{"id":5964,"date":"2025-10-13T06:55:00","date_gmt":"2025-10-13T11:55:00","guid":{"rendered":"https:\/\/www.oxidationtech.com\/blog\/?p=5964"},"modified":"2025-10-11T11:09:49","modified_gmt":"2025-10-11T16:09:49","slug":"reviving-an-idle-ozone-system-for-a-meat-processing-plant","status":"publish","type":"post","link":"https:\/\/www.oxidationtech.com\/blog\/reviving-an-idle-ozone-system-for-a-meat-processing-plant\/","title":{"rendered":"Reviving an Idle Ozone System for a Meat Processing Plant"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">At Oxidation Technologies, we specialize in <a href=\"https:\/\/www.oxidationtech.com\/services\/repair.html\">servicing any ozone equipment in any condition <\/a>\u2014 even when they\u2019ve been sitting idle for months or years. Recently, we had the opportunity to help a meat processing plant in Sioux Center get their ozone system back up and running after it had been abandoned.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This particular ozone system was built by Ozone Solutions, Inc.\u00a0 and installed at a <a href=\"https:\/\/www.oxidationtech.com\/applications\/agri-food\/pork-processing-with-ozone.html\">pork processing plant <\/a>for use in a carcass chiller.\u00a0 This system was installed with the intention to dissolve ozone in chilled water sprayed on carcasses in the cooler.\u00a0 This provides an antimicrobial intervention for the carcasses through the ozone water sprayed on the carcasses while cooling carcasses faster due to chilled and eliminating any potential shrink.\u00a0 The overall application was good, however the ozone system was never able to operate due to start-up issues that could not be overcome by the equipment manufacturer or the plant personnel.\u00a0<\/p>\n\n\n\n<figure class=\"wp-block-image size-large is-resized\"><a href=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-Solutions-waterzone-system-at-pork-plant-repair.png\"><img loading=\"lazy\" decoding=\"async\" width=\"854\" height=\"1024\" src=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-Solutions-waterzone-system-at-pork-plant-repair-854x1024.png\" alt=\"Ozone water system for pork processing\" class=\"wp-image-5972\" style=\"width:414px;height:auto\" srcset=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-Solutions-waterzone-system-at-pork-plant-repair-854x1024.png 854w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-Solutions-waterzone-system-at-pork-plant-repair-250x300.png 250w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-Solutions-waterzone-system-at-pork-plant-repair-768x921.png 768w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-Solutions-waterzone-system-at-pork-plant-repair.png 900w\" sizes=\"auto, (max-width: 854px) 100vw, 854px\" \/><\/a><figcaption class=\"wp-element-caption\">Ozone solutions ozone water system to be used for pork processing.<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large is-resized\"><a href=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-solutions-waterzone-system-to-be-repaired-at-pork-plant.png\"><img loading=\"lazy\" decoding=\"async\" width=\"683\" height=\"1024\" src=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-solutions-waterzone-system-to-be-repaired-at-pork-plant-683x1024.png\" alt=\"Ozone water system for pork processing.  Provides ozone in water for antimicribial intervention.\" class=\"wp-image-5966\" style=\"width:278px;height:auto\" srcset=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-solutions-waterzone-system-to-be-repaired-at-pork-plant-683x1024.png 683w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-solutions-waterzone-system-to-be-repaired-at-pork-plant-200x300.png 200w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-solutions-waterzone-system-to-be-repaired-at-pork-plant-768x1152.png 768w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Ozone-solutions-waterzone-system-to-be-repaired-at-pork-plant.png 800w\" sizes=\"auto, (max-width: 683px) 100vw, 683px\" \/><\/a><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">When we first arrived on site, our goal was simple: evaluate the existing system, get it as close to startup-ready as possible, and give the customer a clear path forward.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Our Initial Visit<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">During our first few hours on site, we started the system, checked each component, and identified several key issues that needed to be corrected before handing over operation to the customer. The good news? The installation, water plumbing, and points of ozone use all looked very good \u2014 the foundation for a reliable system was already there.