Novel apparatus and methods to improve infection control in facilities

Abstract

An Apparatus that generates onsite three antimicrobial solutions by electrolyzing a dilute brine solution. At least one of the generated solutions can be used to dissolve protein, emulsify oils and fats making it an effective general purpose cleaner. A second solution can be used as a non-corrosive, fast active general purpose sanitizer and a third solution can be used as a high level disinfectant, capable of killing all microorganism, including MRSA (methicillin resistant staphylococcus aureaus ), C. diff ( clostridium difficle ), VRE (vancomycin resistant enterococci) and acinetobactor baumannii . The onsite generated antimicrobial solutions reduce the occurrence of infectious diseases in hospitals, other human or animal health care settings, cruise-ships, hotels and other facilities whereas there is a higher risk of spreading infectious diseases.

1 . An apparatus for the onsite generation of antimicrobial solutions by electrolysis of a dilute brine solution comprising: an apparatus having two or more electrolysis cells each consisting of an outer cylindrical electrode separated from an inner cylindrical electrode by a cylindrical ion-selective membrane arranged coaxially one within the other to create a cathode chamber and an anode chamber; a pair of end pieces to each of said cells where a space between said inner cylindrical electrode and said cylindrical ion-selective membrane and a space between the ion-selective membrane and the outer cylindrical electrode defines anode and cathode chambers; wherein one of said electrodes functions as an anode and the other electrode functions as a cathode to generate three different antimicrobial solutions utilizing different volumes and flow-patterns, applying different voltage and current on the electrolysis cells as well varying the conductivity of the diluted brine solution pumped through said electrolysis cells. 
     
     
         2 . The apparatus of  claim 1 , wherein the antimicrobial solutions are during the onsite generation are checked for pH, Temperature and ORP before the antimicrobial solutions are temporarily stored in dedicated storage containers located at the rear of the apparatus always filled and ready to be dispensed on demand to dedicated dispensers. 
     
     
         3 . The apparatus of  claim 2  including a Programmable Logic Controller (PLC) receives signals from several level-switches in the solution storage tanks, so that the PLC prioritize what antimicrobial solution needs to be generated. 
     
     
         4 . The apparatus of  claim 2  wherein said measurement of pH, Temperature and ORP is adjusted to ensure that the dispensed antimicrobial solutions from the solution storage tanks meet a predefined EPA specification wherein properties are adjusted by controlling the voltage and current applied to the electrolysis cells, the flow and conductivity of the electrolyte and the flow pattern of the electrolyte. 
     
     
         5 . The apparatus of  claim 1 , wherein the generation of antimicrobial solutions is monitored from a remote server that periodically reports and alarms the operator enabling the operator to remotely start, stop or adjust settings wherein an operator may remotely service, maintain and upgrade the apparatus as well invoice the user or owner of the apparatus for services provided and antimicrobial solutions used. 
     
     
         6 . The apparatus of  claim 6  including a Human Face Interface (HMI) to periodically send an e-mail containing all production data to a remote server for data storage whereas said HMI sends an e-mail to address any amoralities is said production data. 
     
     
         7 . The apparatus of  claim 1 , wherein the active ingredient of the on-site generated antimicrobial cleaning solution consists of approximately 150 to 200 ppm Sodium Hydroxide (NAOH) and said cleaning solution has a conductivity between 1000 and 5000 us, an ORP between −500 and −900 mV and a pH between 11 and 13. 
     
     
         8 . The apparatus of  claim 7 , wherein an antimicrobial efficacy of said cleaning solution is at least log 4 wherein the cleaning solutions is classified as a low level disinfectant using EPA standards and can be registered as sanitizer by the EPA. 
     
     
         9 . The apparatus of  claim 1  wherein each said cleaning solution includes a food grade dye. 
     
     
         10 . The apparatus of  claim 1 , wherein the active ingredient of the on-site generated sanitizing solution consists of Hypochlorous Acid (HOCL) and wherein the sanitizing solution has a conductivity between 1000 and 3000 uS, an ORP between 800 and 1200 mV, a pH between 4.5 and 6.5 and approximately 250 ppm Free Available Chlorine (FAC). 
     
     
         11 . The apparatus of  claim 10  wherein the antimicrobial efficacy of the sanitizing solution is at least log 4 whereby the sanitizing solution is classified as a low level disinfectant using EPA standards and can be registered as sanitizer by the EPA. 
     
     
         12 . The apparatus of  claim 1  including a small amount of concentrated citric acid solution added to said solution to create a distinctive fragrance. 
     
     
         13 . The apparatus of  claim 1 , wherein the active ingredient of the on-site generated disinfectant consists of Hypochlorous Acid (HOCL) and wherein the on-site generated disinfectant has a conductivity between 2000 and 6000 uS, an ORP between 800 and 1200 mV, a pH between 6 and 7 and approximately 460 ppm Free Available Chlorine (FAC). 
     
     
         14 . The apparatus of  claim 13 , wherein the antimicrobial efficacy of the on-site generated disinfectant is at least log 6 wherein the solution is classified as a high level disinfectant using EPA standards and can be registered as sterilizer or sporicide by the EPA. 
     
     
         15 . The apparatus of  claim 1 , wherein the brine solution is a saturated brine prepared in a brine tank using purified granular Sodium Chloride saturated in purified softened or reverse osmoses water by means of gravity wherein the saturated brine solution is pumped from the bottom of the brine tank utilizing a peristaltic pump and diluted with purified softened water or reverse osmoses water to achieve a predetermined conductivity in the electrolyte prior to electrolysis of the diluted brine solution. 
     
     
         16 . The apparatus of  claim 15  wherein conductivity is set by a Programmable Logic Controller (PLC) and the conductivity of the electrolyte controls the speed of the peristaltic pump to dose a saturated brine solution in the RO/softened water. 
     
     
         17 . The apparatus of  claim 1 , wherein the stored antimicrobial solutions are delivered on demand to a nearby or remote dispensing station whereby buckets, bottles and containers can be filled by opening a faucet or valve. 
     
     
         18 . The apparatus of  claim 1 , wherein a food grade dye as a powder or liquid is added to a dedicated storage tank filled with reverse osmoses water or softened water and whereas a small fraction of the concentrated dye-solution is added periodically to the cleaning solution using a peristaltic pump to give the cleaning solution a distinct color. 
     
     
         19 . The apparatus of  claim 1 , wherein a food grade citric acid powder or concentrate is added to a dedicated storage tank filled with reverse osmoses water or softened water and whereas a fraction of the concentrated citric acid solution is added to the sanitizing agent using a peristaltic pump to give the sanitizing agent a distinct fragrance. 
     
     
         20 . The apparatus of  claim 1 , wherein a neutralizing agent is added to a dedicated storage tank filled with solutions that did not meet the specifications and thus drained from the storage tanks as waste and/or directly disposed as waste from the electrolytic cells during electrolysis. 
     
     
         21 . The apparatus of  claim 20 , wherein no acidic, nor any alkaline solutions are drained directly into the drain or sewage system to prevent corrosion, but wherein all rejected solutions are neutralized by flowing through a neutralizer tanks filled with coral, lime stone or another neutralizing media. 
     
     
         22 . The apparatus of  claim 1 , wherein outer dimensions of the apparatus does not exceed 90 inch height, 48 inch width and 48 inch depth, weight of the apparatus does not exceed 1000 lbs, and the apparatus utilizes a 208-240 vAC single phase power source at a maximum load of 30 A.