Low-Voltage Electrolysis Ozone Disinfection Plan for Food Processing Facilities
Release date:
2024-03-28
Providing a sterile environment in food production facilities is a prerequisite for preventing viral infections. Creating a sterile environment and performing disinfection and sterilization are among the most critical foundational tasks. Ozone can serve as a substitute for chemical disinfectants such as formaldehyde and peracetic acid in large-scale disinfection efforts. In addition to the high efficiency and broad-spectrum sterilization capabilities shared with other sterilization methods, ozone sterilization boasts many unique advantages. First, ozone sterilization is extremely easy to operate—unlike formaldehyde fumigation or peracetic acid spraying, it doesn't require much labor or time, and there's no need for secondary cleaning to address residual contamination. Unlike ultraviolet lamps, which have dead spots, ozone can rapidly diffuse throughout the air, ensuring that every corner is thoroughly disinfected. Particularly, with... Combined with the air conditioning ventilation system, ozone can be used to carry out thorough disinfection every day.
In food processing facilities, to effectively control microorganisms, it is essential to select appropriate disinfection methods that can eliminate unwanted bacteria from the air, as well as from building surfaces and object surfaces. Traditionally, common methods for indoor air disinfection and sterilization have included ultraviolet (UV) irradiation, gaseous fumigation with peracetic acid, formaldehyde, ethylene oxide, and other agents, spray application of disinfectants, and high-temperature sterilization. However, these conventional disinfection and sterilization methods have numerous drawbacks: For instance, with UV irradiation, the effectiveness of UV lamps diminishes over time as their usage duration increases, leading to a gradual decline in their germicidal capacity. Moreover, UV light has weak penetration power and creates dead zones; its bactericidal effect varies depending on the type of microorganism. Additionally, humidity significantly affects the efficacy of UV disinfection. When using chemical fumigants or spraying disinfectants, although the effects last relatively long, this necessitates prolonged non-production operation of air-conditioning and purification systems, thereby increasing energy consumption. Furthermore, chemical fumigation may leave residual substances, causing secondary contamination. For example, formaldehyde fumigation can result in the formation of polyformaldehyde polymers (white powders) that adhere to interior decorative structures and object surfaces. Typically, within a few days after disinfection, the number of suspended particles in the air tends to rise, and these polyformaldehyde polymers gradually decompose into free formaldehyde, posing health risks to workers in the facility. On the other hand, since chemical fumigation cannot be carried out daily, while sources of microbial contamination—people and objects—enter and exit the facility every day, the microorganisms they bring in cannot be completely eliminated merely by thorough cleaning and routine disinfection through wiping and spraying. As a result, microbial populations tend to increase rapidly over time.
Compared with conventional disinfection and sterilization methods, the ozone sterilization method has the following characteristics:
- High Efficiency: When operating, an ozone generator produces a certain amount of ozone. In a relatively enclosed environment, the ozone diffuses evenly and exhibits excellent coverage, thereby overcoming the inherent drawbacks of ultraviolet disinfection, which often leaves dead spots. As a result, it can achieve comprehensive, rapid, and highly effective sterilization and disinfection. Moreover, ozone boasts a broad-spectrum antimicrobial capability—it can effectively eliminate not only bacterial vegetative cells, spores, hepatitis A and B viruses, fungi, and protozoan cysts, but also neutralize botulinum toxin and rickettsiae. Additionally, ozone possesses strong capabilities in removing mold, odors, and other organic malodors.
- High Purity: The unique advantage of ozone as a disinfectant and sterilizer lies in its ability to rapidly and naturally decompose into oxygen after eliminating microorganisms. During the oxidative sterilization process, excess oxygen atoms [ O ]At 30 ~ 50 minutes later, they combined again to form oxygen molecules.[ O 2 ], there are no toxic residues whatsoever, which not only addresses the issue of secondary pollution but also eliminates the need for re-cleaning after disinfection is complete.
- Simple operation: During sterilization, simply connect the ozone generator’s outlet pipe to the indoor space or the central ventilation system. Just set the timer switch according to the validated sterilization duration, and the device will automatically turn on and off as scheduled. It’s exceptionally easy to operate, and its running costs are very low.
Ozone disinfection and sterilization method
The circulating air from the air-conditioning ventilation system is used as a carrier for ozone. Specifically, the ozone gas produced by the ozone generator is delivered and dispersed throughout the controlled area via the pressurized airflow generated by the fresh-air fan in the air-conditioning system, ensuring a uniform distribution of ozone concentration in the air. In this spatial environment, no additional disinfection measures are required to achieve sterilization. At the same time, this method effectively eliminates harmful bacteria and mold from the air-conditioning system’s supply ducts. Practical experience has shown that this disinfection and sterilization approach also exerts a bacteriolytic and cleansing effect on the filters, thereby extending their service life.
The duration of ozone disinfection and sterilization is determined by verifying and checking the bacterial count according to the microbial colony count requirements specified in environmental hygiene standards, after which a timer can be set to automatically start the process. Regarding the frequency of disinfection, since ozone sterilization and ozone reduction can be completed within two hours, whereas chemical fumigation and air exchange take considerably longer, it’s possible to switch from regular chemical disinfection to ozone disinfection once per shift—specifically, two hours before the start of each shift. At that time, the fresh-air handling unit and the ozone generator are activated to carry out microbial elimination and self-cleaning of the air, removing dust particles.