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Here\u2019s what we found and planned:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Replace expired ozone sensors to ensure accurate monitoring<\/li>\n\n\n\n<li>Install a new <a href=\"https:\/\/www.oxidationtech.com\/av88-membrane-cap.html\">flat cap membrane<\/a> and <a href=\"https:\/\/www.oxidationtech.com\/catalog\/product\/view\/id\/5186\/s\/av88-electrolyte\/\">electrolyte<\/a> for the Thermo Scientific dissolved ozone sensor<\/li>\n\n\n\n<li>Install a new <a href=\"https:\/\/www.oxidationtech.com\/sm-3.html\">SM-3 ozone leak sensor<\/a> inside the equipment enclosure<\/li>\n\n\n\n<li>Add a remote ozone sensor for the <a href=\"https:\/\/www.oxidationtech.com\/f12-d-integral-sensor-holder.html\">ATI F12D ambient monitor<\/a><\/li>\n\n\n\n<li>Repair a terminal clip for one plasma block electrode<\/li>\n\n\n\n<li>Reconfigure the ozone flow control valve (it was plumbed incorrectly and needed to be moved downstream of the ozone generator)<\/li>\n\n\n\n<li>Test and bump-check the remote leak sensors to verify that they will shut off ozone production if ambient levels rise above safe thresholds<\/li>\n\n\n\n<li>Improve cabinet drainage by drilling a small drain hole<\/li>\n\n\n\n<li>Address PLC programming issues \u2014 the current PLC was not properly controlling ozone ON\/OFF cycles to maintain the dissolved ozone setpoint.<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-full is-resized\"><a href=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-wiring.png\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"969\" src=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-wiring.png\" alt=\"AV88 Dissolved ozone meter to measure ozone in water for pork processing.\" class=\"wp-image-5967\" style=\"width:438px;height:auto\" srcset=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-wiring.png 800w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-wiring-248x300.png 248w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-wiring-768x930.png 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/a><figcaption class=\"wp-element-caption\">AV88 Dissolved ozone sensor was wired direct to the ozone generator, by-passing the PLC due to the failure of the PLC to properly control ozone levels.<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-full is-resized\"><a href=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-Ozone-Meter-at-Pork-Processing-Plant.png\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"1022\" src=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-Ozone-Meter-at-Pork-Processing-Plant.png\" alt=\"F12 Ozone meter for human safety in a pork processing plant\" class=\"wp-image-5968\" style=\"width:438px;height:auto\" srcset=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-Ozone-Meter-at-Pork-Processing-Plant.png 800w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-Ozone-Meter-at-Pork-Processing-Plant-235x300.png 235w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-Ozone-Meter-at-Pork-Processing-Plant-768x981.png 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/a><figcaption class=\"wp-element-caption\">The <a href=\"https:\/\/www.oxidationtech.com\/f12-d-integral-sensor-holder.html\">F12 ozone safety meter<\/a> required a new sensor.  After the sensor was replaced wiring issues were resolved to allow the sensor to operate properly.<\/figcaption><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">To solve the PLC issue, we asked the plant if they could download the program and email us a copy. This would allow us to troubleshoot and find the best long-term solution. In the meantime, we planned to wire in a manual ozone ON\/OFF switch, integrate relays for generator control, and tie the dissolved ozone monitor directly into the system for closed-loop control \u2014 ensuring safe, consistent ozone levels even before the PLC programming is updated.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full is-resized\"><a href=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-ozone-meter-at-pork-plant.png\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"794\" src=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-ozone-meter-at-pork-plant.png\" alt=\"F12 ozone meter used to ensure human safety in the pork carcass chiller\" class=\"wp-image-5970\" style=\"width:405px;height:auto\" srcset=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-ozone-meter-at-pork-plant.png 800w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-ozone-meter-at-pork-plant-300x298.png 300w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-ozone-meter-at-pork-plant-150x150.png 150w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/F12-ozone-meter-at-pork-plant-768x762.png 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/a><figcaption class=\"wp-element-caption\">The<a href=\"https:\/\/www.oxidationtech.com\/f12-d-integral-sensor-holder.html\"> F12 ozone sensor <\/a>is used to measure ozone in air to ensure human safety for workers that enter the cooler.<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-full is-resized\"><a href=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-in-use-in-pork-plant.png\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"752\" src=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-in-use-in-pork-plant.png\" alt=\"AV88 dissolved ozone meter measures ozone in water for a pork processing plant.\" class=\"wp-image-5971\" style=\"width:407px;height:auto\" srcset=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-in-use-in-pork-plant.png 800w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-in-use-in-pork-plant-300x282.png 300w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/AV88-dissolved-ozone-sensor-in-use-in-pork-plant-768x722.png 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/a><figcaption class=\"wp-element-caption\">The <a href=\"https:\/\/www.oxidationtech.com\/av88-ozone.html\">AV88<\/a> was used to measure ozone in water.  