CN106573079B - 用于流体灭菌的系统和方法 - Google Patents
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Abstract
用于流体灭菌的系统和方法。该系统包括UV发射器(1)，UV发射器被相对于UV发射器同心布置的拉长元件(2)围绕，冷却UV发射器的冷却剂流体循环通过拉长元件(2)，拉长元件(2)被相对于所述UV发射器同心布置的拉长元件(3)围绕，待灭菌的流体循环通过拉长元件(3)，拉长元件(3)被相对于所述UV发射器同心布置的拉长元件(4)围绕，冷却或加热待灭菌的流体的冷却剂或加热流体循环通过拉长元件(4)。在用于流体灭菌的方法中，待灭菌的流体在范围为‑20℃至160℃的温度下经受UV辐照。
Description
发明领域
本发明涉及一种用于通过受控顺序和/或同时施加杀菌紫外线辐照(优选C型)和温度用于处理流体从而用于对所述流体进行卫生处理和/或灭菌的系统，所述温度范围为产品(诸如食品、成分、香料、味剂、化妆品、药物产品(药)、医院用品(血清、血液学流体等)、化学品、含酒精的产品、石油衍生物等)的低温至适中的温度(优选)和高温。
发明背景
工业中需要解决的问题由对流体(食品、成分、香料、味剂、化妆品、药物产品(药)、医院用品(血清、血液学流体等)、化学品、含酒精的产品、石油衍生物等)进行卫生处理和/或灭菌组成，由于它们特定的特征而对特定的热处理敏感，由此在功能或技术水平(发泡、乳化、着色、增稠、形成质地的能力(texturizing capacity)等)、在营养水平(维生素、氨基酸和必需脂肪酸、多酚、抗氧化剂等的损失)或在感官水平(味剂、风味、颜色、质地等的损失)等方面都存在有质量损失。
UVC光作为改善水的口味和气味的低成本且安全的替代方案已被应用于水的净化和处理。UVC光对微生物具有杀菌作用。尽管它被认为是一种杀细菌剂，但它对所有类型的微生物(病毒、细菌、藻类、真菌、酵母和原生动物)都会产生影响。UVC光的消毒能力是其对细胞DNA产生作用导致其呼吸活性降低并阻断合成过程和抑制或延缓有丝分裂的结果。另一方面，UVC光对DNA或RNA中的同一链的两个相邻胸腺嘧啶或胞嘧啶碱基(嘧啶)的影响产生各自的二聚体来阻止微生物中的DNA或RNA复制，从而阻止它们的繁殖。
UVC光的杀菌作用主要取决于施加于微生物的剂量，并且同样取决于辐照度和施加时间。辐照度是以微瓦/平方厘米测量的每单位面积的UV光的效能。相应的剂量是辐照度/施加时间的结果，以毫焦/平方厘米或以微瓦/秒·平方厘米表示。
UVC光的另一个特征是其杀菌效果随时间(剂量)累积。
UV辐照会使化学品和/或副产物的形成减到最少。与能量消耗非常高的常规热处理相比，该处理还是干的、冷的，并且几乎无需维护并且具有较低的运行成本。另一方面，因为这些是低温或适中的温度的处理，所以避免了常规热处理的不期望的效果。由于这些原因，人们对使用UVC光来消毒食品越来越存有兴趣。然而，每种食品、化妆品、药物产品等都具有其自身的组成，并且这可能决定它们之间所需的UVC剂量不同。使用UVC光进行卫生处理的缺点是大多数流体具有低透射比，这使得仅仅发射器附近的薄层才可能得到有效处理。
众所周知，在除水以外的大多数液体中UVC光具有低透射比。UVC光穿透的效果取决于液体的类型、在特定波长处的吸光度以及存在于液体和悬浮材料中的溶质。正如大的悬浮颗粒可以阻断光对微生物载荷的入射一样，增加固体的量也会降低UVC辐照的穿透强度。例如，由于果汁的化合物或悬浮颗粒引起90％的光的吸收，UV光在果汁中的穿透范围在几百微米和几毫米之间变化。
在某些食品或工艺过程中，可能需要减少或失活某些酶，例如在蔬菜汁或果汁中导致质地损失的果胶-甲酯酶(PME)的失活，催化氧化过程的过氧化物酶(PO)的失活，或在变黑或褐变反应中起作用将酚类化合物氧化成醌的多酚氧化酶(PFO)的失活。关于UVC对酶的影响，一般来说按照它们在其中被发现的剂量和基质，会引起一定程度的失活。
目前存在的不同基本类型的UV发射器，其中，基于汞蒸汽的发射器可能相对比较突出。
