Maintaining a clean environment is a clear priority for the food processing industry. A new high performance thermoplastic stock shape product line that incorporates permanent antimicrobial protection has been introduced by Westlake Plastic Technologies (WPT). Its Silveron® antimicrobial rod and sheet can be used in food processing equipment, cutting boards, counter tops, bulk food containers and restaurant equipment. The silver compound suppresses the growth of bacteria, algae, fungus, mold, and mildew when blended into plastics manufactured by WPT and protects against odors, bio-film and deterioration caused by micro-organisms. Westlake Plastic Technologies, based in Lenni, Pennsylvania, is a wholly-owned subsidiary of Westlake Plastics Company, which has been manufacturing high performance thermoplastic shapes and film since 1951. Silveron® incorporates antimicrobial directly into conveyor belts and components. It relies on Milliken Chemical’s Antimicrobial ALPHASAN®, a silver-based antimicrobial agent that has received both EPA and FDA regulatory approval for food and water contact applications, to do the job.  The built-in antimicrobial protection of ALPHASAN in WPT’s Silveron® products has proven effective against a broad spectrum of microbes, quickly suppressing the growth of bacteria, fungus, mold and mildew in and on the product. Tests have also shown the efficacy lasts over the life of a product. Since a few bacteria can grow into a million in a matter of hours in the fertile environment of a food processing plant, the ability of an antimicrobial product to be both fast-acting and long-lasting makes a critical difference in effectiveness to protect the equipment.
WPT is currently in production with UHMW-PE sheet and rod. Research and development are also under way to bring antimicrobial benefits to a broad range of plastics, including HDPE, polypropylene, acetal, Radel and Ultem. Four factors were critical to the selection of Milliken’s antimicrobial agent for the new product line, according to WPT business manager Kate Koslosky. “ALPHASAN’s antimicrobial performance and processing capabilities are excellent. It has no effect on color, so we’re able to add color pigments as necessary during processing. We’re also able to reduce material costs due to the mix of resin and ALPHASAN. No other ingredient is needed!” ALPHASAN is thermally stable and does not discolor or decompose when exposed to high temperature. Safe and non-toxic when used as directed, it is not flammable, explosive or corrosive, all critical factors in environments where people work or where food products that are destined for human consumption are processed. With headquarters in Gent, Singapore, Sao Paulo, and Spartanburg, SC, Milliken Chemical is a leading manufacturer of plastic additives, colorants, textile chemicals, and other specialty products. Milliken Chemical is a division of Milliken and Company, a manufacturer of fabrics and yarns for home furnishings, industrial products, automotive and apparel markets as well as specialty chemical products. Q. What is an antimicrobial and why do you need one?
A. Antimicrobials were developed to address microbial concerns and to control the growth of microbes on the surface of a material. Surface growth of microbes on a material is called a biofilm or slime. The buildup of biofilm or slime on materials, both plastics and textiles, can lead to a high microbe count, foul odors, discoloration, as well as contribute to the material’s degradation. Q. What is ALPHASAN?
A. ALPHASAN is an inorganic antimicrobial based on silver. It comes in powder form and is made of an ultra porous zirconium phosphate-based ceramic containing silver ions. This new class of biocide was chosen over all other silver technologies by Milliken Chemical. The ceramic carrier, which distinguishes ALPHASAN from other antimicrobials, acts as a sponge for silver ions. This “sponge” allows for a controlled release of silver based on its environment. It is also thermally stable and inert in most materials. ALPHASAN is specifically designed for use in a broad range of polymers or it can be applied as a coating on stainless steel, walls, ceilings, etc. Q. How does ALPHASAN work?
A. ALPHASAN is uniformly distributed throughout the product or on the surface as a coating. Fresh ions or crystals are exposed on the surface of product each time there is abrasion. The silver ions attack protein groups of the bacteria cell. In defense, the cell begins to collapse causing the cell wall and its contents begin to separate. The silver ions bind with different proteins and disrupt the metabolic process of the cell. Silver looks for something to bind with and needs to exchange with something to release. The Silver in ALPHASAN has the ability to bind with over a thousand different protein groups to reduce bacteria. The environment’s bio-burden and ionic content of the bulk fluid will determine the rate of silver release. If it is a lowburden environment, the silver release will be low. Q. How does ALPHASAN differ from other antimicrobial technologies?
