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P a r t icu la r F ea t u r es of t he P u lse L igh t St er ilizer ( P u lse Bea m er ) a n d it s Su p er ior it y

April 1, 2005 ECONOS JAPAN CO., LTD.

491-1, Yoshisawa, Kikugawa-shi, Shizuoka Pref. Japan TEL: 0537-35-0667 FAX: 0668 Technology Dept. FAX: 0669 1. Introduction

(Now is the Time for the Transition from UV to Pulse!)

Light sterilization using the so-called Ultraviolet Sterilizing Lamp (UV) consisting of a low-voltage mercury lamp emitting a bright line spectrum at 253.7nm has been employed for a long time as the only method of sterilization with light. In recent years, however, sterilizing equipment has to meet more exacting demands as food production lines have been upgraded to increasingly higher speed performance and the needs for sterilization have become more sophisticated. Sterilizing equipment is required to achieve reliable and unfailing sterilization in an extremely short time, in other words, they must offer short-time high-efficiency sterilizing performance. Since UV sterilization (UV) does require a certain amount of time to sterilize, it is now difficult to meet these more sophisticated needs with UV. We are seeing a shift from a time where the mere use of a sterilizing system was all that was needed to a new era that demands reliable, unfailing sterilization in a short moment of only a few seconds. We are also witnessing an extension in the scope of sterilized microbes to highly resistant lactic bacilli and spore bearing bacterium such as molds. To achieve adequate sterilization with UV, a long sterilizing line is required. The problem with the UV sterilizing system is that while it produces a sterilizing effect the long time required to achieve this sterilizing effect leads to significant damage to the sterilized product in terms of protein degeneration and odor alteration due to the prolonged exposure to radiation. For this reason, attention is now focused on the pulse light sterilizer (Pulse Beamer) which has a high sterilizing capability and high performance within a short time. The Pulse Beamer generates a continuous flash light by converting the electrically stored energy to light in a wide wavelength range. With this instantaneous flashlight energy (equivalent to roughly twenty thousand times that of the UV (65W)), the revolutionary Pulse Beamer, fully aligned with present day needs, is capable of sterilizing micr oorganism, including bacteria and molds, in an extremely short time of less than a second. At present, this high sterilizing effect of the Pulse Beamer comes PET bottle cap sterilizing process into its own in all areas. It is therefore progressively used for surface sterilization in a wide range of applications, including food surface and container surface sterilization. The basis technology for pulse light sterilization goes back to the 1980s when Ushio Inc. took out a patent on a sterilizing method using xenon gas flashlight emission. After this, Maxwell Technologies, Inc. and its subsidiary Pure Pulse Technologies, Inc. developed the technology for commercial application in the form of the Pure Bright Pulse Light Process. The Food and Drug Administration of the United States (FDA) approved the flashlight irradiation process for controlling microorganisms on food surfaces in August 1996. The ECONOS Pulse Light Sterilizer is the result of a long process of original technology research. Its commercial name is Pulse Beamer. In Japan, it is the only pulse light sterilizing system that has been commercially developed and that has gained a high level of acclaim mainly in the food industry. 1
Photo 1

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2. Principle of Light Emission and Mechanism of Sterilization

(Ultraviolet light (DNA destruction) and infrared light (heat rays) act together to produce a powerful double-hammer effect!) (20,000 times the impact force of UV (equivalent to 65W))
The Pulse Beamer applies a high voltage to the xenon lamps electrodes to generate powerful light energy (electromagnetic waves) produced through xenon gas discharge in the form of a continuous flashlight at intervals of roughly five times per second. Fig. 1 shows the spectral distribution of this powerful continuous flashlight (electromagnetic wave). It can be seen that this energy has two characteristic peaks: one in the broad ultraviolet range (200 - 300 nm) and the other one in the near-infrared (heat rays) region. These two peaks combine to produce a synergic effect resulting in a dramatic sterilizing action. The hammering effect of the Pulse Beamer can be imagined by likening it to the action of an overwhelmingly powerful electromagnetic hammer with a peak and integral value at the time of emission roughly equal to 20,000 times the impact of UV (equivalent to 65W), with the harmful microorganisms being pounded with this hammer many times a second. Its major advantage is that despite this dramatic output, it consumes relatively little power.
Fig.1- Pulse Light Wavelength Characteristics (200 - 950 nm)
Spectral distribution in the absence of materials traversed by the beam
(QSO-130380, Power supply: 2.2 kV. Apr. 7, 2001)

