniaturised emitters, which
may be introduced via the neck of the packaging, with a very
low energy beam.
It is this second method, more reliable and easier to apply in
production, that Serac has retained for its E-Beam treatment
ßluStream.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
CONTENT
01E-Beam: Scope and prin-
ciple of application
02An emerging technology
in the packaging sector
03The key advantages
of E-Beam decontamination
Reduction of environmental impact at the workstation
Acceleration and safety of the decontamination process
04
Incorporation of E-Beam
decontamination in the
production line
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
03Reduction of environmental impact
at the workstation
"zero chemicals" sterilisation
Electron beam sterilisation is a physical treatment
method which requires no chemical products.
The process therefore generates no toxic waste
requiring treatment before evacuation into the
natural environment, and for which the company
may potentially face payment of duty or taxes.
Savings are therefore both economical as well
as environmental and concern the installations,
purchasing of consumables and management
of waste.
The absence of chemical products is also
interesting for manufacturers wishing to
present their customers with a production
process which is both responsible and
natural, or where the target consumers
are particularly sensitive (babies, immu-
nodeficient persons.
Dry sterilisation
The absence of chemical products also
means no need to rinse the packaging.
Foodstuff industries which use a great deal
of water in their processes, are particularly
sensitive to the environmental impact of this
consumption. Water is therefore often one of the
first items concerned by improvement plans.
E-Beam treatment offers the factory the possibili-
ty to reduce water consumption at the workstation
to practically zero and to present a considerable
improvement in their environmental balance.
Water is also potentially a major source of contami-
nation; another reason to reduce its use in foodstuff
processes.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
03Sterilisation at ambient
temperature
E-Beam technology requires no hea-
ting or generation of steam.
Decontamination with low-energy
electron beams therefore presents a
positive energetic balance compared
with conventional technologies.
The energy transmitted by the
electrons does no significantly
increase the packaging tem-
perature. Thanks to the eli-
mination of heating, E-Beam
treatment may be used on
thinner packaging resulting
in a reduction of raw mate-
rials consumption.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
03Acceleration and safety
of the decontamination process
Shorter treatment times
The electrons interact very quickly with the material
onto which they are beamed. This is what enables
them to offer a high useful dose rate*. With this
property, a microbiological reduction compliant with
aseptic requirements (5 log for Bacilus pomelos)
is possible in only a few seconds.Thanks to this
duration in treatment time, electron beam de-
contamination enables increasing of the aseptic
production line work-rates or reduction of the
production line footprint for a given work-rate.
Limited cleaning
As the E-Beam decontamination systems
require no circulation of water or chemical
products and do not enter into contact
either with the packaging or soiled solu-
tions, they require very little cleaning.
For this reason, they have no negative impact
on the OEE* (Overall Equipment Efficiency) of
the line and stoppage times are set according
to the filling machine cleaning cycles.
Only 3 parameters to be set
Electron beam treatment is controlled with 3 para-
meters (voltage, current and exposure duration),
whereas decontamination systems using hydrogen
peroxide or peracetic acid require the setting of
respectively 7 and 6 parameters to ensure efficient
decontamination.
This is why E-Beam systems are presently the easiest
aseptic decontamination solutions to manage during
production.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
03The E-Beam systems are also very easy to operate (ON/OFF
system), which avoids loss of packaging and further increases
the OEE*.
Perfectly controllable
physical parameters
In addition to the fact that there
are less, the critical parameters
of the E-Beam systems are also
far easier to control, monitor and
record in the quality system.
It also enables individual trac-
king of packaging elements
via a continuous monitoring
system. They also offer
industrialists more gua-
rantees in relation with
treatment continuity and
conformity of results
obtained.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
CONTENT
01E-Beam: Scope and prin-
ciple of application
02An emerging technology
in the packaging sector
03The key advantages
of E-Beam decontamination
Initial dosimetric study
Equipment: The key points taken into consideration
What are the implications during production?
04
Incorporation of E-Beam
decontamination in the
production line
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
04Initial dosimetric study
In order for E-Beam decontamination to be perfectly
reliable, it is important to ensure the entire surface of
the packaging receives the dose of radiation defined
and required. If homogeneous exposure of a flat film
or carton to an electron beam is relatively simple,
this operation becomes a lot more delicate in a
bottle filling line, both due to the complexity of the
packaging shape as well as the diversity of the
formats which may be processed in this produc-
tion line
Definition and validation
of treatment times
The treatment times are defined for each
packaging format according to the level
of decontamination required. Validation
is carried out with dosimeters* placed
at critical points in various zones of the
bottle. The dosimeters the most com-
monly used for this purpose change colour
more or less intensely depending on the
dose of radiation received and thus enable
mapping of the dose dispersion inside as well
as outside the bottle. It is indeed impossible
to apply a perfectly uniform dose to packaging
with such complex shapes;
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
04The dosimetric study therefore guarantees that
all zones of the bottle have at least been exposed
to the minimum decontamination dose necessary
without any particular zone receiving too high a dose
which could have a negative effect on the physical
properties of the packaging.
