Seminar:
Materials challenges in food & pharma
– spotlight on hygiene, corrosion and rouge

Microorganisms thrive on most surfaces, where they start to grow to form biofilms if conditions are permitting, i.e., if there is moisture and nutrients present together with temperatures above the freezing point. If not removed, the attached microbial communities will start to produce the protective slime layer that is characteristic of biofilms. This slime layer will protect the microorganisms against antimicrobial compounds used in cleaning. Biological activity in older biofilms can also deteriorate the surface, e.g. cause stainless steel to corrode. Of concern is the ability of biofilms to house pathogenic and spoilage microorganisms which can affect product safety and quality. This talk will highlight recent findings and actions that can be taken to control formation of biofilms.

Stainless steel is not always stainless. Dependent on the steel grade, the media, and the operating conditions, corrosion may occur and the bright and “perfect” steel may suffer from a minor flood of corrosion problems, spanning from the fairly uniform “general corrosion” to the more local (and more severe) attacks connected to pitting and crevice corrosion, as well as the destructive stress corrosion cracking.

For all types of corrosion, we take a closer look at the importance of the alloying elements of the steel, plus the effect of the media, including the concentration of salts (in particular chloride), the temperature, contact time, and also the effect of various oxidants. The latter is very important as the various disinfectants may contain a fair amount of oxidants, which may pose a risk to the steel if they are not handled correctly.

Finally, rouging is a “special problem” connected to pharma production. In short, rouge is a thin layer of ferric (Fe(III) oxides covering the steel. This is most annoying in a pure-water system, and although rouge has never caused penetration, a lot of effort is done trying to prevent the phenomenon, or at least reduce the problem. Here, mechanisms, causes, possible prevention, and removal is discussed.

There are several different polymer types that are suitable for hygiene systems. What should you consider to find the optimal solution for a given application? Focus on media, temperature, exposure time, cleaning systems, etc.

This presentation explores the challenges of microbially influenced corrosion (MIC) of stainless steel. The environment beneath biofilms can differ significantly from bulk water, creating conditions that may promote localized corrosion, thereby compromising hygiene, safety, and operational efficiency. Examples of MIC mechanisms will be provided, along with its impact on water installations and approaches for identifying and analyzing failures caused by MIC. Additionally, the talk will offer insights into strategies for reducing the threat of MIC and implementing mitigation measures to protect stainless steel surfaces while ensuring compliance with hygiene standards.

Imagine being able to immediately spot every hygienic design weakness in a production line — welds that appear sound but conceal crevices for biofilms, surfaces compromised by polishing or glass-beading, or seals that swell and release particles into the product stream. With the right perspective, these issues become visible long before they cause contamination, corrosion, or costly downtime.

In this presentation, I will share case stories from food, biotech, and pharmaceutical production where even materials of proper hygienic design failed due to improper installation, welding, or surface treatment — and where poor material choice created unnecessary risks. The aim is to train your “hygienic design eyes” to recognize the most common pitfalls during inspections or Gemba walks, and to discuss how EHEDG guidelines can be applied in practice as a valuable — but not absolute — tool for preventing such failures.

When a failure (material, mechanical or process) occurs in a piece of equipment or on a production line, the focus of the operator is typically on re-establishing production as soon as possible. But how does this reconcile with a failure analysis whose purpose is to ensure that the damage does not reoccur and/or conducted for the purpose of non-compliance reporting? Failure analysis in cleanroom environments is often challenged by limited and cumbersome access, limited possibilities for sampling, equipment limitations, etc. To quickly secure and preserve relevant evidence, an interdisciplinary and often creative approach is required, where a broad knowledge of the existing analysis techniques and possibilities is essential.
A practical approach on how to perform failure analysis, dos and don’ts, typical pitfalls, illustrated with examples, is presented.

Steam boilers are critical components in food and pharma industrial processes. Their efficiency and longevity depend heavily on the quality of water used and the methods employed to treat it. Improper water treatment can lead to scale formation, corrosion, poor steam quality and reduced performance, ultimately resulting in costly shutdowns, repairs, or even catastrophic failures. Therefore, understanding the principles and best practices of water treatment in steam boilers is essential for plant operators, engineers, and maintenance personnel. This talk will introduce key element in proper operation of steam boiler

In the pharmaceutical industry governed by strict regulations to ensure patient safety and product purity, it is paramount that the process equipment is clean and sterile and that this can be visually confirmed every time it is inspected.
To achieve this, stainless steel equipment, the industry’s backbone, as well as polymer materials in the production equipment face constant exposure to aggressive sanitation protocols. But what happens beneath the polished surface? Each use and CIP/SIP cycle with potentially aggressive cleaning chemicals and high purity steam—gradually eats away at the material’s integrity. Corrosion, micro-pitting, rouging, and polymer degradation threatens not only equipment longevity but also the reliability of every batch produced.

How can one achieve the best conditions for cleaning, sterilization and inspection, when you also want to steam sterilize the equipment before each use, while still avoiding material degradation?
This presentation will touch on both initial cleaning of equipment, daily cleaning and not least ongoing maintenance. The topic will be elucidated both for directly product-affected equipment and indirectly affected equipment such as WFI and clean steam systems.