Near UV range

Visible light spectrum

Near IR range

Pulse spectrum distribution

UV lamps wavelength: 254 nm

200nm

300nm

400nm

500nm

600nm

700nm

800nm

900nm

The sterilization mechanism in the ultraviolet range is essentially the same as with the UV and is based on the killing effect of ultraviolet light on the DNA. The unique feature of the Pulse Beamer, however, is that whereas the UV has a single wavelength at 254 nm in its emission spectrum, the pulse beam is most effective in destroying DNA because of its emission over the entire ultraviolet range from 200 to 300 nm, peaking at 265 nm, the absorption peak of DNA. Moreover, the Pulse Beamer generates an instantaneous energy that is roughly 20,000 times that of UV (equivalent to 65W). This accounts for the overwhelmingly destructive power of the pulse light beam. The pulse light beam has another mechanism based on the destructive potential of its near-infrared radiation: the heat rays effect. Electron microscopy of the microbial surface after pulse light irradiation reveals evidence of damage and destruction on the microbial surface that can be attributed to heat attrition. This suggests that the Pulse Beamer achieves the synergism of two effects: DNA destruction effect by the overwhelmingly powerful instantaneous ultraviolet radiation energy that is roughly 20,000 times stronger than the UV (equivalent to 65W) and the destructive heat rays effect due to its near-infrared radiation. The application of this pulse light as a continuous flashlight produces a surprisingly potent sterilization effect even on the fungi or spore bearing bacterium that are both difficult to sterilize. 2

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Fig. 2 - Characteristic DNA Absorptivity /Wavelength

1 0.9 0.8 0.7 0.6 0.5 0.4 Peak Wavelength 0.3 (254 nm) in UV 0.2 Spectr um Distr ibution 0.1 0
DNA Absorptivity Peak (265nm)
Wavelength distribution of the pulse light in the ultr aviolet spectr um r ange

Relative Absorptivity v[ T8S s

220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

Wavelength (nm l w(nm)

3. Particular Features

(Instantaneous - Powerful - Space-saving)

The Pulse Beamer has many outstanding features the conventional UV sterilizer did not possess. The main features are summarized below: % Instantaneous, powerful sterilizing action 0Approx. 1/3000 4D effect on bacilli in a mere 0.8 seconds! (4 irradiation passes) 0Approx. 1/1000 3D effect on aspergillus niger in a mere 1.4 seconds! (7 irradiation passes) (UV sterilization at 65W has almost no effect on these microorganisms and requires irradiation for 4.0 seconds or even longer in a 400W water-cooled system.) % Space-saving benefits in a sterilizing line 0For a cap sterilizing line at a throughput of 600 bpm, the Pulse Beamer can make do with a mere 0.5 m (unit length: 1.2m) of space. (With the UV 400W water-cooled system, more than double the line space was necessary.) 0Easy to install on to an existing line. % In contrast to the UV, no unproductive waiting time for startup and light emission is required. 0Instantaneous startup and immediate sterilizing action. 0Operates as the line is switched on and off 0No unproductive light emission 0No mechanisms such as shutters required % Virtually no damage on the sterilized product 0Imparts almost no odor and causes almost no degeneration. % Lower running costs than the UV 0Striking difference from the UV in terms of lamp replacement costs 0Outstanding difference from the UV when considering the difference in sterilizing effect 0The Pulse Beamer also has a relatively low energy consumption. Photo 2 - Control Box 4. Equipment Structure (Small sterilizer section but somewhat bigger peripherals) The Pulse Beamer consists of a light emitter, power supply unit, cooling unit, and a control panel for controlling these units. Photo 2 shows an integral system consisting of the power supply unit, cooling unit and control panel. While the Pulse Beamers emitter (sterilizing unit) can be made compact the accessory equipment does require a certain amount of installation space because a large-capacity condenser is required to generate the high instantaneous energy. 3

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5. Comparison of the Pulse Light Sterilizer with other sterilizing systems (A strong case for the Pulse

Beamer!)
Pulse Sterilizer Sterilization range Bacteria in general Fungi Spores Quality assurance Treatment time Equipment space Influence on peripheral equipment Initial costs Running costs Miscellaneous Ultraviolet sterilization Chemical sterilization Thermal sterilization
% % % (Deterioration of flavor and color) (Several tens of minutes needed) Cooling process required % % % (Effective on surface only) (Effective on surface only) (Effective on surface only) % % % % % % % % % % (Degeneration, (Residue problem) imparting of odor) % % Treatable in a few (Several minutes (Several tens of minutes seconds needed needed) % % % No cooling process No cooling process (Several tens of minutes required required needed) % % % % % % %

Effect

% Effluent problem [Reference: Food Industry]

6. Sterilizing Effect

(Instantaneous, powerful sterilizing action!!)

