Cleaning Methodologies A Discussion on the Various ways to most effectively clean Interior & Exterior Surfaces. Internal

Transcription

1 Cleaning Methodologies A Discussion on the Various ways to most effectively clean Interior & Exterior Surfaces Internal 1

2 Cleaning Methodologies Categories of Cleaning Basically two overall approaches to cleaning: Internal Process Cleaning External Process Cleaning Internal 2

3 Cleaning Methodologies Categories of Cleaning CIP Clean in Place Foam Cleaning COP Cleaning Manual/Automated Spray Cleaning High Pressure/Medium Pressure Parts Washers Batch Conveyorized Vats / Totes / Bins Cabinet Washers Fogging Manual Hand Detailing/Scrubbing Internal 3

4 What Do Manual, Cabinet Washers, COP and CIP Have in Common? T ime A ction C hemistry / Concentration T emperature W ater I ndividual N ature of Soil S urface to be cleaned Cleaning requires both physical and chemical processes. Action Concentration /Chemistry Time Temperature

5 TACTWINS Time Time elapsed before cleaning is performed Time spent cleaning Time until cleaned equipment is reused Action Kinetic Energy Flow (pipelines) / Cascade / Impingement Flow rate / pressure Contact required to assure effectiveness Chemistry / Concentration Selection of proper chemistry for the soil conditions Control and monitoring of concentration Grouping strategies ie: base before acid, acid before base Temperature What temp. works best? Higher is not always better Equipment / drain limitations Has the optimum temperature for cleaning been defined?

6 TACTWINS Water What type of water will be used If potable water, hardness could have effect on cleaner Temperature / availability of water to be used for cleaning Individual Has the individual been trained on cleaning? Do they understand the cleaning process? Nature of Soil What is the type of soil protein / fat / mineral / solids / allergens? How is the soil deposited on the surface to be cleaned? How long does the product sit before a cleaning? Test worst case Surface to be cleaned Stainless / glass / plastic / other? What is the surface finish? Is it built for CIP?

7 Clean-In-Place Designing for Food Safety

8 Purpose of CIP: Provides for: Safe Foods Quality Foods CIP - Part of the Process Effective Cleaning Efficient Cleaning Clean and Sanitized Process Equipment Regulatory Compliance

9 Industry Challenges: 10) Process Equipment Design 9) Employee Turnover / Training 8) Water / Effluent / Environmental Issues 7) Operating Costs energy / chemical 6) Allergens 5) Production Time 4) Personnel Safety 3) Difficult Soils 2) Microbial Growth 1) Product Quality / Food Safety

10 What is the most important component in a CIP system?

11 What is the most important design criteria for a CIP system?

12 What is CIP-able? Sanitary design criteria - Materials / Design / Fabrication: 304 / 316L SS, or similar corrosion resistance Smooth finish w/o cracks or crevices (32 microinch Ra) No threads Radiused corners Proper pitch Suitable / approved / compatible elastomers and plastics Free draining no water pooling 3-A / AMI / EHEDG or similar design & fabrication standards. 5 fps minimum flow rate or higher Sanitary welds (AWS D18) Complete spray coverage No dead legs > 2 pipe diameters CIP System should meet 3A standards for Dairy applications.

13 Basic CIP Steps 1) Preparation Critical Equipment connections / set-up Pre-rinse heavy soils / solids 2) CIP Pre-Rinse Step Water the best cleaning agent Remove easily rinsed soils Temper for fats / oils / greases Product Recovery? 3) Wash Step Detergent / concentration Time / Temp Flow / Pressure 4) Post-Rinse Step Rinse to ph setpoint / conductivity Water recovery 5) Sanitize Step Concentration Contact Time Temp

14 CIP Applications Process equipment includes: Product Storage Tanks Over-the-Road Tankers Mixers & Blenders. Processing Vessels. Spray Dryers, Fluid Bed dryers, Coating Equipment Product Transfer Pipelines. Variety of other specialty equipment.

15 CIP SYSTEM TYPES Single Use Re-Use 3 Tank Single-Use Rinse Recovery Ultra-Flow CIP

16 Single-Use CIP Single-Use CIP systems recirculate a fixed volume of CIP solutions and discharge them to drain after the wash cycle. All rinses are pumped in a single pass to drain. They are best suited to critical cleaning applications and high soil conditions where detergents cannot be re-used in subsequent cycles. Advantages Multiple cleaning regimens Minimize thermal shock Minimize potential cross contamination Smaller tank and footprint Lower cost CIP system Detergent concentrations can be metered Disadvantages Longer heat-up times Higher chemical usage Higher water usage Higher steam usage

