Client Profile:
North American prepared meal facility is located in California, USA. It specializes in the processing of prepared salads and ready-to-eat meals. The facility covers an area of 1,200 square meters and supplies products to U.S. supermarket chains and fast-food brands. Prior to our collaboration, the client faced three major challenges: First, sterilization of the facility’s air, equipment surfaces, and food contact surfaces was incomplete, resulting in total bacterial counts frequently exceeding limits and failing to meet FDA food production hygiene standards (Total bacteria ≤300 cfu/m³), which posed a risk of failing random inspections; Second, traditional UV disinfection left blind spots and lacked sustained sterilization effects, creating a high risk of cross-contamination of ingredients; Third, chemical disinfectants left residues that affected product taste, failing to meet the production requirements for high-end prepared meals.
Client Requirements:
- Achieve comprehensive sterilization of workshop air, equipment surfaces, and food contact surfaces to ensure total bacterial counts ≤300 CFU/m³, comply with FDA food production hygiene standards, and eliminate disinfection residues;
- Address blind spots in UV disinfection, provide sustained sterilization effects, and reduce the risk of cross-contamination of ingredients;
- Provide CE- and FDA-certified ozone generators with an English-language interface, capable of scheduled disinfection and automated control;
Solution:
Based on the layout of the client’s prepared meal production facility and FDA compliance requirements, a customized comprehensive ozone sterilization solution was developed:
- Four CH-Y oxygen-source ozone generators (output: 60 g/h, CE- and FDA-certified) were selected and installed in the equipment room, with ozone distributed via piping;
- Implemented an intelligent timed disinfection control system, allowing for 3 hours of comprehensive disinfection daily at 3:00 AM and 1 hour of targeted disinfection during production breaks. Air disinfection concentration was maintained at 25–30 mg/m³, while equipment surfaces were disinfected via ozone fumigation, ensuring no disinfection blind spots;
Implementation Results:
One month after the equipment was put into operation, significant results were achieved:
- Sterilization Compliance: The total bacterial count in the workshop air has stabilized below 220 CFU/m³, and the total bacterial count on equipment surfaces and food contact surfaces is ≤50 CFU/cm², fully complying with FDA food production hygiene standards. The facility has successfully passed random inspections by local food regulatory authorities for three consecutive months;
- Residue-Free Assurance: Ozone rapidly decomposes into oxygen after disinfection, leaving no chemical residues and having no impact on the taste of ingredients, meeting the requirements for high-end prepared meal production; 3. Elimination of Hidden Hazards: Completely resolved the issue of UV disinfection blind spots, reduced the risk of cross-contamination of ingredients by 90%, and lowered the product non-conformance rate from 5% to 0.3%;
Customer Reviews:
The ozone generator provides comprehensive sterilization for our prepared food workshop, fully meeting FDA standards with no residues. The equipment is easy to operate and has no dead ends in sterilization, which greatly reduces the risk of food contamination. We are very satisfied with the solution and after-sales service.
-Director of Plant Operations:Ms. Smith
