Pharmaceutical Water Pipeline Biofilm Removal: A Vantsteri Case Analysis
- Addtime: 2026-06-28 / View: 100
Introduction
In industrial production, pharmaceutical manufacturing, food processing, and other fields, the cleanliness and hygiene of water pipeline systems are directly related to product quality and the safety of the production environment. However, biofilm contamination in water pipelines occurs from time to time and can create serious challenges for production and operations.
This case study examines how Vantsteri engineers successfully removed biofilm from the water pipeline system of a pharmaceutical company. It discusses the risks associated with biofilm contamination and the solution developed for this case.
Characteristics of Biofilm Contamination in the Pharmaceutical Industry
Vantsteri engineers studied biofilms in pharmaceutical production systems and process pipeline systems. Bacteria can easily adhere to equipment and environmental surfaces in production systems, where they form bacterial biofilms and become significant potential contamination sources.
Based on the characteristics of pharmaceutical production systems, Vantsteri researched the main contamination characteristics of biofilms and methods for their removal.
Bacterial Contamination Analysis of Pharmaceutical Water Systems
Pharmaceutical water systems can be difficult to clean. Storage tanks and heat exchangers are both challenging to clean and disinfect and can become important contamination sources.
Vantsteri engineers conducted residual bacterial contamination analysis at 30 sampling points in the purified-water system of a pharmaceutical factory. Molecular biological sequencing was then used for identification, and multiple bacterial species were isolated. The main identified groups included Acinetobacter, Bacillus, and Pseudomonas.
| Item | Description |
|---|---|
| Sampling system | Purified-water system of a pharmaceutical factory |
| Sampling points | 30 sampling points |
| Identification method | Molecular biological sequencing |
| Main identified bacterial groups | Acinetobacter, Bacillus, and Pseudomonas |
Tolerance of Isolated Strains to Conventional Thermal Cleaning and Disinfection
Vantsteri used hot alkaline treatment, hot acid treatment, and steam disinfection methods commonly used in pharmaceutical factories. After treatment, sampling points in the solution-preparation system were resampled for culture and colony counting.
These treatments were highly effective against planktonic bacteria in the pipelines, with a killing rate of more than 99.9%. However, the reduction rate for biofilm bacteria attached to pipeline walls and tank surfaces was only 70%.
This indicated that once biofilm forms in a pharmaceutical production system, it becomes more tolerant of conventional cleaning methods and more difficult to remove.
Vantsteri Biofilm Removal Case
Background
Terminal sampling results from the process pipeline system of a pharmaceutical company showed that the total colony count exceeded the acceptable limit. The problem repeatedly returned after conventional disinfection and could not be fundamentally resolved.
After preliminary analysis, Vantsteri engineers determined that the issue was caused by persistent biofilm formation on the inner walls of the process pipelines.
Preliminary Assessment
Vantsteri engineers first measured and calculated the length, diameter, and retained water volume of the pipeline system. They also investigated the microbial contamination associated with the biofilm through pipeline endoscope observation and water-sample testing.
| Assessment Item | Method |
|---|---|
| Pipeline dimensions | Measurement and calculation of pipeline length and diameter |
| Retained water volume | Measurement and calculation |
| Biofilm condition | Pipeline endoscope observation |
| Microbial contamination | Water-sample collection and testing |
Solution Development
Based on the specific conditions of the pharmaceutical company, Vantsteri engineers developed a detailed biofilm removal plan. The plan included selecting suitable cleaning agents and Vantsteri-developed biofilm removal methods, as well as determining the required cleaning duration and biofilm removal frequency.
Vantsteri’s independently developed biofilm removal technology was used in this project. According to the project description, the disinfectant used in the process provides strong antimicrobial activity, rapidly breaks down biofilm, does not cause corrosion, and does not leave harmful residues.