Inspection during production
Once the application has been validated,
routine inspections may be carried out in a
fast and easy manner. A single dosimeter*
on a single "sample bottle" is all it takes to
confirm that the dose is correct.
This operation only takes a few minutes
per day.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
04Equipment: The key points
to be taken into consideration
Working life and maintenance
of emitters
E-Beam emitters are obviously key operating com-
ponents in the system; their working life, as well
as possible maintenance operations required have
an impact on the OEE* and TCO* (Total Cost of
Ownership) for the entire line.
The new generations of hermetically
sealed emitters offer a double advan-
tage: their working life is considerably
increased compared with emitters of the
previous generation and they are practically
maintenance-free.
System redundancy
The number of emitters used is a key safety
factor for the decontamination process.
A system using only one or two emitters may fail
to function entirely if one of the two emitters is
defective. In the case of a system using multiple
emitters however, the line may continue to operate
in downgraded mode.
Booth design
The booth design form must take into account the X-ray*
interference emitted by the E-Beam treatment, even if this
interference is extremely low. Protection screens must be
The maintenance times will be considerably reduced
if the emitters may be replaced in the same way as a
light bulb; Indeed, replacement of an internal compo-
nent (window, cathode) is not a simple operation.
* See glossary on page 29
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
04incorporated into the treatment chamber and the
booth casing must be reinforced.
This reinforcement is calculated according to the
maximum beam energy and power; it is much lighter
for low-energy beams which represents a conside-
rable cost saving compared to high-energy beams.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
04What are the implications
during production?
Adopting an innovative technology is always a poten-
tial source of industrial risk and legitimate questions
are asked concerning the incidence this change may
have on production.
If E-Beam technology is considered a potentially
interesting decontamination solution, the following
3 points must be considered:
- This technology benefits from decades of expe-
rience feedback in other sectors (see intro part 1),
- The reliability of the latest generation of
miniature emitters is also beginning to be well
documented as these devices have been in
use for around 8 years already and have also
been used in several other activity sectors,
- E-Beam decontamination is much easier
to use than currently available decontami-
nation methods (H2O2 and PAA).
Incorporation in existing
production lines
All industrialists wishing to benefit quickly
from the advantages offered by E-Beam tech-
nology with regard to the environmental impact
and safety in aseptic processes will have to ask
the question about how to incorporate it into an
existing production line.
In fact, even if this change requires adaptation of
the machine interfaces upstream and downstream
which represents a major modification, incorpo-
ration of the E-Beam into an existing line remains
perfectly feasible. The E-Beam modules pose no
problem as far as space requirement is concerned as
they are more compact than other decontamination
modules, and their installation is by no means compli-
cated as they are "Plug and run" modules which simply
require an electrical supply.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
04Production work-rate
As presented above, thanks to its high dose rate*,
E-Beam treatment enables reduction of individual
treatment times for packaging elements and the-
refore offers a promising perspective with regard to
increasing production work-rates.
Of course, obtaining of the promised work-rate increase also
depends on the capacity of the filling machine to adapt to
this change. This will be that much easier if the latter is not
already working at its maximum capacity, or if it has been desi-
gned to enable an easy upgrade to higher work-rates.
Training of operators
The operators must understand all para-
meters to be taken into consideration with
this new process, the new safety precau-
tions to be taken, and the new cleaning
procedures. But here again, this lear-
ning curve is fast and easy for persons
experienced in the use of the complex
decontamination methods used today in
aseptic filling processes.
The operating simplicity of the system will enable a rapid rise in
work-rate capacity. Based on the experience feedback from exis-
ting E-Beam sterilisation applications, several weeks is sufficient
to allow perfect control of this technology during production and
use of the decontamination module to its full capacity.
* See glossary on page 34
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
Glossary
Cathode
The electrode connected to the negative pole of the
electrical supply, point of exit or emission of elec-
trons
Dose rate
Dose of radiation absorbed per unit of time, mea-
sured in Grays per second (Gy/s).
Dissociation (reaction):
Reaction by which the molecules separate
into smaller particles (atoms, ions or radi-
cals), often in an irreversible manner.
Dosimeter
A device placed on the product and desi-
gned to measure the dose of radiation it
receives. When irradiated, this device
presents a quantifiable modification of
one of its properties according to the
dose absorbed. This change is measured
using appropriate analysis techniques and
instruments.
Electron-volt (eV)
Kinetic energy acquired by an accelerated
electron from rest with a potential difference of
one volt 
Ionisation
Phenomenon resulting in addition or loss of elec-
trical charge in an atom or molecule. Ionisation may
be obtained with the impact of an electron, photon,
by applying thermal energy or by means of a chemi-
cal reaction.
Isotope
The isotopes of a chemical element are atoms which
contain the number of protons characterised by this ele-
ment, but a different number of neutrons.
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
The core of cobalt 59, stable isotope of the element
contains for example 27 protons and 32 neutrons,
whereas that of cobalt 60, radioactive element,
contains 27 protons et 33 neutrons.
