Safe use of

Compressed Air & Nitrogen

in the Food and Beverage Industry
Nalin Amunugama
General Manager BOGE Asia Pacific

F&B Conference, Jakarta Nov 2016 in conjunction with SIAL 2016

BOGE Kompressoren Asia Pacific

Introduction

During production, processing, handling, packing and

transportation of food at all stages, from source to consumer,
the safety of the food may become compromised and then
subject to recall. One source of possible contamination is when
compressed air is used in conjunction with the food chain.
Use of compressed air in food/ beverage manufacturing shall
be as identified in the BRC Global standard for food safety ISO
22000 ,ISO 22002-1, Codex Alimentarius CAC/RCP1, etc

Contamination Sources

Ambient atmospheric air

Air compressor
Air storage and distribution system
Production area
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Introduction

Contaminants in Compressed Air

Solid particles (Dirt) in compressed air
Water (Humidity)
Oil (in Liquid, Aerosol, vapour)
Presence of microbiological organisms (Bacteria)

Variations in design of compressors require

Oil in the compression stage (Oil Injected)
No oil in compression stage (Oil Free)

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Introduction
Oil Contaminants in Compressed Air
In food production when compressed air comes into direct
contact with the food, the amount of oil present and the type of
oil allowed should be strictly controlled
Use of food grade lubricants Class H1 (registered by NSF as
class H1) for use where there is potential for incidental food
contact
Some food producers have initial requirements where no oil is
allowed to come into contact with food
Maintenance is the key element to ensure that the compressors
and other equipment retains acceptable operating conditions

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Air Purity
Production of food products
Air that comes into direct contact with food (Direct Contact)
Air that could come into direct contact with food (In-direct Contact)
Direct Contact with food - ISO 8573-1:2010[2:2:1]
Dirt -

the max. number of particles in the following size range shall not exceed

Particle size, dm
Maximum number of particles; per m

Humidity
Total oil

0.10< d 0.5

0.5< d 1.0

1.0< d 5.0

400 000

6 000

100

- 40C pdp (at air line pressure)

less than 0.01mg/m

The contaminant values for Dirt and Oil are at reference conditions in ISO 8573-1 at a temp of 20C, ATM 1 bar, RH 0%
Reference BCAS best practice Guideline 102
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Air Purity

In-Direct Contact with food ISO 8573-1:2010[2:4:2]

Dirt -

the max. number of particles in the following size range shall not exceed

Particle size, dm
Maximum number of particles; per m

Humidity
Total oil

0.10< d 0.5

0.5< d 1.0

1.0< d 5.0

400 000

6 000

100

+ 3 C pdp (at air line pressure)

less than 0.1mg/m

The contaminant values for Dirt and Oil are at reference conditions in ISO 8573-1 at a temp of 20C, ATM 1 bar, RH 0%

Reference BCAS best practice Guideline 102

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Air Purity

Microbiological contaminates
Many applications within F&B processing will require sterility or
level of control over the presence of Micro-organisms
Hazard analysis will establish the risk of contamination by
microbiological contaminants from compressed air.
The microbiological particles are considered to be solid particles;
and therefore will be included as a measurement for solids
particles.
ISO 8573-7 is the method to detect the contaminant in compressed
air for solid particles and microbiological particles
Note: Microbiological testing of end product should not be relied
upon for compressed air compliance
The compressed air purity should be tested and verified at least twice per year
or in accordance with manufacturers recommendations
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Use of Compressed air in Food & Beverage Ind.

Manufacturing Process- Automation

Packaging
PET bottle blowing (Hot filling/cold filling)
Food filling
Food conveying
Food pumping
Air Knifes
Preserving
Colour sorting
Not cover the use of compressed air as a
food/beverage ingredient

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Nitrogen in Food production

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Composition of ambient air

Characteristics

Nitrogen (N2)
78,09%

O2 available in ambient air (21%)

N2 available in ambient air (78%)
Flavourless

Argon (Ar)
0,93%
Carbon dioxid
(CO2) 0,03%

Odourless
Oxygen (O2)
20,95%

Invisible
Extremely dry
(pressure condensation point
from -40 to -70 degrees C)

Nitrogen is an inert gas and non reactive / not flammable

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Applications

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Beverage
Use of Nitrogen has become very common to
prevent product oxidation and any enzymatic or
microbiological reaction. Nitrogen is a gas that is
inert, odourless, it cannot be dissolved, it is non
toxic and it reduces the use of additives.

Winemakers
Nitrogen gas is commonly used in wineries during
different production stages such as sparging,
blanketing and flushing. This reduces enzymatic
oxidation, bacterial growth and preserves the wine
from oxidation.

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Beer Foaming

When beer is foamed using nitrogen, the hordeinderived polypeptides produce the most stable foams
thus giving the beer a creamy head texture.

Bottling
The turbulence that results from bottling has the
potential to mix a lot of air with the liquid to be
bottled, increasing the risk of oxidation. Nitrogen
works to replace the oxygen and preserve the liquid
during bottling.

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Controlled Atmosphere Fruit Storage

A typical storage system for fruit is controlledatmosphere (CA) storage. In CA storage the oxygen
and carbon dioxide content of the storage environment
are controlled in such a way as to retard senescence
and further deterioration of the fruit. Oxygen levels are
reduced by displacing oxygen with nitrogen.

Kiln/Grain Drying
The extremely low dew point of nitrogen makes it an
ideal choice for drying of grain and kiln, so efficiently
inhibiting microbial growth.