从杀菌的角度来看，低压发射器通常是工业中使用最广泛的，因为它们提供几乎单色的发射并且容易处理和操纵，该发射聚焦于254nm，其非常接近于DNA分子在260nm的最大吸收值。与中压和高压发射器相比，低压发射器具有更好的性能(30-40％相对于中压的10-15％)，并且在更适中的温度下工作(40℃-110℃相对于600℃-900℃)，尽管每波长单位发射的UV效能低得多。
发明描述
本发明提供了一种用于流体灭菌的系统，其包括UV发射器(1)，UV发射器被相对于UV发射器同心布置的拉长元件(2)围绕，冷却UV发射器的冷却剂流体循环通过拉长元件(2)，拉长元件(2)被相对于所述UV发射器同心布置的拉长元件(3)围绕，待灭菌的流体循环通过拉长元件(3)，拉长元件(3)被相对于所述UV发射器同心布置的拉长元件(4)围绕，冷却或加热待灭菌的流体的冷却剂或加热流体循环通过拉长元件(4)，以下称为本发明的系统。
在本说明书中，术语“流体”是液体或气体。
一个实施方案是本发明的系统，其中待灭菌的流体通过其循环的拉长元件(3)具有粗壁或螺旋通道。
这使得待灭菌的流体以湍流和非层流方式循环，以确保整个流体体积经受相同的UVC剂量和温度的处理。
在本发明中，待处理的流体层的厚度甚至可以小于1mm。流体与湍流促进器一起经受的背压(通过背压阀)，使得即使在如此狭窄空间中待处理的流体也能在其处理期间以湍流方式循环。
不同的书目来源表明，有必要将流体的所有部分暴露于至少400J/m2(40mJ/cm2)剂量的UVC光(254nm)中，以确保目标或标记微生物充足的5的对数减少，从而获得(在食品工业的情况下)微生物学上安全的食品。为确保液体流体被同等地处理，应该考虑到将所述剂量的UVC施加于整个系统。
在本发明中，因为系统被设计为使得不定数量的系统可以串联耦合在一起，所以可以在处理结束时达到所述剂量或更高剂量。能够在仅仅几秒的处理中给予所述剂量的尖端灯(准分子和汞弧发射器)的强度，也使其可以容易达到所述剂量。此外，通过叶轮泵调节流速(流体将通过系统循环的速度)，可以增加处理时间并因此增加剂量。本发明考虑了以下可能性：如果需要降低通过系统的流速，则系统组可以并联耦合在一起，以防止设备总生产流速(L/小时)的降低。
另一实施方案是本发明的系统，其中待灭菌的流体选自由食品、化妆品、药品、药物组合物、医院流体、味剂、香料和化学化合物组成的组。
另一实施方案是本发明的系统，其中UV发射器的发射波长为200至312nm。
另一实施方案是本发明的系统，其中拉长元件(2)的外壁与拉长元件(3)的内壁之间的距离为0.5至5mm。
另一实施方案是本发明的系统，其中一个或多个系统可以串联或并联耦合在一起。特别地，其中系统之一具有发射波长为290至320nm的UV发射器。
本发明还任选地考虑了使用一个或多个(组件)UVB系统的可能性，其具有与UVC系统相同的设计，因此可以串联或并联耦合在一起，并且放置在UVC系统之后。UVC系统的主要目的是施加更长波长的处理以修复或重建某些化合物，这些化合物取决于待处理的流体的组成可能会被流体本身的其它化合物降解或反应(主要通过氧化)，稍微(但可能明显地)改变处理过的流体的生物化学特征、感官特征和/或营养特征，并且在食品的情况下，给所述食品带来质量损失。所述步骤的使用是任选的，因为其使用将受到期望的最终产品以及产品的最终组成(脂肪、蛋白质、糖等)的高度影响。
另一实施方案是本发明的系统，其包括用于测量和控制UV发射器发射辐照度的装置。
另一实施方案是本发明的系统，其包括用于测量和控制温度的装置。
由于发现UVC灯位于系统的中央并且与待灭菌的流体以及冷却剂和加热流体通过其循环的同心管的其余部分气密绝缘，所以形成待被用作循环系统的空间的涂层在连接到下一系统的入口的系统出口处需要连接器管(在两种流体之间独立)，其中这些流体在所述空间中循环。通过所述系统的冷却剂或加热流体被再循环，而待灭菌的流体(例如食品)，尽管其也可以通过系统再循环，但一般会优选地通过串联或并联的系统组来连续处理而不是再循环，除非任意一种变量的下降使得不能达到所需剂量，会因此将产物(通过分流阀)分流到初始罐或容器用于后续的再循环。可以在系统的入口或出口处添加用于冷却/加热的调节系统，以在UV光处理之前和之后冷却/加热待处理的流体。