Nucleotide
An organic molecule, basic element of a nucleic acid
such as DNA or RNA.
OEE
Overall Equipment Efficiency. It is obtained by multiplying
the synthetic efficiency (operating rate x efficiency rate x
rate of compliant products) by the load rate (working time
on workshop opening time).
Reticulation
Reaction of linking macromolecular chains in three-dimensio-
nal grids.
X-ray
Electromagnetic radiation composed of
photons, used in a wide range of applications
such as medical imagery
TCO (Total Cost of Ownership)
Total cost of ownership of an item which
represents the total sum spent by the
owner over the entire life cycle of the
item.
Ultra-vacuum
A very high vacuum, characterised by
pressures generally below 10-7 Pa
or 100 nPa
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
Use of electron beams (E-Beam) for the
decontamination of packaging lines is a true
innovation. It has all the elements necessary
to be perfectly controlled
" Even though E-Beam technology is still very new
for the treatment of packaging lines, it is well pro-
ven in other industrial sectors. We have been wor-
king for over thirty years with companies using
this technology. Ionising treatments are presently
the most effective solution for decontamination
purposes whereas E-Beam is the green tech-
nology with no source of radioactivity and no
chemical products; It therefore offers all the
advantages necessary to become the stan-
dard in aseptic packaging.
We are extremely pleased to have accompa-
nied Serac in the validation of its process.
This is a key component in the success of
a project for which resource centres such
as ours have the experience and means
necessary to offer a secure approach to
industrialists.
We hope that this white paper will help convince
industrialists to use E-Beam treatment in their
aseptic packaging applications."
Alain Strasser
Head of the Aérial Technologies Resources Centre
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
About Aérial
Founded in 1985, Aérial, Technologies Resources Centre and Agricultural Food Industry
Technical Institute, started out as part of an applied research programme into the ioni-
sation of foodstuffs.
Since the early 90’s, Aérial has been independently offering its specific know-how to
agricultural food industries as well as all other industrial sectors using ionisation
techniques.
Aérial is equipped, in its various laboratories, with highly-efficient analytic instru-
ments (dosimetric, microbiological, physico-chemical, sensory analysis, freeze-
drying), as well as an electron beam ionisation experimental station.
Aérial accompanies industrialists in the calibration and development of dosime-
tric systems in a wide range of industrial activity sectors (agricultural foodstuff,
medical and para-medical, para-pharmaceutical, packaging).
–  E-BEAM: Fast and reliable, chemical-free decontamination technolog –
Safer and better for the environment, I am
absolutely convinced that E-Beam decontamin-
ation technology has a promising future
ahead of it in the aseptic packaging sector
"Serac has perfectly controlled decontamination of its
packaging elements for the last 35 years in its ultra-
clean and aseptic filling lines.
Over the last decade, we have noted that our custo-
mers wish to make true progress in matters such as
environmental impact, but also want to render their
decontamination process safer in order to avoid any
potential health hazard.
As all we offered at the time were chemical treat-
ment processes, we turned our attention to phy-
sical, dry decontamination alternatives. It is with
this in mind that we co-developed (with Cla-
ranor) the pulsed light treatment process for
ultra-clean applications.
With ßluStream, our E-Beam decontami-
nation module, we now propose a solution
which required neither water, nor chemicals
for aseptic packaging applications.
E-Beam technology is still in the teething
stage in the packaging sector, but is well
proven in other activity sectors.
In our business, it offers the double advan-
tage of simplicity and reliability. This is why
I am convinced of the fact that it will soon
seduce industrialists in the agricultural food
sector.
I am extremely pleased to have participated in
the development of ßluStream, which undoubte-
dly bears the Serac trademark: This is a reliable
and versatile solution which anticipates the needs
and expectations of our customers."
Delphine Gueguen
Head of the Aseptic Equipment Division
Publisher: Serac
12 route de Mamers
72400 La Ferté-Bernard
Designer : Nexteo Conseil
Writer: A Fond les Bases
Completed in September 2017
by printing ITF Imprimeurs
ZA Le Sablon – CS40051
72230 Mulsanne
Copyright Serac : September 2017

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E-BEAM: Fast, chemical-free food decontamination

  • 1. E-BEAM,Fast and reliable, chemical-free decontamination technology
  • 2. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – It is because industrialists in the agricultural food sector are increasingly faced with this difficulty, that manufacturers such as Serac have developed decontamination solutions based on E-Beam technology. The capability of the electron beams to efficiently destroy micro-organisms has been well known for decades and its reliability when used in a high-speed industrial production context has been confirmed in numerous applications, in particular for surface cross-linking of plastic materials. Their use for the decontamination of pac- kaging lines is however far more recent. It is associated with the development of a new generation of emitters, which are more compact and longer lasting, as well as the ground work undertaken by equip- ment manufacturers in the qualification of pro- cesses specific to this field of activity. Without water or chemical products, E-Beam decontamination has a very low environmental impact. Once the process has been validated, this technology is far easier to control than the deconta- mination processes using hydrogen peroxide (H2O2) or peracetic acid. It is also a lot faster which enables a reduction in the space required for the decontami- nation module. It thus offers all the advantages necessary to meet the needs and expectations of industrialists. How can we meet the ever-increasing health and safety requi- rements both with regard to consumers as well as operators, while at the same time reducing the environmental impact and space requirements for packaging production lines?
