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Industrial Processes

Understanding how biofilms form, the risks they present, and the most effective strategies for prevention and removal is essential for maintaining safe, efficient, and compliant industrial operations.

Biofilms & Industrial Processes

Biofilms pose significant challenges in various industrial processes due to their ability to form resilient microbial communities leading to material or equipment degradation, reduced efficiency, and the production of foul odours. Biofilms can harbor pathogenic bacteria, posing serious health risks to employees and customers. Biofilm formation in pipelines can induce corrosion and blockages. They can also reduce heat exchange efficiency, increase energy consumption, and their presence necessitate frequent cleaning. These structured microbial layers are difficult to remove and can resist chemical disinfectants, making maintenance more complex and costly. Regular monitoring and early detection are critical for preventing biofilm establishment. Understanding how biofilms form, the risks they present, and the most effective strategies for prevention and removal is essential for maintaining safe, efficient, and compliant industrial operations.

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Oil & Gas

In the oil and gas industry, biofilms create persistent problems due to their resilient structure and ability to colonise a wide range of surfaces. These microbial communities attach to pipelines, tanks, and drilling equipment, forming protective layers that make them highly resistant to biocides and harsh environmental conditions. A major concern is microbiologically influenced corrosion (MIC), particularly from sulfate-reducing bacteria that produce hydrogen sulfide, which causes pitting and degradation of metal components. Biofilms can also obstruct pipelines, reduce flow rates, and impair the function of critical infrastructure such as sensors and valves, leading to increased maintenance demands and costly operational disruptions. Furthermore, their impact extends into subsurface environments, where they alter reservoir properties and hinder enhanced oil recovery (EOR) efforts. Mitigating these effects requires a combination of mechanical removal, targeted chemical treatments, and innovative approaches such as advanced coatings and microbial monitoring systems.

Water Treatment, Filtration & Cooling waters

In water treatment and filtration systems, biofilms can clog membranes and filter media, reducing efficiency, increasing back-pressure, and leading to frequent cleaning or replacement of components. In cooling water systems, biofilm formation on heat exchange surfaces diminishes thermal conductivity, thereby lowering heat transfer efficiency and increasing energy consumption. Additionally, biofilms serve as reservoirs for pathogenic microorganisms, posing risks to public health and complicating disinfection efforts. Their resistance to conventional biocides further exacerbates these problems, as embedded microbes are often shielded from chemical treatments. Over time, biofilms can damage infrastructure and lead to costly repairs. Effective management requires regular monitoring, optimised biocide application, physical cleaning methods, and the integration of biofilm-resistant materials or surface coatings.
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Paper Production Industry

In paper production, biofilms are a persistent issue that can negatively impact both product quality and operational efficiency. Microbial communities form on surfaces within the paper machine system, such as on the wires, felts, and piping, where warm, wet conditions and abundant organic material promote microbial growth. Biofilms can slough off into the pulp slurry, leading to defects in the final paper product, including spots, holes, and odour. Biofilm (slime) formation can clog nozzles, foul machinery, and cause unplanned shutdowns. The resilience of biofilms to standard cleaning and biocide treatments as well as the high organic loading of the paper pulp, complicates control strategies, necessitating the use of continuous monitoring, targeted antimicrobial agents, and mechanical cleaning techniques to minimise their impact and maintain product consistency and system reliability.

The Leather Industry

In the leather industry, biofilms can disrupt production as the contamination can degrade raw materials and processing equipment. During hide preservation and processing, especially in soaking and liming stages, the moist and nutrient-rich environment supports microbial adhesion and biofilm development on hides and in drums and pipelines when they are not maintained well. The presence of microbial populations can lead to the breakdown of collagen and other structural proteins, compromising hide quality and resulting in discoloration, foul odours, and decreased tensile strength. Metabolic byproducts produced during the growth of microorganisms can also alter pH and enzymatic activity in processing baths, interfering with chemical reactions critical for tanning and finishing. Routine chemical disinfection is often insufficient to eliminate biofilms, preventive measures such as improved sanitation protocols, enzymatic cleaners, and regular mechanical maintenance is therefore required to ensure consistent leather quality and extend equipment lifespan.

The Textile Industry

In the textile industry, biofilms affect both manufacturing processes and the end-use of products. During textile processing, particularly in wet finishing operations, microbial colonisation can occur on machinery surfaces and within water circulation systems, leading to uneven dye uptake, fabric staining, and unpleasant odours. Beyond production, biofilms demonstrate remarkable persistence on worn and laundered garments, where residual moisture, body oils, and textile fibres provide a favourable microenvironment for microbial adherence and regrowth. Even after conventional washing, viable biofilm-forming bacteria can remain embedded within fabric matrices, especially in synthetic textiles, contributing to malodour development and potential skin irritation. These microbial residues also increase the risk of cross-contamination in communal laundering settings. Inadequate removal of biofilms from both industrial equipment and consumer textiles underscores the need for enhanced antimicrobial treatments, high-efficiency laundering protocols, and fabric innovations designed to resist microbial colonisation and growth.
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Wet State Product Production

(Paint / Coating manufacturing, Adhesive production, cosmetic and personal care) 

Biofilms present a significant concern in the manufacturing of liquid products including paints, coatings, adhesives, and cosmetics due to the inherent susceptibility of water-based formulations to microbial contamination. Biofilm-forming microorganisms can colonise mixing tanks, pipelines, and storage vessels, leading to product spoilage, viscosity changes, discoloration, and unpleasant odours as well as consumer safety concerns. Biofilms can persist on manufacturing surfaces and in partially processed products, introducing a microbial load that either overburdens or even resists standard preservatives and can compromise product stability. The resilience of biofilms to cleaning and sanitisation procedures necessitates stringent hygiene practices, the use of broad-spectrum preservatives, regular microbial monitoring, and equipment designs that minimise dead zones where biofilms can develop and persist. 

wet state product

Landscape of biofilm regulations and standards

While direct regulations on biofilms within industrial processes are sparse, the control of biofilm production is embedded within broader frameworks for hygiene, contamination, and corrosion control. Industries rely on a combination of international standards, national regulations, and industry-specific guidelines to inform decision-making with regards to process treatments. As awareness grows, we can expect the development of more explicit biofilm-focused standards and the increasing availability of biofilm-specific treatment, detection and monitoring technologies. The effective regulation of biocide treatment chemistries will require the development of new laboratory simulation methods to enable their effectiveness to be assessed. 

Landscape of biofilm regulations

Goals of the Biofilm Alliance in Enhancing regulation and standards

The mission of the Biofilm Alliance is to strengthen the understanding, management, and regulatory oversight of biofilms across the industrial processing sector. We aim to bridge gaps between science, industry, and regulators by promoting standardised methodologies for detecting, preventing, and removing biofilms. The Alliance also prioritises raising awareness and training across the industrial processing sector, equipping stakeholders with the knowledge and tools required to manage biofilms effectively, uphold safety standards and register novel treatments.

 

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