剂量应当相等地施用于整个产物体积，并且正如已描述那样，这在本发明的系统中得以实现。不同的因素可以帮助在整个产品体积中实现相等剂量，例如：产品必须通过串联或并联的几个(2个或更多个)系统循环；在这些系统之间，管道(连接出口和下一个系统的入口)具有与系统的区段中的分段体积(section volume)不同的分段体积；系统的几何和空间布置迫使流体或产品改变其在空间中的方向(不是流体通过其循环的部分内的方向)，也可以通过水平或垂直(或交替)放置使得系统之间方向从右向左或从左向右的发生改变(总是考虑的是从一个系统的出口进入另一个系统的入口)；待处理的流体(产品)的回路可以通过背压阀(在回路的末端)而被背压处理；系统出口处均化器的存在迫使流体在下一个系统的入口之前混合；在待处理的流体通过的腔室中存在的湍流促进器增加了湍流和后者的均匀性。
将UV施加于待处理的流体的同时施加不同的受控温度，并且是以这种有效且均匀的方式，可能在不同应用中起到作用，例如：
-获得协同的微生物灭活结果，即这样的结果超过如果一起加入并分开施加UVC和温度而得到的那些结果。
-获得对于对紫外线和热处理具有不同程度敏感性的各种微生物的总微生物灭活，从而使得可能使用更适中的温度。
-通过施加适中的温度，例如60至80℃，获得酶灭活。
-获得协同的酶灭活结果，其超过分开的UVC和温度处理的总量。
-使某些组分(例如蛋白质)在适中的温度下在某些流体中稳定。
-因为是低温或适中的温度，促进了待处理的流体中各种化合物的均化、溶解和分散。
-使用低温或适中的温度来促进某些化学或酶反应的动力学，这有利于待处理的流体的最终目标。
-温度及其控制可以促进具有一定粘度水平的产品或流体的流动性，从而促进其通过整个回路的循环。
-一旦生产已经结束，温度及其控制可以促进回路中的清洁过程，因为其有助于溶解和拖曳处理过的流体的残留物，并且进一步增加清洁产品(诸如碱(80℃下3％的NaOH)、酸(45至50℃下2％的“硝酸”HNO3)、市售洗涤剂、酶产品、过乙酸(C2H4O 3)、过氧化氢(H2O2)等)的有效性。
-当使用高温时，温度及其控制可以促进系统中区域的消毒和灭菌。
本发明考虑了各种安全系统以防止和检测同心管之间的泄漏和破损问题，并且更具体地考虑了与UV发射器和围绕该发射器的材料(优选为石英)相关的问题。这样的安全系统关于材料(石英)对待处理的流体的可能偏差、电短路对设施的损坏、操作者的安全性等方面能提供更高安全性，并且最重要的是为处理的UV剂量(强度和时间)、温度和背压等预设条件提供了安全的系统，防止了“差”处理的流体被当作正确的流体进行包装。
此类安全措施可以概括形式列出为：
-沿着回路以及主要在系统的出口(但不限于)具有温度传感器，其不断地将关于待处理的流体的温度的信息发送到控制面板。
-具有测量每个系统内部的非电离辐照(UVC和/或UVB)辐照度的传感器，并且其不断地将关于由发射器发射的辐照度的信息发送到控制面板。
-在发射器的石英和/或起保护作用的石英盖中具有薄的电子轨道。石英的任何破损将导致导电轨道的破损，从而会因此切断电流并发送信号到控制面板，并且后者采取已被编程的动作。所述导线优选(但不限于)由金制成。
-在石英上具有UV可穿透的聚合物盖，发生破损时包含碎片并防止它们进入待处理的流体。
-具有提供UV发射器和石英盖之间接头的气密性和密封的垫圈。所述垫圈由常用于食品工业的耐受最极端条件的CIP型(原位清洁)清洁与消毒和SIP(原位蒸汽)灭菌的设计和材料(例如但不限于氟化聚合物)制成。
-具有背压系统(优选但不仅限于背压阀)，并且对待处理的流体的向前运动施加恒定压力，从而有助于产生湍流特征(profile)。