  • 3. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – CONTENT 01E-Beam: Scope and principle of application 02An emerging technology in the packaging sector 03The key advantages of E-Beam decontamination A technology based on the emission of a beam of electrons The future of ionising treatment processes A double action on micro-organisms Proven treatment already used in numerous sectors 04 Incorporation of E-Beam decontamination in the production line
  • 4. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 01A technology based on the emission of a beam of electrons E-Beam stands for "electron beam" E-beam treatment consists of exposing the products to be decontaminated to a beam of accelerated elec- trons. This technology is nothing new to the industrial sector; it has been perfectly mastered and used for over fifty years for the sterilisation of medical equipment, cross-linking of plastic materials or drying of resins or inks Creation of the beam The beams are generated in an ultra-vacuum* chamber by heating a cathode* under the effect of an electrical current. Subjected to a very high electrical voltage, they are then accelera- ted and directed towards a "window" through which they leave the emitter. * See glossary on page 29
  • 5. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – Interaction with the surrounding environment When they leave the emitter, the electrons pass through the air before entering into contact with the material to be treated. The impact of the electron beam on the molecules of the material they hit modifies the latter by means of an ionisation* reaction. The ionisation process draws away electrons from the material which, due to this, is no lon- ger electrically neutral and it reacts in turn to create new stable molecules. It is the consequences of these ionisation reactions which enable us to destroy the mi- cro-organisms, dry the monomers or cross- link the plastic materials depending on the use made of the E-Beam technology. * See glossary on page 29
  • 6. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 01A technology based on the emission of a beam of electrons High and low energy electron beams An electron beam is characterised by its energy, ex- pressed in electron-volts*, and its power, expressed in watts. The energy of the beam characterises its capacity to penetrate the materials it encounters, whereas the power defines its treatment capacity. It is common these days to separate the elec- tron beams in two main categories: High-energy beams (several million electron-volts*) and low energy beams, which do not exceed a few hun- dred kilo electron-volts* (keV). For packaging decontamination applications, some solutions require high energy beams, whereas other systems function perfectly well with low energy beams depending on the shape of the product and the way it is placed in the radiation field. The choice of energy and power levels of a beam are defined according to the intended application and pro- cess to ensure the electrons arrive at the correct point and in sufficient quantity to destroy the micro-orga- nisms present. This quantity is expressed in the absor- bed dose, the unit value of which is the Grey (Gy), repre- senting the unit of energy in relation to the mass of the material irradiated. * See glossary on page 29
  • 7. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – E-Beam and gamma rays are today the two main ionisation* treatment methods used in industry. But the trend is clearly leaning towards the development of E-Beam technology which offers advantages both from an environmen- tal as well as an industrial viewpoint. A solution without a radioactive source The electron beams are produced from a neutral material (generally tungsten) whereas gamma rays are produced from a radioactive isotope* of cobalt (cobalt 60). The use of E-Beam technology therefore avoids the presence of a radioactive source inside the fac- tory, presence which is particularly restrictive from a health and safety viewpoint, has a serious environmen- tal impact (waste) and is increasingly frowned upon in terms of company image. Shorter treatment times The dose rate* based on is a key notion in ionising treatment methods It corresponds to the time required by the product to absorb a defined dose of radiation. Furthermore, electron beams have a far greater dose rate* than gamma rays (in the order of kiloGray per second for the first and up to 10,000 times less for the second). This means that with E-Beam technology it is pos- sible to considerably reduce the time the product is exposed to the radiation. A positive point with regard to productivity most certainly, but also for quality as over-exposure may in certain applications cause oxidation with a subsequent drop in the organolep- tic properties of foodstuffs as well as the physical properties of some materials. The future of ionising treatment processes * See glossary on page 29
  • 8. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 01The future of ionising treatment processes Unavoidable for individual treatment in a production line Gamma rays have a far greater material penetra- tion capacity as opposed to electron beams; They are therefore often used for the decontamination of products in their packaging by complete pallet load. On the other hand, however, their low dose rate * excludes their use for high speed treatment; This explains why in most industrial applica- tions for the cross-linking of plastic mate- rials E-Beam technology is used and why this technology is being used today for individual decontamination in a production line. * See glossary on page 29
  • 9. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 01Breaking of the DNA chains The ionisation* reactions caused by the electron beams have an influence on the DNA of the micro-organisms and cause them to break (single or double strand) at the chain link points. These breaks are irreparable and have an immediate and fatal effect on single-cell organisms (bacteria, yeast, mould). Dissociation of water Micro-organisms contain a large quantity of water. The collision between the electron and a water molecule results in the dissociation* of the latter in extremely active free radicals (OH, H, O2). These free radicals, in the same way as ozone which is created by their re-combination, participate in the oxidation reactions which also damage the DNA of the micro-organisms. They prevent, in particular, the pairing of nucleo- tides* affected with those of the other strand. A double action on micro-organisms * See glossary on page 29
