BioDtex UV Biofilm Detection for Microbial Risk Reduction in a Fresh Produce Manufacturing Unit in the UK
1.Background
Fresh produce manufacturers face constant pressure to maintain hygienic conditions due to the high risk of microbial contamination. Contamination can arise from biofilm buildup on food contact surfaces and equipment, leading to potential food safety failures, product recalls, or consumer illness. A mid-sized fresh produce processor handling leafy greens and pre-cut vegetables, sought to enhance its hygiene verification procedures, targeting difficult-to-detect biofilm formations and reducing the risk of environmental indicator organisms (Enterobacteriaceae, coliforms, Listeria & E. coli).2. Challenge
- Traditional visual inspections and ATP swabbing methods failed to consistently detect persistent contamination.
- Routine cleaning and sanitation protocols did not fully eliminate micro loading risk or biofilm-forming bacteria.
- Positive environmental results occurred intermittently, triggering expensive line shutdowns and retesting
3. Solution: Integration of BioDtex UV Biofilm Detection Unit
In Q1 of the year, we introduced the BioDtex Lamp, a handheld biofilm detection tool using UV-fluorescence technology to visualize biofilm residues invisible to the naked eye. The unit was deployed for:- Routine sanitation validation & verification.
- Targeted investigative swabbing.
- Enhanced positive release (EPR) verification before line release post hygiene.
4. Implementation Strategy
A. Baseline Mapping and Training
- BioDtex units were used during post-cleaning inspections over a 2-week baseline period to identify high-risk zones (e.g., conveyor belt undersides, cutting blades, drainage zones).
- Hygiene team members were trained to identify UV-reactive signals and link these to potential microbial harbourage points.
B. Targeted Swabbing and Verification
- Once biofilm presence was identified with BioDtex, swabs were taken from fluorescing zones and tested for:
- Listeria spp.
- Environmental indicator organisms (Enterobacteriaceae, coliforms)
- Swabbing was targeted pre and post hygiene for zones showing repeated UVpositive visual results.
C. Enhanced Positive Release Protocol
- Prior to product release, the BioDtex unit was used as part of a final QA verification.
- Only areas free of biofilm or bioluminescence passed to product release, with swab tests confirming negative results for pathogens or high-risk indicators.
5. Results
Pre hygiene : – visual detections
Post hygiene: – clear of visual detections
A. Microbial Risk Reduction
- Within 4 weeks of implementation:
- Micro loading risk areas were now defined to specific zones and isolated machinery & equipment.
- No positive release delays occurred. B. E@iciency in Investigations
- Root cause analysis timelines shortened when BioDtex was used to pinpoint contamination sources.
- Detection of biofilm hotspots led to revised cleaning SOPs for specific components, especially under belts, rollers and junctions.
- Enhanced compliance with BRCGS Issue 9 – Clause 4.11.1 (Cleaning E@ectiveness Validation).
Test Results:-
6. Conclusions and Lessons Learned
- The BioDtex UV Lamp provided a non-destructive, rapid, and cost-e@ective tool for identifying microbial risks otherwise missed by traditional methods.
- Its integration into enhanced positive release procedures ensured greater confidence in product safety and regulatory compliance.
- The combination of real-time visual confirmation and targeted microbiological testing created a proactive hygiene culture with clear, visual accountability.
7. Future Directions
- We are now exploring the expansion of BioDtex deployment into its incoming raw material inspection areas.
- A quarterly trend report will be established to compare seasonal microbial risk variation and optimize cleaning frequency accordingly.
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