-具有致动分流阀的“控制面板”，该分流阀将置于卫生或无菌包装系统(罐和包装机)之前的待处理的流体分流，该分流阀的调节可能会由于任何初始预设条件(诸如(优选但不限于)温度、UVC或UVB光强度、处理时间(通过泵推动产品通过的流速设置)、灯或石英盖的破损、产品压力的损失等)的失败从而阻止未被适当处理的产品被包装(优选但不仅限于未到达用于进一步卫生或无菌包装的储存器或无菌罐的情况)，使得产品可以通过分流阀分流到用于再循环的初始罐，或者在其他情况下分流到其它的任何罐以便丢弃产品。
本发明还提供了一种用于流体灭菌的方法，在系统中进行该方法，该系统包括UV发射器(1)，UV发射器被相对于UV发射器同心布置的拉长元件(2)围绕，冷却UV发射器的冷却剂流体循环通过拉长元件(2)，拉长元件(2)被相对于所述UV发射器同心布置的拉长元件(3)围绕，待灭菌的流体循环通过拉长元件(3)，拉长元件(3)被相对于所述UV发射器同心布置的拉长元件(4)围绕，冷却或加热待灭菌的流体的冷却剂或加热流体循环通过拉长元件(4)，该方法包括使待灭菌的流体在-20℃至160℃的温度下经受UV辐照。
另一实施方案是本发明的方法，其中温度范围为2至80℃。
附图简要说明
图1所示为本发明的系统的外部侧视图，其中可以观察各种流体回路的入口点和出口点的布置：待灭菌的流体的入口(5)和出口(6)，冷却剂或加热流体的入口(7)和出口(8)，空气入口(9)和出口(10)。
图2所示为本发明系统的纵向截面，其中可以观察各种流体循环通过的各种腔室的布置以及UV发射器的布置。
图3所示为纵向截面的放大图，其中可以更详细地观察各种流体循环通过的腔室的布置：空气(2)，待灭菌的流体(3)，冷却剂或加热液体(4)，UV发射器(1)。还可以观察在发射器、石英盖和产品循环通过的腔室之间提供气密性的垫圈或密封件(11、12、13)的布置。
优选实施方案
实施例1.UVC光处理对不同微生物致死率的影响。
借助于实施例来证明本发明的有效性，在具有低吸光系数(0.43cm-1)的水溶液中和在具有高吸光系数(107cm-1)的液体蛋清中在不同温度下具有对UVC处理不同水平敏感性的各种微生物进行了研究，其中接种的水溶液的处理温度为20和50℃，接种的液体蛋清的处理温度为20和55℃。对照样品中微生物的浓度约为106-107cfu/ml。为了计算接收的剂量(等式1)，必须通过Beer-Lambert定律(等式2)计算透射的辐照度(I)，其中需要考虑到流体的厚度、路径长度(对于水溶液和液体蛋清)，其为1mm(d＝0.1cm)以及λ＝254nm的吸光系数(如上所述)和入射辐照度(I0＝31mW/cm2)。表1至3中的微生物学结果表示为致死率(等式3)。
剂量＝辐照度·时间(等式1)
在等式1中，以mW·S/cm2表示剂量，以mW/cm2表示辐照度并且以秒表示时间。
I＝I0·10-εd(等式2)
在等式2中，I是透射辐照度，I0是入射辐照度，ε是吸光度系数，d是路径长度。
致死率＝Log10(N0/N)(等式3)
在等式3中，N0是处理之前的初始cfu/cm2数而N是处理之后的cfu/cm2数。
表1.在20℃以31mW/cm2辐照度的UVC光进行不同暴露时间的处理对水溶液(吸光度系数：0.43cm-1)中不同微生物的致死率的影响。数据源自重复定量每个实验的三次独立实验的结果(n＝6)。显示的是平均值±标准偏差。以cfu/cm2表示致死率。
表2.在50℃以31mW/cm2辐照度的UVC光进行不同暴露时间的处理对水溶液(吸光度系数：0.43cm-1)中不同微生物的致死率的影响。数据源自重复定量每个实验的三次独立实验的结果(n＝6)。显示的是平均值±标准偏差。以cfu/cm2表示致死率。
表3.以31mW/cm2辐照度的UVC光进行不同暴露时间的处理对液体蛋清(吸光度系数：107cm-1)中不同微生物的致死率的影响。数据源自重复定量每个实验的三次独立实验的结果(n＝6)。显示的是平均值±标准偏差。以cfu/cm2表示致死率。
从上文的表(表1-3)中表示的数据开始，已经观察到致死率在较长暴露时间下线性地和成比例地增加，至少在已测试的时间范围内是这样。