  • 10. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 01Proven treatment already used in numerous sectors Sterilisation of medical equipment E-beam treatment has been used for almost 50 years in the medical sector for the sterilisation of textiles, plastic elements (syringes, tubes, pouches) or implants. Often contracted out to specialised service compa- nies equipped with large-scale installations, E-beam decontamination is in this particu- lar case usually carried out with high energy beams. This enables the electrons to pass through packaging in order to sterilise the product contained therein. However, mini- sterilisers using a low energy beam are also now becoming available on the market. These sterilisers are used for individual ste- rilisation of products in a packaging line. E-beam treatment is recognised by the AAMI (Association for the Advancement of Medical Instrumentation) Sterilisation of pharmaceutical products and reactive substances Sterilisation of active substances is a delicate matter; The process must be perfectly mastered in order to deliver a sufficient dose of electrons without modifying the properties of the product. Electron beam sterilisation is also used for this type of application (sterilisation of freeze-dried vaccines, syringes filled with vaccine or blood sampling tubes containing a reactive agent). It is incorporated into the good manufacturing practice guide in the pharmaceutical industry (GMP) and it is particularly interesting for heat-sensitive substances; Indeed, when per-
  • 11. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 01fectly controlled, the exposure to this radiation does not significantly increase the temperature inside the product. Reduction of microbial content in foodstuffs On the international stage, E-beam technology also replaces gamma rays in more and more foodstuff or phytosanitary applications (decontamination of meat, or fruits and vegetable, disinsectisation of cereals…). The primary arguments in favour of this change of technology are the elimination of a radioactive source and reduction of the footprint of decontamination units. However, the use of E-Beam technology often requires redesigning of the processing line in order to incorporate the decontamination unit upstream of the packaging line. E-beam treatment is recognised and approved by the FDA (Food and Drugs Administration). Decontamination of water and effluents E-Beam technology has also been used for around twenty years in pilot projects for the treatment of industrial water and effluents as well as slurry from waste water treatment plants (reduction of chemical contaminants in the drinking water in Austria, treatment of effluents from dying processes in Brazil or, more recently in China, treatment of slurry and waste water in South Africa and USA…). Its effect destroys the organic pollutants, or increases their biodegradability in order to render their elimination in the receiving medium easier. It is the environmental aspect of the E-Beam treatment which gave rise to this project; Indeed, contrary to conventional de-pollution systems, E-Beam treatment requires no chemical product and pro- duces no toxic by-products.
  • 12. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – CONTENT 01E-Beam: Scope and principle of application 02An emerging technology in the packaging sector 03The key advantages of E-Beam decontamination A new field of application for a proven technology Targeted markets and technical approaches 04 Incorporation of E-Beam decontamination in the production line
  • 13. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 02A new field of application for a proven technology Conscious of the advantages of E-Beam technology, its environ- mental impact, user safety and running costs, manufacturers of aseptic filling and packaging lines have closely examined the use of this technology in their trade. The initial operational solutions appeared on the market very recently and were in particular rendered possible thanks to the miniaturisation of emitters. They combine the well- known efficiency of E-Beam technology on micro-orga- nisms with its capacity to be incorporated into high-speed industrial processes; It is this aspect which renders them particularly innovative High-speed, individual decontamina- tion on production line The effectiveness of ionisation* treatment in decontamination applications has long been proven; It has been used for this purpose for over fifty years. Moreover, the electron beams are often used on high-speed, non-stop production lines (cars, cables, ducting) and have therefore proven beyond doubt their industrial reliability. Application of this technology in the decontamination of packaging lines however is a very new arrival on the scene. The appearance of these inno- vative solutions was rendered possible by recent developments in the design of ultra-vacuum* chambers and the minia- turisation of low-energy beam emitters. Now much more compact, less expensive and longer lasting, these new generation emitters may easily be incorporated into a production line. * See glossary on page 29
  • 14. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 02In-depth groundwork on the qualification of processes The main challenge in developing solutions for decontamination of packaging lines is adapting the E-Beam treatment process to this use: - ensuring the wide variety of applications encountered in this sector (decontamination of films, pre-formed and formed packaging elements), - comply with the hygiene standards required. This prerequisite demands extensive groundwork in areas such as size, power, positioning and the number of emitters, all of which are validated with dosime- tric studies which guarantee that each packaging element has been sufficiently exposed to the electron beam in a uni- form manner.
