BIOFILM SENSORS
Monitor & Control Bacteria Biofilm
Protect Public Health ~ Consumer & Food Safety ~ Product Quality ~ Process Hygiene 
Maintain Operational Efficiency ~ Plant Performance & Reliability
Comply with Regulations and Food Safety Legislation 

What is Bacterial Biofilm?

Biofilm Video

Biofilms are naturally occurring complex communities of micro-organisms. They start by free-floating individual 'planktonic' bacteria cells attaching to a surface in a wet environment. 'Bacterial Biofilm' is the first step in a microbial colony. Only certain bacteria have the ability to attach and form initial biofilms.  Where favourable conditions exist  planktonic bacteria will attach and quickly proliferate.

The first cells attach to surfaces using their adhesion features - Fimbrea, Pili and a Polysaccharide (slime) layer. Once anchored the growing multicellular community communicate between cells by Quorum Sensing. Together they begin to exude a hydrogel, a sticky slime known as  “Extracellular Polymeric Substances” (EPS). The slimy layer is often felt on the surfaces of containers of static water after just a few days.  The hydrophobic EPS gel provides increasing levels of protection for the growing biofilm community and improves adhesion to the surface. Within the colony millions of single cell bacteria take up different roles. Together they act much like a multi-cellular organism, including the exchange of DNA. Enabling adaptions to develop rapidly, such as antibiotic resistance. Some cells eventually break away from the colony. Once detached those now mobile cells float downstream to quickly spread infections to new locations. 

As a core biofilm develops, members of the increasingly complex community gain protection from turbulence, heat, cleaning chemicals, biocides, anti-microbial agents and antibiotics. Biofilms can be extremely difficult to kill or remove once they become established in a system.  Eventually a hard protective outer plaque layer can even form. Coating and blocking membranes, tanks, pipework and machinery. On a smaller scale it is seen as dental plaque on teeth. Inside the biofilm plaque corrosive excreta from the organisms accumulates. Damaging equipment such as heat exchangers by 'MIC' - Microbiologically Induced Corrosion. These acids causes dental cavities. 

The effects of Biofilms are wide reaching. If allowed to develop biofilm matrices become havens for other unicellular and multicellular micro-organisms. Allowing numerous other species of bacteria, yeasts, fungi, amoeba, protozoa, etc. to proliferate; even harbouring viruses. Each colony is unique. Unless controlled, biofilms facilitate the spread and persistence of pathogens, waterborne diseases and toxins in any water rich environment.  

Why do I need a Biofilm Sensor?

Biofilm normally starts with a small number of bacterial cells attaching to a surface. They are the first stage in the formation of a biofilm matrix. Which can provide protection for millions of micro-organisms.

Initially biofilm is a single layer of bacteria just one cell thick. A collaborative, protective EPS gel gradually develops as an anchoring foundation for a new colony. At the start it is relatively easy to remove with standard cleaning or sanitising techniques. However bonds within the EPS matrix strengthen in time, gradually making removal more difficult. Primary infection is undesirable, especially if it is pathogenic, but subsequent secondary and tertiary  invasion of the biofilm colony becomes a serious danger. Risking persistent and tenacious infection by Legionella, Listeria, Staphylococcus, E. Coli, etc.  Early intervention is therefore extremely important. ALVIM sensors are designed to detect early stage biofilm.

Traditional microbiological testing methods involve  regular liquid sampling and/or surface swabs. Followed by laboratory analysis using various techniques and technologies. Such as agar plates, ATP, PCR, etc.
There are unfortunately some potential downsides:
1) Swabs must be taken from all critical control points in a system where bacteria is likely to reside. However Swabbing inside pipes and process systems is often impractical.
2) Liquid samples are not ideal. Because bacteria can only be present in a liquid sample if viable cells happen to be free-floating in the liquid at the sampling point and at the moment when the sample is taken. Considering about 90% of bacteria reside in biofilms not free-floating in liquid, sampling is unfortunately a pretty unreliable method.  
3) Very frequent “micro” tests by laboratory personnel is time consuming, tedious and expensive.

Fortunately, Biofilm sensors can complement existing 'micro testing' techniques. Installed in pipes and tanks, the sensors provide continuous monitoring, indicating the presence and coverage of early stage biofilm as an analogue 4-20 mA output signal. Integration into site facilities allows  24/7 record keepingautomatic 'High Micro' alarms and the scheduling of cleaning and sanitization sequences.

Essential Public Health Regulations for Legionnaires Disease and Food Safety require strict control of hygiene in water systems and process equipment. Biofilms Sensors can enhance existing HACCP control systems. Making them more robust, reducing risks, improving record keeping and strengthening Due Diligence.   

For best results, one or more Biofilm sensors are installed in a system, ideally at critical points. Typically in positions of relatively low turbulence where bacteria are most likely to attach to a surface. As Critical Control Points, they tend to be at or just after positions in a system that are the least easy to clean.  