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Grain Silos Explosion Prevention

Grain dust in oxygen-rich grain silos and grain

elevators is very hazardous. Nitrogen is used to
inert and eliminate explosions.

Food Industry

Nitrogen is an efficient, cost-effective way, without

the use of additives to stop bacterial growth,
reduced oxidation, and preserve the taste and
texture of the product. It also extends product
shelf life and improves the visual appeal of
freshness

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Modified Atmosphere Packaging

Nitrogen is an efficient, cost-effective way, without

the use of additives to stop bacterial growth, reduce
oxidation, preserve product taste and texture, and
extend product shelf life and to improve the visual
appeal of freshness.

Milk Powder Packaging

Packaging of milk powder with MAP system
increases its shelf life and avoids product
wastage

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Fish Farms

Fish hatcheries are well aware of the benefits of

oxygen on fish health, fish growth and increasing fish
density. For remotely located fish farms, oxygen onsite production is an indispensable source.

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Compressed Air Generation

Oil-lubricated screw compressors

Oil-free screw compressors

Oil-lubricated piston
compressors & Boosters

Oil-free scroll compressors

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Oil-free piston compressors

Screw compressor - Oil Free Air - Class 0

SLF40-3 BLUEKAT

40 - 60 Hp BLUEKAT
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Why BLUEKAT
Cost and efficiency comparison
S 50-3 with DCZ

38.727

35.000
Costs per year

40.000

S 50-3 BLUEKAT

SO 61 A

56.607

44.377

45.000

50.000

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55.000

60.000

Compressed air Souce available in the market

Comp. Air quality

Method

BLUEKAT
(integrated converter)

Oil free
compression

Oil lubricated
compressors with
Filter / Absorber

Class 0

Depending on the quality

of the ambient air *

Depending on the applied

filter and the quality of the
maintenance*

Oxidation of the hydrocarbon

chains to form CO2 and water:
No residues left to be cleaned
or serviced

No additional oil brought

in. Therefore, no oil
filtration.

The oil will be gathered in the

oil water separator and the
activated carbon filter /
absorber
Possible

Oil flood

Condensate

Not possible

Not possible

In case of incorrect
dimensioning of filters or
neglected maintenance

Oil free compressor

Oil free compressor

Oil emulsion compressor

Oil free air treatment

Oil free air treatment

Oil free air treatment

* Class 1 achievable

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BLUEKAT
What will be converted in the catalytic converter?
Splitting of long-linked hydrocarbons into water and carbon dioxide

Silicone
Silicate
Silicate sticks to the surface of the catalytic beads (Polysiloxane
content <= 0,3g/Nm acc. NIOSH 1501)
Sulphur - The Sulphur is suspended in the compressor oil.
Therefore the sulphur content is very small
CO is eliminated to less than 0.1 % like in a CO filter
Germs are being reduced
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Compressed air treatment & accessories

Refrigerated dryers +3C

Compressed air filters 0.01mg/m

Oil Vapour absorbers

Adsorption dryers -40C
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Air@40 Bar with Multiple Boosters

for PET Bottling Industry

The Focus Controller on both Screw & Boosters compressor, that

can synchronies up to 4 Boosters to operate as per demand only.
This will eliminate high starting peaks & running current of motor
compared to a single compressor with large capacity motor,
No risk of complete production lost due to compressor down time.
Option to choose the right combination of equipment to get dry, dust
& oil free compressed air with down stream air purification
accessories.
Low pressure instrument air requirement fulfilled from the Screw
compressor. Saving cost and pressure reducing loss from 40 bar to 7
bar.
Low maintenance cost and simple to maintain
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Nitrogen in Food production

Manufacture in-house:
Nitrogen & Oxygen to meet your specific needs!

No commitment with gas suppliers required

Building construction for tank installation
Only space requirement for storage of cylinders, bundles as a
back up if needed
Continued order- and invoicing admin procedures
Logistic efforts
Highly flexible and always expandable
Continuous monitoring of purity level

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Sample installation for nitrogen

Screw compressor

7,5 - 9 bar

9 - 10 bar
N2 outlet
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Modular Pipe systems

Compressed Air Distribution
Compressed air is comonly distributed through carborn steel pipes that corrode due to
the presence of water in the compressed air. Other piping meterial readily available
includes aluminium, copper, stainless steel or number of plastic alternatives

Compressor

Receiver

Dryer

Filter
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Application
#

Modular Pipe systems

Full aluminium piping system

Long lifetime due to high quality aluminium and

stainless steel components
Quicker and easier installation compared to carbon
steel, SS and copper pipes
Easy to expand the pipe system
Less weight to the building structure
No diflation of pipe system as in some plastic
alternatives
Economical to install

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Modular Pipe systems

Efficient and clean
Steel pipes corrode up to 40% more over the lifetime
which effects the air flow and the air quality
Aluminium pipes guarantee 100% flow rates and
best air quality
No corrosion means no contamination from pipe
systems and energy efficiency even after 10 years

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Thank you!

BOGE KOMPRESSOREN
Asia Pacific Pte Ltd
9 Toh Guan Road #03-01
Singapore 608604

Nalin Amunugama
General Manager - BOGE AP
Mobile: +65 97279866
Email: a.nalin@boge.com

BOGE KOMPRESSOREN
Otto Boge GmbH & Co. KG
Otto-Boge-Strae 1-7
33739 Bielefeld
BOGE Kompressoren Asia Pacific