  • 15. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 02Targeted markets and technical approaches Primarily for liquids in cartons and bottles E-Beam decontamination is primarily used for the aseptic packaging of liquids. Although trials have been carried out on flexible packaging elements (pouches, bag-in-box), the units presently in operation are only used for cartons and bottles. Where bottles are concerned, the E-Beam deconta- mination solutions were initially developed for the treatment of PET. Indeed, with this new technology it is possible to avoid certain phenomena relative to the migration of hydrogen peroxide or peracetic acid in the plastic. This having been said, E-Beam treat- ment is not limited exclusively to this material and the treatment of PEHD, PP, aluminium and even glass is now possible. Electron beam treatment is used for aseptic packaging of a wide variety of acidic or basic products: fruit juices, dairy products, vegetable milks, waters, teas… Decontamination of films, pre-formed packaging or bottles Three solutions are currently proposed on the market, each with its own treatment process. The simplest case is flat treatment of the sheet before forming the carton packaging. This is fol- lowed by the treatment of pre-formed elements with a small volume and relatively simple shape. E-Beam treatment of formed bottles is, bearing in mind the complexity and diversity of shapes available on the market, more delicate. It is there- fore this solution which requires the most research to guarantee the minimum exposure to the electron beam in every part of the packaging. E-Beam treatment may also be used for the decontami- nation of caps when necessary.
  • 16. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 2 methods for interior decontamination Presently two methods of E-Beam treatment are pro- posed for bottles and pre-formed packaging: Sterilisation from the exterior only, or exterior/interior sterilisation. The first method requires an electron beam with an energy level sufficiently high to pass through the packa- ging; The second uses ultra-miniaturised emitters, which may be introduced via the neck of the packaging, with a very low energy beam. It is this second method, more reliable and easier to apply in production, that Serac has retained for its E-Beam treatment ßluStream.
  • 17. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – CONTENT 01E-Beam: Scope and prin- ciple of application 02An emerging technology in the packaging sector 03The key advantages of E-Beam decontamination Reduction of environmental impact at the workstation Acceleration and safety of the decontamination process 04 Incorporation of E-Beam decontamination in the production line
  • 18. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 03Reduction of environmental impact at the workstation "zero chemicals" sterilisation Electron beam sterilisation is a physical treatment method which requires no chemical products. The process therefore generates no toxic waste requiring treatment before evacuation into the natural environment, and for which the company may potentially face payment of duty or taxes. Savings are therefore both economical as well as environmental and concern the installations, purchasing of consumables and management of waste. The absence of chemical products is also interesting for manufacturers wishing to present their customers with a production process which is both responsible and natural, or where the target consumers are particularly sensitive (babies, immu- nodeficient persons. Dry sterilisation The absence of chemical products also means no need to rinse the packaging. Foodstuff industries which use a great deal of water in their processes, are particularly sensitive to the environmental impact of this consumption. Water is therefore often one of the first items concerned by improvement plans. E-Beam treatment offers the factory the possibili- ty to reduce water consumption at the workstation to practically zero and to present a considerable improvement in their environmental balance. Water is also potentially a major source of contami- nation; another reason to reduce its use in foodstuff processes.
  • 19. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 03Sterilisation at ambient temperature E-Beam technology requires no hea- ting or generation of steam. Decontamination with low-energy electron beams therefore presents a positive energetic balance compared with conventional technologies. The energy transmitted by the electrons does no significantly increase the packaging tem- perature. Thanks to the eli- mination of heating, E-Beam treatment may be used on thinner packaging resulting in a reduction of raw mate- rials consumption.
  • 20. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 03Acceleration and safety of the decontamination process Shorter treatment times The electrons interact very quickly with the material onto which they are beamed. This is what enables them to offer a high useful dose rate*. With this property, a microbiological reduction compliant with aseptic requirements (5 log for Bacilus pomelos) is possible in only a few seconds.Thanks to this duration in treatment time, electron beam de- contamination enables increasing of the aseptic production line work-rates or reduction of the production line footprint for a given work-rate. Limited cleaning As the E-Beam decontamination systems require no circulation of water or chemical products and do not enter into contact either with the packaging or soiled solu- tions, they require very little cleaning. For this reason, they have no negative impact on the OEE* (Overall Equipment Efficiency) of the line and stoppage times are set according to the filling machine cleaning cycles. Only 3 parameters to be set Electron beam treatment is controlled with 3 para- meters (voltage, current and exposure duration), whereas decontamination systems using hydrogen peroxide or peracetic acid require the setting of respectively 7 and 6 parameters to ensure efficient decontamination. This is why E-Beam systems are presently the easiest aseptic decontamination solutions to manage during production. * See glossary on page 29
  • 21. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 03The E-Beam systems are also very easy to operate (ON/OFF system), which avoids loss of packaging and further increases the OEE*. Perfectly controllable physical parameters In addition to the fact that there are less, the critical parameters of the E-Beam systems are also far easier to control, monitor and record in the quality system. It also enables individual trac- king of packaging elements via a continuous monitoring system. They also offer industrialists more gua- rantees in relation with treatment continuity and conformity of results obtained.