17 Rinse-Recovery CIP Rinse-Recovery CIP systems recirculate a fresh volume of CIP wash solution and save it for pre-rinse of subsequent CIP cycles. Post-rinse water may also be saved to reduce water consumption. They are well suited to critical cleaning applications and high soil conditions where detergents cannot be re-used in subsequent cycles, and when water usage must be reduced. Advantages Multiple cleaning regimens Minimize potential cross contamination vs. re-use Reduce water usage vs. single-use CIP systems Improved pre-rinse vs. single-use Disadvantages Longer heat-up times than re-use Higher chemical usage vs. re-use CIP Higher steam usage vs. re-use CIP

18 Re-Use CIP Re-Use CIP systems save wash solutions for re-use in subsequent CIP wash cycles. Acid and post-rinse solutions may also be saved in separate recovery tanks. They are well suited for low to moderate soil conditions where detergents can be re-used in subsequent cycles, and total cost of operation must be minimized. Advantages Reduce chemical cost Reduce water usage Reduce steam usage Simple to operate Shorter heating times and CIP cycles Increase production time Disadvantages Higher potential for cross contamination Limited cleaning regimens Detergent concentrations must be verified frequently CIP tanks must be cleaned and recharged Higher initial cost Larger footprint

19 Single-Use Eductor CIP Single-Use eductor CIP systems recirculate a fixed volume of CIP solutions and discharge them to drain after the wash cycle. The systems use a single pump for both CIP supply and vacuum return flow, eliminating return pumps. Rinses are recirculated and discharged to drain. They are best suited to tank CIP in critical cleaning applications and moderate to high soil conditions. Advantages Multiple cleaning regimens Minimize thermal shock Eliminate cross contamination Smallest tank and footprint Detergent concentrations can be metered Eliminate return pumps Minimize water pooling Disadvantages Higher chemical usage on line circuits vs. re-use Higher water usage on line circuits vs. re-use Higher steam usage on line circuits Limited applications flow rates and temperature must be verified

20 Recirculation Methods Six methods of returning CIP solutions: Gravity return (limited applications) Centrifugal Return pump Eductor w/ motive tank and pump Eductor assisted return Ultra-Flow CIP (Single-use eductor) Liquid Ring return pumps

21 Liquid Ring Return Pumps Liquid Ring return pumps are becoming more common. They can be applied to wide variety of cleaning applications and can resolve many hydraulic problems in CIP returns. The pumps are very close tolerance, and must be protected from solids that could damage them. Advantages Multiple applications Eliminates air relief valves Self priming (after initial pump flooding) Good evacuation of tanks Return from multiple locations Low NPSH requirements Disadvantages High cost pumps (2-3 x) Close tolerance requires special care for maintenance Poor pump efficiency Limited pump flow ranges available Pump casing must be flooded or filled initially

22 Educator Return CIP (motive tank) Eductor Re-use CIP systems were quite common several years ago. They utilize a motive pump and tank on the CIP skid to create a vacuum, which sucks the CIP solutions back to the CIP system. Due to improvements in other methods of CIP return, these systems are rarely implemented in current applications. Advantages Good evacuation of tanks Eliminates multiple return pumps Eliminates air relief valves Self priming Return from multiple locations Disadvantages Requires large return lines High initial equipment cost Limited temperature ranges Motive tanks are unsanitary Hydraulic problems are masked

23 Fixed Spray Devices

24 Rotary Spray Devices Sani-Matic Conveyor Spray Image courtesy of Lechler Image courtesy of Alfa-Laval Images courtesy of Alfa-Laval

25 CIP CONTROLS: Controls The best designed CIP system will fail or run inefficiently / ineffectively if not controlled properly. The CIP control system opens / closes valves, runs pumps, performs controls functions, and has setpoints to ensure proper CIP cycle operation. Plant operators must be able to do the following:

26 CIP CONTROLS: Controls Select individual programs for each CIP circuit Monitor the CIP status Receive alarms in the event of malfunction Take corrective action Verify CIP performance Make changes if necessary (password protected)

27 Types of CIP Controls Rotary drums / cam timers - obsolete Electronic sequencers - obsolete Manual CIP control limited in applications Programmable Logic Controller (PLC) Provides control of CIP including cleaning recipe storage Utilize pin charts for program sequence steps. Temperature, flow and chemical control/monitoring and alarm functions. Can be interfaced to process for interlocks and control of process valves and pumps. PC based controls PC based units available providing report generation and data archiving capability Integrated microprocessors Integrated microprocessors are computers designed for only one function CIP. User friendly, but limited in flexibility. Operator Interface (HMI) Provides operator means to select, monitor, and initiate CIP operations.

28 Recordkeeping Recording of Wash Cycle- for record of wash time and return temp. as a minimum, optional: supply flow, conductivity / chemical volume, and supply pressure Circular Chart recorder provides hard copy for record on time based paper chart. Recorders utilize pens having markers or thermal printer. Strip chart recorder-same functions as circular chart recorder but data plotted on rolled paper and usually easier to decipher. SCADA-PC based system running a data acquisition software. SCADA systems archive data onto magnetic storage media allowing for easy retrieval of data. Data may be viewed or printed both numerically or graphically.

