Experiencing These Challenges? Here's why.
Conventional microbiological tests used for QA/QC activities can reveal some threats but considering the fact that only a small portion of the population is revealed using these tests, many threats can go unnoticed. 2nd Generation ATP monitoring provides the ideal combination of rapid feedback and all-inclusive results, meaning that all biological growth is revealed. This information can guide QA/QC activities to prevent problems earlier in the process and conduct pass/fail assessment on final product in a fraction of the time that would normally be needed.
The fastest pathway to product contamination is often in the raw materials or make-up water. Unfortunately, the slow feedback of culture tests (2+ days) means that raw materials are already in use and product is often made by the time that test results are know. The speed of 2nd Generation ATP monitoring enables rapid screening of raw materials to ensure their quality before being used in production, thus pre-emptively avoiding contamination early in the manufacturing process.
Conventional microbiological tests typically require at least 2 days to return results, after which products can be shipped to distribution centers. If problems are detected at this point, they must be removed to be reworked or discarded – both of which incur significant cost. These QA/QC tests can be reduced to mere minutes using 2nd Generation ATP monitoring to not only release product faster, but also to prevent contamination incidents earlier in the process to significantly improve the overall production cycle.
Due to the inability of traditional culture tests to quantify the total microbiological population (typical tests are restricted to 1% or less), many threats can go unnoticed. As such, some types of microbes can slip through QA/QC programs into final product that is delivered to customers, resulting in costly recalls once the issue is eventually revealed via subpar product quality. Since 2nd Generation ATP monitoring detects all microorganisms, it is an ideal compliment to QA/QC programs to truly characterize the overall microbial threat and ensure that control programs are effective.
How can 2nd Generation ATP® monitoring help to mitigate these challenges?
The first impression you can expect by using LuminUltra’s solution is its speed and accuracy. Being able to identify contaminated product on-the-spot rather than having to wait days or even weeks for culture test results to be known results in significantly shorter production cycles. Not only can batches be flagged as contaminated much more quickly, but the effectiveness of corrective action can also be assessed in real-time.
Overall, this can reduce production cycles by up to two weeks! This kind of same-shift troubleshooting is simply not possible when using any culture-based microbiological analyses.
Moreover, LuminUltra’s solutions detect all living organisms, not just the relatively small percentage that forms colonies in typical growth media. Following this initial testing, follow-up tests involving specific culture tests can be done to validate control mechanisms to guard against spoilage.
How can you realize immediate cost savings?
When examining the total cost of ownership, LuminUltra’s solutions provide you with significantly more opportunities for cost savings and improved control.
Microbiological threats are best addressed in their early stages of growth. Since the doubling time of some microbes can be as low as 30 minutes if left unchecked, microbial proliferation can get out of hand very quickly. Incubation times of days or weeks associated with traditional methods usually results in system contamination becoming exponentially worse by the time results are known.
LuminUltra’s solutions are able to help you to achieve greater accuracy and substantial savings in turn-around time for your microbiological testing program. By reducing this time lag from days or weeks to mere minutes, your team is able to address and validate solutions immediately and further reduce product quarantine times.
What is the return on investment?
Our customers have consistently achieved benefits through reductions in waste disposal costs, labour costs, receiving costs, and product recall costs. Considering that the raw material cost for products such as paints or coatings can cost tens of thousands of dollars, preventing the loss of a single batch of basic product easily covers the investment cost for ATP monitoring. Even if product only needs re-working, the cost of remediation activities and troubleshooting time can be substantially less since the effectiveness of corrective action can be assessed immediately rather than having to wait several days for traditional microbiological test results to be known.
Economic Analysis: Microbiological Control in Product Preservation
This whitepaper discusses how 2nd Generation ATP monitoring can serve as an effective alternative to provide a much more complete indicator of contamination in paint products in a tiny fraction of the time that would otherwise be needed using culture-based microbiological tests.
Recommended Test Kit
QuenchGone21 Specialty (QG21S™)
QuenchGone21 Specialty (QG21S) test kits provide a real–time and complete measurement of total microorganism concentration (and optionally, stress level) in raw materials, intermediates, and finished chemical products. Use this information to identify process contamination and/or spoiled product immediately enabling swift action to be taken to re-work or scrap contaminated product, ultimately leading to shorter production cycles and faster time-to-market!
The QG21S test kit is designed for testing Manufactured Chemical Products:
- Paints, Coatings & Mineral Slurries
- Adhesives, Admixtures & Polymers
- Personal Care Products
- Household & Industrial Care Products
Testing for ATP in a sample has become the ‘gold standard’ by which the numbers of active cells in the sample can be counted. Good correlations were found between ATP in the samples and the time lapses generated by the BART testers. This has been so conclusive that no samples at DBI are tested for bacterial activity before any ATP tests are undertaken and this has now become standard operating procedures.