  • 22. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – CONTENT 01E-Beam: Scope and prin- ciple of application 02An emerging technology in the packaging sector 03The key advantages of E-Beam decontamination Initial dosimetric study Equipment: The key points taken into consideration What are the implications during production? 04 Incorporation of E-Beam decontamination in the production line
  • 23. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 04Initial dosimetric study In order for E-Beam decontamination to be perfectly reliable, it is important to ensure the entire surface of the packaging receives the dose of radiation defined and required. If homogeneous exposure of a flat film or carton to an electron beam is relatively simple, this operation becomes a lot more delicate in a bottle filling line, both due to the complexity of the packaging shape as well as the diversity of the formats which may be processed in this produc- tion line Definition and validation of treatment times The treatment times are defined for each packaging format according to the level of decontamination required. Validation is carried out with dosimeters* placed at critical points in various zones of the bottle. The dosimeters the most com- monly used for this purpose change colour more or less intensely depending on the dose of radiation received and thus enable mapping of the dose dispersion inside as well as outside the bottle. It is indeed impossible to apply a perfectly uniform dose to packaging with such complex shapes; * See glossary on page 29
  • 24. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 04The dosimetric study therefore guarantees that all zones of the bottle have at least been exposed to the minimum decontamination dose necessary without any particular zone receiving too high a dose which could have a negative effect on the physical properties of the packaging. Inspection during production Once the application has been validated, routine inspections may be carried out in a fast and easy manner. A single dosimeter* on a single "sample bottle" is all it takes to confirm that the dose is correct. This operation only takes a few minutes per day. * See glossary on page 29
  • 25. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 04Equipment: The key points to be taken into consideration Working life and maintenance of emitters E-Beam emitters are obviously key operating com- ponents in the system; their working life, as well as possible maintenance operations required have an impact on the OEE* and TCO* (Total Cost of Ownership) for the entire line. The new generations of hermetically sealed emitters offer a double advan- tage: their working life is considerably increased compared with emitters of the previous generation and they are practically maintenance-free. System redundancy The number of emitters used is a key safety factor for the decontamination process. A system using only one or two emitters may fail to function entirely if one of the two emitters is defective. In the case of a system using multiple emitters however, the line may continue to operate in downgraded mode. Booth design The booth design form must take into account the X-ray* interference emitted by the E-Beam treatment, even if this interference is extremely low. Protection screens must be The maintenance times will be considerably reduced if the emitters may be replaced in the same way as a light bulb; Indeed, replacement of an internal compo- nent (window, cathode) is not a simple operation. * See glossary on page 29
  • 26. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 04incorporated into the treatment chamber and the booth casing must be reinforced. This reinforcement is calculated according to the maximum beam energy and power; it is much lighter for low-energy beams which represents a conside- rable cost saving compared to high-energy beams.
  • 27. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 04What are the implications during production? Adopting an innovative technology is always a poten- tial source of industrial risk and legitimate questions are asked concerning the incidence this change may have on production. If E-Beam technology is considered a potentially interesting decontamination solution, the following 3 points must be considered: - This technology benefits from decades of expe- rience feedback in other sectors (see intro part 1), - The reliability of the latest generation of miniature emitters is also beginning to be well documented as these devices have been in use for around 8 years already and have also been used in several other activity sectors, - E-Beam decontamination is much easier to use than currently available decontami- nation methods (H2O2 and PAA). Incorporation in existing production lines All industrialists wishing to benefit quickly from the advantages offered by E-Beam tech- nology with regard to the environmental impact and safety in aseptic processes will have to ask the question about how to incorporate it into an existing production line. In fact, even if this change requires adaptation of the machine interfaces upstream and downstream which represents a major modification, incorpo- ration of the E-Beam into an existing line remains perfectly feasible. The E-Beam modules pose no problem as far as space requirement is concerned as they are more compact than other decontamination modules, and their installation is by no means compli- cated as they are "Plug and run" modules which simply require an electrical supply.
  • 28. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – 04Production work-rate As presented above, thanks to its high dose rate*, E-Beam treatment enables reduction of individual treatment times for packaging elements and the- refore offers a promising perspective with regard to increasing production work-rates. Of course, obtaining of the promised work-rate increase also depends on the capacity of the filling machine to adapt to this change. This will be that much easier if the latter is not already working at its maximum capacity, or if it has been desi- gned to enable an easy upgrade to higher work-rates. Training of operators The operators must understand all para- meters to be taken into consideration with this new process, the new safety precau- tions to be taken, and the new cleaning procedures. But here again, this lear- ning curve is fast and easy for persons experienced in the use of the complex decontamination methods used today in aseptic filling processes. The operating simplicity of the system will enable a rapid rise in work-rate capacity. Based on the experience feedback from exis- ting E-Beam sterilisation applications, several weeks is sufficient to allow perfect control of this technology during production and use of the decontamination module to its full capacity. * See glossary on page 34
  • 29. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – Glossary Cathode The electrode connected to the negative pole of the electrical supply, point of exit or emission of elec- trons Dose rate Dose of radiation absorbed per unit of time, mea- sured in Grays per second (Gy/s). Dissociation (reaction): Reaction by which the molecules separate into smaller particles (atoms, ions or radi- cals), often in an irreversible manner. Dosimeter A device placed on the product and desi- gned to measure the dose of radiation it receives. When irradiated, this device presents a quantifiable modification of one of its properties according to the dose absorbed. This change is measured using appropriate analysis techniques and instruments. Electron-volt (eV) Kinetic energy acquired by an accelerated electron from rest with a potential difference of one volt  Ionisation Phenomenon resulting in addition or loss of elec- trical charge in an atom or molecule. Ionisation may be obtained with the impact of an electron, photon, by applying thermal energy or by means of a chemi- cal reaction. Isotope The isotopes of a chemical element are atoms which contain the number of protons characterised by this ele- ment, but a different number of neutrons.
