We are a newly built company that produces dried algae biomass. We use a spray dryer to dry the slurry into fine powder. The temperature set is 200 degree celcius. The production area and the spray dryer as well as other equipment are cleaned with water and sodium hypochlorite. 70% ethanol is used as disinfectant.
The TPC results are out of specification and keep on increasing. Limit is <1 x10^7.
The slurry was tested before each spray dry and the result we found was around 1x 10^4. However, once it is spray dried, the powder contains more than 1 x 10^7 cfu/g. We did swabs the spray dryer parts and the swab results were >10cfu/10cm2.
I need to decide on the corrective actions and please advice on how to find the source of contamination. I need your help to guide me on this issues ( what should I do? and any solution that can be done to encounter this issue)
I really appreciate your help.