Approx. 1/3000 4D effect on bacilli in a mere 0.8 seconds!! (4 irradiation passes). Approx. 1/1000 3D effect on aspergillus niger in a mere 1.4 seconds!! (7 irradiation passes) (In the case of UV sterilization using 4 lamps of 65W each, it has not been possible to confirm a 1/10 or higher effect even after irradiation for 5.0 seconds..) With the Pulse Beamer, it is possible to achieve a high sterilizing effect even for Aspergillus niger (bread mold) which is known to have a high resistance to ultraviolet light, as can be seen in the figures below.
Sterilizing test using0 0 Pulse Beamer on 00 f 00 the 0000k00 Aspergillus niger k Number of irradiation passes (sec.) vs. Sterilizing power qg\ V (yep )0hk R ep Live bacteria
u ep(# 5 & count (CFU))

1200 1000 800 600 400 200 0

1100

Live ep(# 5 u bacteria & count (CFU)

Sterilizing test using UV at 5-second irradiation on Aspergillus niger Sterilizing power0k00 00 f 56 yqg\ at each time interval after k irradiation with po_lamps of 65W each R 4 UV }LNfB 0T0h0nk 65w4po000p
2000 1800 1600 1400 1200 1000 800 600 400 200 0
co

1900 1700 1700

870 600

27
1 ( .0 y 5 times) (1.0 sec.) 7V 1 ( .4 y 7 times)

(1.4 sec.) 10V 2. ( 0 y) 10 times (2.0 sec.)

co cont. nt

After 10 min. 2

After 20 60 min.

10 R

qg\ V ep(y ep) No. of irradiation passes (sec.)

Analysis by: Kitasato Res. Center of Environ. Sciences R g :( t X )S y[f 0000

T p po}LNfB _ y k Sterilization for 5 seconds after each time interval R g :()S Center of Environ. Sciences t X y[f 0000 Analysis by: Kitasato Res.

Pulse beam in a mere 1.4 seconds 100% sterilization effect in 7 passes

UV is not effective even after irradiation for 5.0 seconds. Not capable of sterilizing in a short time.

(A UV system without temperature control decreases its sterilizing power because the sterilizing beam diminishes with increase in temperature.) 4

After 60 min.

5y _ After

n cont.t

5 sec.

5V

0R

R_

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8. Comparison of Running Costs

(Overwhelmingly cost-efficient considering the effect!!)

Practical Calculations for the Pulse Beamer and the 400 W UV
The 60 - 65 W type UV sterilizing lamp system is the most widely used one in the beverage industry. It has almost no effect on fungi or molds. As a result, we have here compared the Pulse Beamer with the 400 W water-cooled UV system that has a higher sterilizing effect than the 65 W system although it is still not up to the performance level of the Pulse Beamer. 1. Line Conditions $` Sterilized work: 28 PET bottle caps/inner surfaces of bottle caps $a Line used: PET beverage bottle fed at a speed of 600 bottles /minute: Filling line. Work speed: 320 mm/sec. (Outside diameter of work: 32) 2 $b Sterilization level: Killing black molds to the level of 10 or better $c Operating time: 20 hours/day 20 hours/day x 250 days = 5000 hours/year 2. Comparison of Running Costs UV Sterilizer for caps Pulse Beamer Equipment Spec. $` Power supply 200V AC 200V AC $aLamp 400W x 2 x 2 in-series units Equiv. 400W x 1 lamp $bPower consumption Approx. 2.5kW (incl. water-cooling unit) 1.8kW (Rated 5 kW) $cAvailability 100% 85% (Actual measurement value) ; Continuous light emission while line ; Pulses are irradiated only while the is ON sterilized work passes by. $dLife of lamp 2000 hours 1000 hours (Guaranteed 800 hours) $eUnit price of lamp 180,000 yen/each (fixed cost) 150,000 yen/each (Type B) Electricity costs 2.5 Kw 5000 hours18 yen/ Kwh 1.8Kw5000 hours18yen /Kwh0.85 225,000 yen/year 137,700 yen/year ! Lamp replacement costs 5000 hours /year2000 hours /time 5000 h./year0.851000 h. /times $` Freq. of replacement 2.5 times /year 4.25 times/year $aNumbers replaced 4 units2.5 times/year units/year 1 unit4.25times/year 4.25 units/year $bReplacement costs 180,000 yen/unit10 units 150,000 yen/unitType B4.25 units " 1,800,000 yen/year 637,500 yen/year Total costs approx. 2,025,000 yen/year 775,200 yen/year A B calculated per year Difference 1,249,800 yen/year It is clear from the above that the Pulse Beamer has an overwhelmingly powerful sterilizing effect and also marks a revolutionary advance on the UV system in terms of its low running costs. The lamp shows virtually no deterioration (decrease) in light emission intensity during the life of the lamp. It can therefore be relied upon to achieve its sterilizing task. On a cap sterilizing line (operating at a throughput rate of 600 bottles per minute), in particular, the Pulse Beamer offers major space-saving benefits as it can make do with only about 1.0m space (the actual lamp length is 0.5m). To achieve the same effect, a UV sterilizing system would need a sterilizing system length roughly double that. Besides, the prolonged exposure of the cap to UV required would result in problem associated with cap deterioration.

