Plasma Fresh: Cutting-Edge Conveyor Belt Sanitisation – A Smarter Way to Clean Food Production Lines

Challenge

Plasma Fresh developed an innovative system using cold plasma to continuously decontaminate conveyor belts in food production. This approach reduces harmful microbes while lowering reliance on traditional cleaning chemicals.

Along with his professor and a fellow student, Co-founder Dr Aaron Dickenson identified the need for this solution during his PhD research. His expertise in plasma technology for surface cleaning led him to identify a need for a system that mounts onto conveyor belts, delivering consistent microbial reduction throughout operation.

Solution

To bring this idea to life, Plasma Fresh needed to develop a lab-scale prototype and create a way to integrate the technology into existing food production lines. Plasma Fresh joined the DeepTech Catalyst Bio (formerly known as Biotechnology Business Incubation Centre or Bio BIC) at Daresbury Laboratory to refine their system to make it both practical and scalable.

The DeepTech Catalyst Bio gave Plasma Fresh access to state-of-the-art lab facilities, 3D printing technology, and expert support. This allowed them to test and refine their prototypes quickly and affordably.

Benefits

By using cold plasma, Plasma Fresh’s system not only improves decontamination efficiency but also reduces cleaning costs by 50%, saving an estimated £250k per production line.

Plasma Fresh carried out trials at Campden BRI, the technology was tested against food hygiene standard EN 13697, ensuring it meets strict safety requirements. The aim of the trials was to confirm that the system effectively breaks down allergens, which could significantly reduce fluid use in food production, enhancing safety, lowering maintenance costs, and reducing chemical risks. The team has also patented a scalable design that increases plasma coverage over larger areas.

Since joining the DeepTech Catalyst Bio, Plasma Fresh has grown from two to five permanent staff, with plans to expand further. The team also have a commercial prototype ready, and full-scale product development was set to begin in Q2 2025.