Microbiological validation of sterilization processes

Microbiological challenge tests to identify weak points in the sterilization process

We use microbiological challenge tests to validate the effectiveness of your sterilization process (e.g., for food or packaging materials) and identify potential weak points or areas for optimization. To do this, we use process-specific bioindicators, which are individually produced using customized contamination methods and resistance-tested test organisms. By combining specific test organisms with practical test conditions, we create the basis for reliable and meaningful results.

We also advise on process optimization and system design

Using defined test organisms, we precisely quantify the inactivation efficiency of your packaging and machine sterilization. For this purpose, bioindicators (artificially contaminated carrier materials such as packaging or machine parts) are introduced into the real process. Based on the results of the microbiological validation, we advise you on process optimization and system design. At the same time, we provide you with microbiological proof of efficacy in accordance with the recommendations and information sheets of the VDMA.

Regular tests and inspections help to assess the functionality of filling systems and to identify potential weak points. They also provide transparent evidence for audits and documentation.

We use microbiological challenge tests as an important tool to validate and verify the effectiveness of heating processes in food production. In this way, we ensure that potentially pathogenic microorganisms are reduced to a safe level by heating and that product safety and shelf life are guaranteed. The product is specifically inoculated with relevant microorganisms (e.g. Salmonella, Listeria) under controlled conditions to test the inactivation of these pathogens by the specific heating process in the specific matrix.

Influence of food properties

The need for microbiological challenge tests arises from the fact that the composition and properties of the food (such as pH, sugar content, salt content, protein content, etc.) can strongly influence the D and z values of microorganisms. A challenge test examines the mortality behavior of microorganisms in the food matrix under standardized, practical conditions.

Challenge tests result in critical control points

The results (D and z values) of a challenge test provide information on the temperature and duration of the heating process required to achieve the desired microbial reduction. The data obtained helps to define critical control points as part of HACCP concepts and to confirm that the heating process is sufficiently robust to minimize potential microbiological risks. It is also possible to optimize oversized heating processes to save energy.

Special hot water autoclave creates realistic test conditions

We use a special hot water autoclave to realistically simulate industrial heating processes on a laboratory scale. In microbiological challenge tests, this allows us to precisely determine the relevant process parameters, such as treatment temperature and treatment duration, under realistic and controlled conditions. On this basis, we can validate heating processes for safe and gentle treatment of products.

You might also be interested in:

• Optimizing the quality and shelf life of food
• Hygienic production and cleaning
• Development of packaging
• Compliance and migration testing of food packaging