Installed in the main duct of the air-conditioning supply system, the fresh-air system requires only that an air-supply pipe be connected to the inlet of the circulating fan. When the fresh-air system is operating, the circulating fan spins at high speed, generating a powerful negative-pressure airflow. This negative pressure draws ozone into the duct, where it mixes with the fresh air before being delivered to various disinfection spaces. For details on the specific installation method, see Figure 1.
Economic Benefit Analysis of Ozone Disinfection and Sterilization
- It saves disinfectant, reduces labor intensity, and simultaneously addresses the issue of secondary contamination caused by disinfectants.
- Thanks to the use of ozone disinfection, secondary pollution caused by chemical fumigation can be avoided, and it also effectively purifies the air.
The filter has a guiding effect, which helps extend the filter's service life.
- Cancel the monthly large-scale disinfection.
Performance Comparison of Ozone Generators
DJ-Q The corona discharge-type ozone generator uses pure water as its raw material and produces ozone via low-voltage electrolysis, requiring no auxiliary materials or additives whatsoever. The ozone concentration produced can reach as high as 20% (by weight of the gas released). The accompanying gas produced alongside the ozone is oxygen itself, with absolutely no secondary pollution. In contrast, conventional high-voltage corona discharge ozone generators use air or oxygen as their feedstock and require multiple pre-treatment steps. They rely on a high-frequency, high-voltage electric field of around 15,000 volts to generate ozone, resulting in a much lower ozone concentration—typically no more than 6%. Moreover, the gases accompanying the ozone produced by these generators include nitrogen, oxygen, nitrogen oxides, and other impurities. Among these, nitrogen oxides are non-degradable, toxic, and carcinogenic substances. Additionally, corona discharge ozone generators suffer from inherent drawbacks such as operational instability and short electrode lifespans (<3,000 hours), which are difficult to overcome. Therefore, when selecting an ozone generator, it is essential to first thoroughly understand the device's functional characteristics to avoid unnecessary losses.
Equipment Performance Metrics and Advantage Comparison
One Equipment advantages
1. The ozone concentration produced is several times higher by weight compared to the high-voltage corona method (reaching up to 20%).
2. The ozone gas produced contains no nitrogen oxides and no carcinogenic substances.
3. It employs low-voltage electrolysis technology (3-5V), eliminating any risk of electrical hazards. It does not generate electromagnetic waves or noise, and when used alongside other precision instruments, it does not cause interference.
4. The ozone generator uses pure water as its gas source and, during operation, does not require an oxygen source or any additional auxiliary equipment beyond the high-pressure ozone generator itself. It is easy to operate and safe and reliable.
5. Low electrode wear, continuous operation capability, and an exceptionally long service life.
6. It is unaffected by the working environment and temperature, and has a humidity resistance of up to 85%.
7. Pure water self-circulating cooling eliminates the risk of overheating caused by continuous operation of the equipment.
8. Due to the high ozone concentration generated, using this method with the same amount of ozone introduced into water can achieve a higher ozone concentration in the water.
II. Performance Indicators and Comparison of DJ-Q Type Electrolytic Ozone Generators vs. Air (Oxygen)-Discharge Ozone Generators
| Performance metrics |
DJ-Q Type Electrolysis |
Corona discharge method |
|
| Panel-style |
Tubular |
||
| Air source |
Deionized water |
Air |
Air or oxygen |
| Air source dew point / o C |
4~35 o C |
-60 |
-60 |
| Cooling method |
__ |
Water-cooled or air-cooled |
Water-cooled |
| Operating voltage |
3~5V |
7.6–20 /kV |
15~19 kV |
| Power frequency / Hz |
50~60 |
50~500 |
60 |
| Power consumption/kW·h/kgO 3 |
50 |
20~30 |
15~19 |
| Dielectric |
Deionized water |
Ceramic chip ( board ) |
Glass tube |
| Air chamber pressure/kPa |
__ |
7~86 |
20~100 |
| Ozone concentration/% (weight ratio) |
18~20 |
1~3 |
1~3( Air source ) 2~6( Oxygen source ) |
| Work environment humidity/% |
≤ 90 |
≤ 40 |
≤ 50 |
| Generator electrode life/h |
≥ 10000 |
≤ 1000 |
≤ 3000 |
| Gas composition of the output |
O 3 + O 2 |
N + O 2 + O 3 + NO X |
N + O 2 + O 3 + NO X |
| Pollution status |
None |
Nitrogen oxides and electromagnetic waves |
Nitrogen oxides and electromagnetic waves |
| Relevant equipment in use |
No need |
Circulating cooling towers, air dehumidifiers, oil-free pumps |
Circulating cooling tower, air dehumidifier (oxygen cylinder or oxygen concentrator), oil-free pump |
| Operating cost /h (Ozone production rate g/h) |
0.08 Yuan |
0.14 Yuan |
0.16 Yuan (oxygen source) |
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