9. Lamp Efficiency

(Can be used for a long time at the outstanding intensity! Xenon has the worlds longest life.)
Rationale for Guaranteeing a Lamp Life of 800 hours As can be seen in the figure below, when a lamp has been used for 1000 hours (18 million times), its attenuation rate for the near-260nm wavelength corresponding to the DNA absorption peak is around 5%. While this present absolutely no problem in terms of the sterilizing effect there are certain variations in the lamps endurance as a function of the operating conditions (e.g., the frequency at which the lamp emits light within a second) and also variations in the lamps manufacturing process. For this reason, we have made our statistical evaluations on the basis of the minimum lamp life encountered so far, and this has led us to guarantee a lamp life of 800 hours. Lamps are constantly being modified and upgraded with improvements in the long-life durability. For the time being, however, we offer a guaranteed lamp life of 800 hours until our actual performance data is collected 1000 units or more. 5

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Even when the guaranteed life of 800 hours is exceeded the lamp and the sterilizing efficiency it provides will not cause the slightest problem. The 800 hours life should be regarded as a rule-of-thumb target for replacing lamps. In contrast to UV lamps, the Pulse lamps need not be on all the time. Rather, the lamp need only flash when the product to be sterilized has reached the sterilizing position. This means that the lamps ON time is coupled with the lines availability.

Variation in UV Spectrum Intensity of Xenon Lamps

100

Attenuation rate (1000 (1000 hours) 253.7nm93.3% 253.7nm! 93.3% 259.2nm! 95.0% 259.2nm95.0%

90

253.7n m 259.2n m

80

0
0 h.

500

1000
500 h.

1500
800 h.

70 freq. 2000 Light emissionV vzQIV epN (Unit: 10,000)

1000 h.

0Operating conditions Equipment: PET bottle cap sterilizing Pulse Beamer lamp: Arc length 500mm xenon tube. Operating time: 1000 hours (No. of light emission passes: 18 million times)

10. Application Areas (Wide application range!) Pulse sterilization has a substantial potential for use in a wide diversity of application fields. For example, it can be used to significantly reduce colon bacilli and fungi by direct irradiation of the food surface prior to sealing for food products such as deep-frozen fish fillets, puddings and yogurt. It also comes into its own for the sterilization of container, such as inner cap surfaces in the case of PET bottles or aluminum bottles and inner surfaces prior to product filling in the case of pudding, yogurt and milk packs and paper container molding and filling. Pulse sterilization also has an encouraging potential for direct use on liquid products with a relatively high transparency, although this does depend to a certain extent on the type or nature of the liquid. When a UV-transparent container is used the container contents may be sterilized by irradiating the Photo: pulse light after product filling or packaging. The Pulse Beamer for Food Surface Sterilization materials with a favorable UV-transparency include, among other things, polyethylene (PE) and PVC film. PET, the plastic currently used for beverage bottles, however, is not transparent to UV and is consequently not suited for sterilization of the inner surfaces. Pulse sterilization is a form of light sterilization. Similarly to UV, the pulse light does not have a sterilizing effect on those parts that are in the shadow of the light. The pulse lights intensity also weakens in a manner inversely proportional to the second power of the distance. For this reason, the shape of the sterilized product and its distance are important factors. One way of increasing the 6

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sterilizing power of the pulse beam may be to increase the input energy. In this case the lamp comes under greater stress and this may have adverse repercussions on the lamps life. It is therefore necessary to strike an optimum balance. 11. Conclusion Pulse light sterilization technology has a promising application potential in areas requiring a high level of sterilization without residual problems and without heat application and contact. Amidst growing health and safety concerns, there is no doubt that the increasingly higher levels of sterilization will be demanded. It is therefore reasonable to expect that the need for pulse light sterilization will increase in a wide user range, including food, beverages, and the medical field. The users currently employing UV sterilization systems are particularly likely candidates for the early replacement of the UV equipment by the pulse beamer system. Econos has conducted sterilizing tests on a wide diversity of products using its pulse light sterilizing technology. These experiments have enabled us to collect a substantial body of data and experience which we are confident will benefit users in many walks of industry. In our effort to serve, we would be only too pleased to answer any inquiries or queries. Please do not hesitate to consult us.
Photo: Pulse Beamer used for sterilizing the inner surfaces of bottle caps.