  • 30. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – The core of cobalt 59, stable isotope of the element contains for example 27 protons and 32 neutrons, whereas that of cobalt 60, radioactive element, contains 27 protons et 33 neutrons. Nucleotide An organic molecule, basic element of a nucleic acid such as DNA or RNA. OEE Overall Equipment Efficiency. It is obtained by multiplying the synthetic efficiency (operating rate x efficiency rate x rate of compliant products) by the load rate (working time on workshop opening time). Reticulation Reaction of linking macromolecular chains in three-dimensio- nal grids. X-ray Electromagnetic radiation composed of photons, used in a wide range of applications such as medical imagery TCO (Total Cost of Ownership) Total cost of ownership of an item which represents the total sum spent by the owner over the entire life cycle of the item. Ultra-vacuum A very high vacuum, characterised by pressures generally below 10-7 Pa or 100 nPa
  • 31. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – Use of electron beams (E-Beam) for the decontamination of packaging lines is a true innovation. It has all the elements necessary to be perfectly controlled " Even though E-Beam technology is still very new for the treatment of packaging lines, it is well pro- ven in other industrial sectors. We have been wor- king for over thirty years with companies using this technology. Ionising treatments are presently the most effective solution for decontamination purposes whereas E-Beam is the green tech- nology with no source of radioactivity and no chemical products; It therefore offers all the advantages necessary to become the stan- dard in aseptic packaging. We are extremely pleased to have accompa- nied Serac in the validation of its process. This is a key component in the success of a project for which resource centres such as ours have the experience and means necessary to offer a secure approach to industrialists. We hope that this white paper will help convince industrialists to use E-Beam treatment in their aseptic packaging applications." Alain Strasser Head of the Aérial Technologies Resources Centre
  • 32. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – About Aérial Founded in 1985, Aérial, Technologies Resources Centre and Agricultural Food Industry Technical Institute, started out as part of an applied research programme into the ioni- sation of foodstuffs. Since the early 90’s, Aérial has been independently offering its specific know-how to agricultural food industries as well as all other industrial sectors using ionisation techniques. Aérial is equipped, in its various laboratories, with highly-efficient analytic instru- ments (dosimetric, microbiological, physico-chemical, sensory analysis, freeze- drying), as well as an electron beam ionisation experimental station. Aérial accompanies industrialists in the calibration and development of dosime- tric systems in a wide range of industrial activity sectors (agricultural foodstuff, medical and para-medical, para-pharmaceutical, packaging).
  • 33. –  E-BEAM: Fast and reliable, chemical-free decontamination technolog – Safer and better for the environment, I am absolutely convinced that E-Beam decontamin- ation technology has a promising future ahead of it in the aseptic packaging sector "Serac has perfectly controlled decontamination of its packaging elements for the last 35 years in its ultra- clean and aseptic filling lines. Over the last decade, we have noted that our custo- mers wish to make true progress in matters such as environmental impact, but also want to render their decontamination process safer in order to avoid any potential health hazard. As all we offered at the time were chemical treat- ment processes, we turned our attention to phy- sical, dry decontamination alternatives. It is with this in mind that we co-developed (with Cla- ranor) the pulsed light treatment process for ultra-clean applications. With ßluStream, our E-Beam decontami- nation module, we now propose a solution which required neither water, nor chemicals for aseptic packaging applications. E-Beam technology is still in the teething stage in the packaging sector, but is well proven in other activity sectors. In our business, it offers the double advan- tage of simplicity and reliability. This is why I am convinced of the fact that it will soon seduce industrialists in the agricultural food sector. I am extremely pleased to have participated in the development of ßluStream, which undoubte- dly bears the Serac trademark: This is a reliable and versatile solution which anticipates the needs and expectations of our customers." Delphine Gueguen Head of the Aseptic Equipment Division
  • 34. Publisher: Serac 12 route de Mamers 72400 La Ferté-Bernard Designer : Nexteo Conseil Writer: A Fond les Bases Completed in September 2017 by printing ITF Imprimeurs ZA Le Sablon – CS40051 72230 Mulsanne Copyright Serac : September 2017