Ozone levels between 2-3 ppm were maintained by controlling the ozone generator directly from the AV88, by-passing the PLC.<\/figcaption><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\">Teamwork and Next Steps<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Our customer was eager to get the system running and fully supported our plan. They quickly coordinated internally so we could return for a second visit to finish the work, install the new components, and complete staff training.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">The Result<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">After our follow-up visit, the plant had:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A fully operational ozone system \u2014 producing and controlling ozone reliably<\/li>\n\n\n\n<li>Safety systems tested and verified \u2014 leak sensors, alarms, and shutdown protocols all working<\/li>\n\n\n\n<li>Proper flow control and plumbing configuration \u2014 ensuring efficient ozone delivery<\/li>\n\n\n\n<li>A trained staff \u2014 ready to confidently operate and maintain the system going forward<\/li>\n\n\n\n<li>A service partner \u2014 Oxidation Technologies will continue to support them with remote diagnostics, replacement parts, and on-site service when needed<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">Today, this plant has an excellent, reliable ozone system that is helping them maintain high sanitation standards while saving time and resources.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full is-resized\"><a href=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Pork-carcasses-hanging-in-spray-cooler-scaled-1.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"800\" src=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Pork-carcasses-hanging-in-spray-cooler-scaled-1.jpg\" alt=\"Hanging pork carcasses in cooler, ozone water is sprayed on the pork carcasses during chilling.\" class=\"wp-image-5965\" style=\"width:538px;height:auto\" srcset=\"https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Pork-carcasses-hanging-in-spray-cooler-scaled-1.jpg 600w, https:\/\/www.oxidationtech.com\/blog\/wp-content\/uploads\/2025\/10\/Pork-carcasses-hanging-in-spray-cooler-scaled-1-225x300.jpg 225w\" sizes=\"auto, (max-width: 600px) 100vw, 600px\" \/><\/a><figcaption class=\"wp-element-caption\"><a href=\"https:\/\/www.oxidationtech.com\/applications\/agri-food\/pork-processing-with-ozone.html\">Pork carcasses<\/a> hanging in cooler.  Water containing ozone levels of 2-3 ppm are sprayed on the carcasses during cooling as an antimicrobial intervention during cooling with chilled water.<\/figcaption><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\">Your Ozone System Can Run Like This Too<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Do you have an ozone system that\u2019s been sitting idle or not performing as designed? Don\u2019t let that investment go to waste. Our team at Oxidation Technologies can inspect, troubleshoot, and restore your system \u2014 and train your staff to keep it running safely and effectively.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><a href=\"https:\/\/www.oxidationtech.com\/contact\/\">Contact us today to schedule a service visit and bring your ozone system back to life.<\/a><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"excerpt":{"rendered":"<p>At Oxidation Technologies, we specialize in servicing any ozone equipment in any condition \u2014 even when they\u2019ve been sitting idle for months or years. Recently, [&hellip;]<\/p>\n","protected":false},"author":10,"featured_media":5972,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"aside","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[1367],"tags":[124,1432,1428,1257],"class_list":["post-5964","post","type-post","status-publish","format-aside","has-post-thumbnail","hentry","category-ozone-applications","tag-ozone-food-processing","tag-ozone-pork-antimicrobial","tag-ozone-pork-processing","tag-ozone-water-systems","post_format-post-format-aside"],"_links":{"self":[{"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/posts\/5964","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/users\/10"}],"replies":[{"embeddable":true,"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/comments?post=5964"}],"version-history":[{"count":3,"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/posts\/5964\/revisions"}],"predecessor-version":[{"id":5975,"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/posts\/5964\/revisions\/5975"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/media\/5972"}],"wp:attachment":[{"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/media?parent=5964"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/categories?post=5964"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.oxidationtech.com\/blog\/wp-json\/wp\/v2\/tags?post=5964"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}