Some dirt particles may be of little importance in everyday life, but they can cause critical failures when making aviation fuel or chemotherapy drugs. Food, transport and drug manufacturers must take extraordinary measures to ensure the purity of their products. How do they prevent particle pollution along all parts of the supply chain?
What is particulate pollution?
Representative product samples containing foreign particles such as metal shavings, cotton fibers or insect remains are considered contaminated. Technicians use particle size analysis to determine the average size of fragments in a liquid or powder sample. This allows them to spot any outliers that might come from a foreign source.
Particulate pollution is harmful to products such as hydraulic fuel and lubrication because it can cause wear, breakdown and clogging, shortening the life of the vehicle. In the medical field, material from surgical tools can transfer foreign material into a patient’s body. Rough surfaces in food processing plants make it difficult to clean the work space, increasing the risk of foodborne illness.
In addition to contaminating products, particles can adversely affect the function of factory machinery. Debris can slow down or break mechanical equipment, leading to costly repairs and long downtime.
Particulates can come from multiple sources along the production line, starting with salts left in the mix at the factory. In addition, materials can become contaminated by coming into contact with water and steel during transport, causing oxidation, or by being left outside where pollen can enter the container. Pests can also cause pollution.
How to guarantee the purity of the product
Because so much is at stake, manufacturers take various measures to reduce particulate contamination and ensure product purity.
1. Inspection
It is often easier to prevent particulate pollution than to try to get rid of it later. Early in the manufacturing process, machinery parts can break and allow shavings or metal fragments to enter the material. Regular inspections allow manufacturers to check for broken or malfunctioning filters, ensure moving parts are properly lubricated, and replace damaged parts.
2. Storage
A 210 liter metal drum is one of the most common containers for storing and shipping materials such as oil or lubricants. Keeping them outside can cause oxidation that contaminates the material. Changes in temperature can cause them to expand and contract, compromising their integrity. Manufacturers must take several steps to keep their storage area clean, cool and dry.
Manufacturers often use various barriers to protect barrels stored outside, making sure the caps are tight and the seams intact. They use roofs or secondary containers to keep drums dry because water can cause changes in temperature and pressure. It is also useful to place oil canisters on the side to ensure that the internal contents are above the level of the stud, preventing the seals from drying out.
Manufacturers should thoroughly clean containers, especially around the caps, to prevent contamination by insect particles, dirt, rust, or water when removing the material from storage.
3. Prevention of internal pollution
Some internal particulate contamination is expected when a material is manufactured, stored, or used. It can result from a problem with the machinery and includes any particle that causes contamination once placed in a closed system.
Wear particles and seal material in the oil are some examples of internal contamination. It comes from the car itself, but it can still indicate a faulty product. Technicians who detect high numbers of particles in tests despite a well-controlled external environment could find particle contamination inside the machinery.
Technicians use several techniques to check particle counts. For example, they can use a test that works with a lightweight blocking method to count the total number of particles, regardless of origin, and catalog their sizes. They must take action if they detect a high number.
Many manufacturers use filters inside their machinery or storage containers to achieve target cleanliness levels. Technicians take representative samples of the material before and after using the filters to check their effectiveness.
Instead of filtering, manufacturers can also manually drain and discard any contaminated material. Another technique, called cryogenic grinding, allows for a more precise particle size distribution to identify sources of contamination. It is up to the manufacturer to decide which method is the most effective and affordable.
4. Training
Simple user errors can lead to contamination. Manufacturers train workers to keep test equipment clean, use it properly, and take accurate sample measurements. They emphasize maintaining a sanitary work environment and properly labeling materials and tools. Regular refresher courses ensure that employees remember their training. In addition to preventing pollution, education also improves workplace safety and prevents dangerous accidents.
5. Pest control
Mice, insects and even smaller pests such as mites can find their way into a product by mistake. Manufacturers check for holes, leaks, and drafts that might allow pests to enter the building or infiltrate storage containers, then take corrective action. Using exterminators also helps keep them at bay.
Also, manufacturers can enforce rules about where employees can eat and drink to minimize infestations. Having a break room for lunch and instructing staff to clean up afterwards is very important.
6. Electropolished
Having a clean and polished indoor workspace also helps prevent contamination. Electropolishing removes a layer of metal to remove contaminants from a surface, such as machinery or countertops. The parts are immersed in an electrolyte solution and attached to a positively charged metal rod. An electric current is then passed through and removes the excess material.
This process reduces bacteria build-up, creates a sanitary finish, improves corrosion resistance and prevents products from sticking to the surface. Electropolishing makes it easier for manufacturers to clean surfaces and can even help machinery parts run more smoothly.
High standards, high quality
Maintaining strict particulate levels is not just a matter of cleanliness. In some industries, such as pharmaceuticals and aviation, it can save lives.
Faulty equipment, user error and poor storage techniques contribute to contamination, but there are many ways to prevent and correct the problem. Using these methods is vital to get the best results. Proper training, regular inspections, pest control, filtering and electropolishing are just some of the main techniques manufacturers use to protect their products and customers.
Emily Newton is a technology and industry journalist. She is also the editor-in-chief of Revolutionized. He has been covering warehousing, logistics and distribution stories for over five years.