Implementation Process
After production safety requirements were confirmed, Vantsteri engineers began implementation according to the established plan. First, the pipeline system underwent acid cleaning and passivation treatment to remove part of the biofilm and accumulated dirt.
Vantsteri-developed biofilm removal technology was then introduced into the process pipelines to ensure sufficient contact with and penetration into the biofilm. After a period of closed treatment, the biofilm microbial community was effectively broken down and inactivated.
Finally, purified water was repeatedly used to flush the pipeline system until the conductivity was below 1.0 μS/cm and the total organic carbon, or TOC, was below 3 ppb.
| Process Stage | Main Activity |
|---|---|
| Acid cleaning and passivation | Removal of part of the biofilm and accumulated dirt |
| Biofilm removal treatment | Introduction of Vantsteri-developed biofilm removal technology into the process pipeline |
| Closed treatment period | Sufficient contact with and penetration into the biofilm |
| Final flushing | Repeated purified-water flushing until conductivity was below 1.0 μS/cm and TOC was below 3 ppb |
Effect Evaluation
After biofilm cleaning was completed, Vantsteri engineers conducted pipeline endoscope inspections and compared before-and-after videos and color photographs. Blue-point testing was also performed after pipeline passivation, with before-and-after videos and color photographs used for comparison.
Engineers collected swab samples from the inner walls of the pipelines and water samples after biofilm removal. Microbial testing of both the pipeline inner walls and the water showed that the total colony count had decreased significantly, while the biofilm spore kill rate exceeded 90%.
Continuous monitoring and evaluation also showed that the biofilm contamination issue was effectively controlled, with no repeated exceedances observed.
| Evaluation Item | Result |
|---|---|
| Pipeline endoscope inspection | Before-and-after videos and color photographs were compared |
| Pipeline passivation test | Blue-point testing with before-and-after video and color-photo comparison |
| Pipeline wall and water microbiological testing | Total colony count decreased significantly |
| Biofilm spore kill rate | More than 90% |
| Continuous monitoring | No repeated exceedances observed |
Key Takeaways
| Key Point | Meaning in This Case |
|---|---|
| Biofilm can become a persistent contamination source | Bacteria can adhere to production equipment and pipeline surfaces, forming biofilms that are difficult to remove. |
| Conventional treatment may not fully remove biofilm | Hot alkaline treatment, hot acid treatment, and steam disinfection were effective against planktonic bacteria but less effective against biofilm bacteria. |
| Pipeline assessment is necessary before treatment | Pipeline dimensions, retained water volume, microbial contamination, and biofilm conditions were assessed before the cleaning process. |
| Biofilm removal required a targeted process | The project combined acid cleaning, passivation, biofilm removal treatment, closed contact time, and repeated purified-water flushing. |
| Effectiveness was verified after treatment | Pipeline endoscope inspection, blue-point testing, swab sampling, water testing, and continuous monitoring were conducted. |
| The contamination issue was controlled | Total colony counts decreased significantly, the biofilm spore kill rate exceeded 90%, and repeated exceedances did not occur. |
Conclusion
This case demonstrates Vantsteri engineers’ professional capability and experience in addressing biofilm contamination in water pipeline systems. Through scientific assessment, a targeted solution, and strict implementation, the team helped the pharmaceutical company resolve a persistent biofilm contamination issue and support production safety and product quality.
As technology and practical experience continue to develop, Vantsteri engineers will continue to focus on water-treatment challenges and provide safer and more reliable water-treatment solutions for industrial operations.
Vantsteri Biofilm Removal Technology
Vantsteri has developed biofilm removal technology for stainless-steel surfaces. In the first step, a proprietary cleaning process disrupts the biofilm layer and bonding layer, breaking the biofilm structure and exposing the bacteria.
In the second step, a proprietary dry-gas process is used to treat and inactivate the exposed bacteria. The technology is designed to remove biofilm, inhibit pipeline corrosion, and control the residual amount of chemical disinfectants.
