Although man affects life on earth more than any other species, some organisms are simply not bothered by us. An immense army of microscopic bacteria and fungi have flourished since time immemorial. They invade every aspect of life, even this computer, as well as you, the reader. For microbes, the chemical industry and chemical products are particularly attractive sources of food. Warm manufacturing plants with plenty of water and nutrients are a paradise. Skin lotions, motor oils, paints and adhesives are perfect breeding grounds, much to the dismay of manufacturers and consumers, because spoiled goods are not only unusable, they often are harmful to health.
However, there are ways and means to keep such unwelcome creatures at bay. At its variety of chemical plants, Clariant takes great care to ensure that the facilities are impeccably clean. When in doubt, the company’s worldwide microbiological analytical laboratories offer support. Clariant also specializes in chemicals that prevent microorganisms from multiplying, such as biocides and preservatives. The company has manufactured such substances for over 70 years (formerly under the name Nipa) and continues to develop new products. |  |
Since early this year, Clairant has made its extensive know-how in plant and product hygiene available to customers: the company offers two kinds of services under the name AMicroS™ (Advanced Microbiological Services). One involves microbiological audits of chemical plants to locate, eliminate and prevent future contamination in the operations of customers. AMicroS is also available to determine how cosmetics and technical chemicals can be optimally preserved. The range of clients includes chemical manufacturers in all industries except pharmaceuticals and food products. “AMicroS is an excellent example of our strategy. The objective is to address specific customer needs and offer tailor-made solutions”, comments Dr. Markus Meder, Head of Marketing for the new service.
A microbiological audit is necessary, for example, when a customer discovers germs in his products and is unable to establish which vat, pipe or raw material is the source of contamination. Matthew Bloomer is the person in the AMicroS team responsible for this type of investigation. When he takes a call for help, he dons lab coat and gloves, packs a camera and a notebook and takes his black audit bag full of sterile sample tubes and test kits. First, he talks to the plant manager, who explains the plant’s material balance with a series of flow charts, and then begins the systematic search for the origin of the problem.
Anybody who believes that an auditor must be a stern know-it-all is mistaken. With his easygoing manner, Matthew Bloomer is a pleasant, competent partner. He knows every nook and cranny where microorganisms prefer to hide, usually wherever water collects, which may be in the dead end of a pipe, a U-tube, a slack part of a hose or simply a puddle. Other potential breeding grounds are open waste containers, drains or vats that are accessible to airborne spores. The auditor takes pictures and notes, dozens of meticulously labeled samples and swab tests. For the latter, the auditor uses a large cotton tip to wipe the inside rim of a mixing vessel that may carelessly have been left uncovered and thus represents a likely contamination source. If he needs to convince a skeptical plant manager right then and there, Matthew Bloomer will perform a quick “litmus test” for bacteria. If the saturated paper strip turns purple after touching a certain surface, this means that the area is contaminated. “Sometimes we inspect an entire plant without finding anything. And then, at the very end, in the product packaging department, it turns out that the filler nozzles are not completely clean, or the finished product has not been properly covered,” the auditor explains.
The samples that Bloomer collects are analyzed in the quality-certified AMicroS laboratory in Horsforth, near Leeds. Detailed results are generally available within two days. The AMicroS team then develops a problem-solving strategy and recommends efficient cleaning methods, using, for example, hot steam or appropriate biocides. The team will suggest only a product category. It is up to the customers to decide which substance they will ultimately use. AMicroS offers routine follow-up audits to monitor long-term effectiveness, which also preserve the customer’s peace of mind, because nothing ruins a reputation faster than having to recall moldy products. |