29 Detergent Injection How to Dispense Timed - Continuous Pulsed Conductivity Controlled Metered Recommended Injection Locations Return Manifold Suction Manifold (Sanitizer) CIP Tank / Fresh Water Tank Chemical Loop Cleaners, Additives, Sanitizers

30 Recommended CIP Solution Strength/Temperature EQUIPMENT Bulk Trucks Bulk Tankers Raw Storage Lines Raw Milk Lines H.T.S.T. (Conven.) Alkali Wash Acid Wash Finished Product Lines Finished Product Tanks CLEANING CYCLE TEMP 5 10 Min 10 Min 15 Min Min 60 Min 30 Min ALKALINITY PER CENT ph TEMPERATURE( DEGREES F) Min/Spur Min

31 39 CIP Cleaning DeLaval Product Suggestions

32 40 CIP Cleaning DeLaval Product Suggestions

33 FOAM CLEANING Pioneered for cleaning food processing facilities where product handled in the Open vs. being enclosed in tanks and lines. An extension of the concept of spray cleaning but air is mixed with chemical solution to turn it into a detergent foam Benefits? Equipment Coverage Adherence to Surfaces Easy to tell where detergent has or has not been applied Can be applied to hard to reach surfaces Downsides? Leave on surfaces too long/too little time Easy to overuse Inadequate foam consistency Cold or Hot Water? 41

34 FOAM CLEANING Best way to Foam? Top to Bottom? Bottom to Top? What about Foam Quality? Wet or Dry? What works best? How long to leave on surface? Minutes Best Approach to Rinsing? Rinse Vertical surfaces sooner as they shed foam faster than horizontal surfaces Rinse with boosted pressure from the bottom up 42

35 FOAM CLEANING TECHNIQUES Cover all Electrical Equipment before Foaming! Wear Proper PPE (Safety Gear) Perform a thorough pre-rinse of equipment surfaces to remove heavy soils prior to foam application Cover all areas to be cleaned tops, sides and bottoms Foam small sections at a time to allow for timely rinsing Cover all vertical surfaces with a thin layer of foam not more than ½ inch thick. 43

36 FOAM CLEANING TECHNIQUES Prepare foam solutions as prescribed in SSOP procedures (review with chemical supply representative) Rinse foam before it dries 10 Minutes on Vertical Surfaces minutes on horizontal surfaces such as belts, tables, floors, etc. Rinse with boosted/high pressure water from the bottom up Why? 44

37 45 Foam Cleaning DeLaval Suggested Products

38 46 Foam Cleaning DeLaval Suggested Products

39 47 COP Cleaning

40 COP Cleaning Tips on Improving the Utilization of your COP Tank 1. Don t Overload the Tank!!! 2. Check chemical concentration with a test kit 3. At conclusion of wash step, don t immediately open the drain valve. 4. Open up the cold water supply instead and let overflow top of tank 5. Why? Allow soil/scum floating on top of wash solution to be flushed to drain without settling on cleaned parts!! 6. Cool water rinse helps prevent mineral film buildup on parts and components 7. Run and Acid wash cycle at least monthly to maintain surfaces free of hard water film buildup 48

41 Recommended COP Solution Strength/Temperature EQUIPMENT C.O.P. Tanks (General usage for parts) CLEANING CYCLE TEMP ALKALINITY PER CENT Min TEMPERATURE( DEGREES F)

42 Spray Cleaning High Pressure Low volume Medium/Booster Pressure High Volume 1. Why is high pressure cleaning so often the preferred method for removing food soils? 2. What is meant by High Pressure Cleaning? 3. Is it the most efficient way to achieve your cleaning objectives? 4. Have you ever considered Booster or medium pressure rinsing with higher water volume utilization? 50

43 51 Spray Cleaning DeLaval Suggested Products

44 Fogging What is This Approach? 1. Essentially using plant compressed air to atomize chemical/water solution into vapor fog 2. Primarily used to broadcast a chemical sanitizer or insecticide into difficult to reach areas in the plant process environment. 3. Also a surprisingly effective way to clean smokehouses/alkar ovens 4. A fogging device is required 5. Can use portable or built in fogging systems 6. Can it be dangerous? Sure turn on fogger and run like hell! 7. Always follow proper fogging procedures in SSOP 52

45 Fogging What is This Approach? 1. What Sanitizers are best to Use? 2. Quats, PAA, CLO2 3. Insecticides 4. Why not Chlorine? 53

46 54 Fogging DeLaval Suggested Products

47 MUCHAS GRACIAS/THANK YOU PREGUNTAS/QUESTIONS?