A. Silver based technologies were developed to address concerns with organic antimicrobials. It is important to distinguish between organic and inorganic antimicrobials. Organic antimicrobials work by leaching out of a solid such as plastic or a coating to the surface. They generally have deficiencies with respect to thermal stability, toxicology, broad-spectrum microbial performance, and durability. ALPHASAN is an inorganic antimicrobial based on silver. Its mechanism of action is through ion exchange, not migration to the surface. There are several types of active ingredients of inorganic antimicrobials such as copper and zinc although silver is widely recognized as the most effective. There are over 40 different technologies utilizing silver as an active antimicrobial ingredient. The main feature that distinguishes ALPHASAN from other silver-based antimicrobials is its carrier, a specialized ceramic based on zirconium phosphate. The ceramic carrier acts as a sponge for silver ions and allows for a controlled rate of release. When the microbial population is high on an ALPHASAN treated surface, the carrier allows for a greater exchange rate of silver into the environment to control the bioburden. Conversely, when the environment has a low microbial population a lower amount of silver is released to control this population. This enables ALPHASAN to offer the best protection against the varying levels of microbes on a surface over time while conserving silver ions for longer durability. Another important feature of ALPHASAN’S controlled rate of release of silver ions is that it doesn’t tend to form color. Silver has a strong affinity to bind with other ions to form silver salts, silver oxides, and other color forming groups. Many of ALPHASAN’S competitors’ silver based antimicrobials form color in plastics and coatings due to a less controlled release of silver ions. This formation of color is not only aesthetically displeasing, it reduces the surface’s antimicrobial effectiveness. Q. Is ALPHASAN safe?
A. ALPHASAN has complete regulatory certifications and has low toxicity.
• ANSI/NSF Standard 51 Food Equipment Materials
• UDA List of Proprietary Substances and Nonfood compounds
• USDA letter of no objection
• FDA (FCN000001)
• EPA FIFRA registered, including food and drinking water contact applications Silver is known to be safe for human contact and effective against a broad spectrum of pathogens that cause odors, discoloration, and biofouling. Silver is well received and has a long historical presence since Alexander The Great. There is a low incidence of bacterial resistance. Additionally, the low toxicity profile of silver is evidenced in everyday life—silver nitrate is placed in babies’ eyes at birth, you eat from silverware, and silver based creams are used for wound care. Q. How is the effectiveness of ALPHASAN measured?
A. Efficacy is defined by a product’s application. In some instances it may be desirable for a product to simply stop the promotion of bacterial growth (bacteriostatic). This would mean a product would not need a percentage reduction in bacteria, but instead prevent a further increase. In other cases, the manufacturer may wish to claim the product is antibacterial. The EPA requires a product to kill 99.9% (a 3-log kill) of bacteria to use the claim antibacterial. There is a spectrum of behavior that can be defined as efficacy depending on the traits of the product. For example, Poultry and Meat processors require at least 80-99% reduction or 1⁄2 to 2 log reduction. Q. What affects the efficacy of the product?
A. It is mostly the environment that affects the efficacy of the product. The antimicrobial ALPHASAN is continually behaving as an ion-exchanger with the active ingredient silver and its surrounding environment, especially moisture. Q. Will Silveron/ALPHASAN replace other safety (cleaning) procedures?
A. While the steps taken by companies associated with the processing and/or preparation of food to reduce bacteria still need to be diligent, ALPHASAN provides these companies with an additional layer of protection from the growth of microbes. Silveron/ALPHASAN should be viewed as a supplement, not a replacement, to proper hygiene practices. With Silveron/AlphaSan in place, food safety practices are enhanced thus reducing the risk of food safety incidents from contamination. Also, hygiene cultures as well as HACCP (Hazard Analysis Critical Control Points) regimes are improved. Q. What are some of the applications for Silveron/ALPHASAN?
A. This new generation of silver based antimicrobial technologies are being adapted into many applications in the food and beverage industries. Current applications include: food processing equipment, meat and poultry equipment, cutting boards, counter tops, knife handles, snack food product lines, bulk food containers, conveyor belts - flat and modular, food packaging, and restaurant equipment. Additionally, some of the known applications outside the food and beverage industries include: wound care dressings, catheters, wear strips, chain guides, uniforms, gloves, coatings on metal equipment, walls, floors, ceilings, non-slip anti-fatigue mats, bulk containers, and reusable pallets. For more information, contact your NeXtconveyor Authorized Representative. | |