ALVIM Biofilm Sensing Probes

Automate for Continuous Real-time Biofilm Monitoring
For maximum benefit continuously monitor for biofilm development by integrating biofilm sensors into the site PLC/SCADA system. 
Use ALVIM Biofilm Sensors to Alert Lab Technicians, Trigger Alarms, Initiate Automated CIP, Verify Cleaning & Biofilm Removal. 
Log biofilm data for hygiene troubleshooting and as valuable evidence of a robust HACCP system 
Bacteria Sensors

Example: Legionella in Hospital Water

There are many bacterial species capable of forming biofilms,  including Listeria, Staphylococcus, Lactobacillus, Lactococcus, E. Coli, Pseudomonas and even Vibrio Cholerae in salt water.  Even if not initially created by pathogenic bacteria, biofilm is ideal for many secondary pathogens e.g. Legionella pneumophila. Such bacteria do not normally form biofilm by themselves.  However biofilm started by other species of bacteria can facilitate the survival and growth of other species. Some can be extremely hazardous. Especially in hospitals and other critical environments,  where for example patients' have compromised immune response. Biofilms are present in all wet environments. They are associated with numerous health conditions including dental plaque & decay, gum disease, also secondary fungal species infections such as Candida and many more. Each biofilm colony is unique, sometimes making them difficult to eradicate from water and process systems

Using laboratory analysis, a hospital had identified Legionella at up to 2500 CFU/litre in the water supply to their maternity unit. A new biocide treatment was applied, greatly reducing the Legionella count. 
An ALVIM sensor was installed. It showed that unbeknown to lab technicians, biofilm was still alive and active in the system, possibly aiding a persistant colony of Legionella. Further more searching swabs and lab analysis confirmed bacterial was indeed present.
Bacterial Biofilm Growth
Applications & Case Reports
Biofilms will form is all water rich environments, quickly too if favourable conditions allow. 
Leading to Hazardous Legionella Infection, Product Contamination, Equipment Corrosion, 
Plant Failure, Higher Costs, Prosecution & Litigation

Control of Legionnaires’ Disease in Water and Evaporative Cooling Systems - A legal requirement!

 "Legionellosis is the collective name given to the pneumonia-like illness caused by legionella bacteria. This includes the most serious legionnaires’ disease, as well as the similar but less serious conditions of Pontiac fever and Lochgoilhead fever. Legionnaires’ disease is a potentially fatal form of pneumonia and everyone is susceptible to infection" UK Health & Safety Executive

The Legionella pneumophila bacteria infects and develops in water systems inside amoeba. Amoeba eat biofilm! 
Therefore in principle:  No Biofilm = No Amoeba = No Legionella

In the UK landlords and employers are legally required to eliminate or control Legionella. Particular attention must be paid to air conditioning systems, cooling towers, evaporative condensers, water systems, humidifiers, indoor fountains, etc.

ALVIM probes respond to Biofilm growth and changes in water conductivity. In effect as well as detecting Bacteria Biofilm Sensors can also provide the significant benefit of continuous indicative REDOX monitoring, e.g. for chlorine or bromine concentrations in cooling towers.

Application Case Report
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Safety in Food Production & Processing Systems

Avoiding bacterial infection of hygiene critical products such as milk, liquid foods, beverages, process water and ingredients is of paramount importance. In dairies lactose induces Bacillus bacteria to form biofilms in milk processing systems. Clean water is vital  for washing salad crops and fresh produce. It is therefore essential to monitor water distribution routes throughout a processing plant and the performance of automated process cleaning CIP systems. To ensure biofilm is effectively removed.

Production of Water-based Products

Increasing numbers of products are water based. Owners and designers of industrial processes producing a wide range of water-based products must ensure their systems are cleanable and thoroughly cleaned between batches. Microbial infection can compromise product quality and process performance.

Protection of Critical Water Cooled Systems

Biofilms in a cooling system can gradually block heat exchangers, reduce flow rates and cause process failure. Acids excreted by micro-organisms cause internal corrosion of heat exchanger plates. Reduced process performance, unplanned stops and poor reliability are very expensive.  Especially for major operations such as Power Stations and continuous 24/7 processes.

Protection of Water Treatment Systems

To maintain the performance and reliability of crossflow membrane systems e.g. reverse osmosis filtration, it is essential to ensure that membrane modules do not become even partially blocked. Detection of infection and well-timed periodic cleaning are of vital importance. If neglected, total system failure can quickly occur, often at great expense and loss for production for extended periods. Bore hole water supplies can be especially susceptible in warm weather.
Downable Application Case Reports
Visit Alvim application cases page...
Application Sector & Link Subject of Application Case Report PDF Report
Open cooling towers Biocide effectiveness and elimination of bacteria Download
Industrial Cooling towers What happens when chlorination fails? Download
Power Plant Water Treatment Improved heat exchange and power production by controlling biofilm growth Download
Legionella prevention Biofilm sensor helps prevent hospital water infection Download
Food Production Detection of bacteria due to failure of sterile filters & UV sanitization Download
Mineral Water Bottling Biofilm sensors detect ineffective CIP cleaning Download
Soft Drinks Production Integration of Biofilm Sensors with automated CIP improves process hygiene Download
RO Water Treatment Biofilm detection allows better biocide scheduling for improved cleaning Download
Membrane Desalination Improved efficiency of biocide in RO system Download
Paper Production Biofilm sensor identifies abnormal bacterial growth. Allowing remedial action Download
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