当在20℃下在具有低吸光系数(0.43cm-1)的水溶液中施加31mW/cm2的辐照度时，暴露时间为3至6秒，在营养细菌中达到了2.5-5.8对数单位(Log)的致死水平(减少)，而更抗紫外线的微生物(枯草芽孢杆菌孢子和黑曲霉孢子)达到了0.5-3Log的减少。
当在20℃下在具有高吸光系数(107cm-1)的流体诸如液体蛋清中施加31mW/cm2的辐照度时，暴露时间为6至18秒，营养细菌(大肠杆菌和藤黄微球菌)和枯草芽孢杆菌孢子分别为1.6-5、1-3和0.5-1.7Log的减少。
当在50℃下在具有低吸光系数(0.43cm-1)的水溶液中施加31mW/cm2的辐照度时，暴露时间为3至6秒，在营养细菌中达到了3至≥6.9Log的致死水平(减少)，而在形成孢子的微生物(枯草芽孢杆菌孢子和黑曲霉孢子)中，则达到了0.4-3Log的减少，几乎与施加室温(20℃)时相同。
然而，当在55℃下在具有高吸光系数(107cm-1)的流体诸如液体蛋清中施加31mW/cm2的辐照度时，暴露时间为6至18秒，营养细菌(大肠杆菌和藤黄微球菌)和枯草芽孢杆菌孢子分别为2-6、1-3.7和0.6-1.8Log的减少。
此外，用或不用UVC和/或温度处理的液体蛋清(LEW)样品从未凝结并始终保持着主要功能特征(颜色、气味、粘度、发泡能力等)。
Claims (2)
1.一种用于流体灭菌的方法，在系统中进行该方法，该系统包括UV发射器(1)，UV发射器被相对于UV发射器同心布置的第一拉长元件(2)围绕，冷却UV发射器的冷却剂流体循环通过第一拉长元件(2)，第一拉长元件(2)被相对于所述UV发射器同心布置的第二拉长元件(3)围绕，待灭菌的流体循环通过第二拉长元件(3)，第二拉长元件(3)被相对于所述UV发射器同心布置的第三拉长元件(4)围绕，冷却或加热待灭菌的流体的冷却剂或加热流体循环通过第三拉长元件(4)，并且该方法特征在于，该方法包括将待灭菌的流体在范围在-20℃至160℃的温度下经受UV辐照。
2.权利要求1所述的方法，其特征在于，温度范围为2至80℃。
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| JP2018019670A (ja) * | 2016-08-05 | 2018-02-08 | 株式会社トクヤマ | 液体の殺菌方法及び殺菌装置 |
| WO2018026008A1 (ja) * | 2016-08-05 | 2018-02-08 | 株式会社トクヤマ | 紫外線殺菌方法及び紫外線殺菌装置 |
| JP6405348B2 (ja) * | 2016-09-08 | 2018-10-17 | 株式会社トクヤマ | 紫外線殺菌方法 |
| WO2018150425A1 (en) * | 2017-02-15 | 2018-08-23 | Ramot At Tel-Aviv University Ltd. | Method and device for water disinfection |
| JP6892788B2 (ja) * | 2017-05-26 | 2021-06-23 | ウシオ電機株式会社 | 殺菌方法、殺菌装置 |
| US10617782B2 (en) * | 2017-08-17 | 2020-04-14 | Bolb Inc. | Flowing fluid disinfection method and disinfector |
| JP2018068313A (ja) * | 2017-12-25 | 2018-05-10 | 株式会社トクヤマ | 液体の殺菌方法 |
| JP2018064586A (ja) * | 2017-12-25 | 2018-04-26 | 株式会社トクヤマ | 液体の殺菌装置 |
| CN108653769A (zh) * | 2018-07-17 | 2018-10-16 | 上海艾魁英生物科技有限公司 | 一种用于新饲料添加剂溶菌酶二聚体离子固化液的快速灭菌装置 |
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