CIP for Hot Surfaces. Dairy Australia / NCDEA webinar. Robert Ellis B Sc(hons) MRACI CChem. Technical Support Coordinator Food & Beverage Division

Transcription

1 Dairy Australia / NCDEA webinar CIP for Hot Surfaces Webinar August 1 st 2014 Robert Ellis B Sc(hons) MRACI CChem Technical Support Coordinator Food & Beverage Division

2 Content Why clean at all? The Equipment being cleaned Types of detergents CIP fundamentals CIP program options Common mistakes with CIP Validation

3 Why clean at all? Definition: a soil is something that is not where it belongs. Dairy type soils, including milkstone usually contain combinations of, or all of the following: Proteins Fats Carbohydrates Minerals

4 Why clean at all? The main purposes for cleaning are to: Sanitise Achieve Plant Efficiencies If surfaces are not clean, sanitation is a waste of time and money. Heating and cooling efficiency Removal of burnt on soils from the heating surfaces. Milkstone has 1 / 20 th of the heat transfer rate of stainless steel. e.g. reduced efficiency of UHT heat exchanger

5 Why clean at all? The longer the soil remains, removal is more difficult. Heated surfaces have the most difficult to remove soils Scale is put down in layers, thus removal can be similar. Heavy duty regimes are usually employed. Soils & scale provide homes for microbes - spoilage organisms.

6 The Soils Soils left on heated surfaces are different from those left on cold surfaces Proteins Denature with temperature Develop cross links which reduce solubility Fats Burn onto surfaces Combine with other soil types Carbohydrates Carbonise and become less soluble Minerals Precipitate out of solution at high temperatures

7 The Equipment Soils left on heated surfaces can vary with the type of equipment used Evaporators Pasteurisers UHT / Sterilisers Holding tubes

8 The Equipment Evaporator Key considerations The temperature at which the product was run, the higher the temperature the harder it is to remove the soil The % solids coming off the final effect, the higher the solids the tougher the soil How long the evaporator ran, 10 hours, 19 hours or up to 50 hours

9 The Equipment UHT sterilisers and Pasteurisers Key considerations The temperature profile within the system e.g. Holding tubes 140C e.g. Heat exchange 80C The product type Skin vs Full Cream vs Flavoured milk Length of run Full clean Intermediate cleans Flavour changes

10 Detergent Types Common cleaning chemicals Alkali Caustic Detergents remove: Fats Oils Carbohydrates Proteins Acids Acid Detergents remove: Minerals Milkstone

11 Detergent Types Alkaline detergent types Raw Caustic (Sodium Hydroxide) Advantages Low cost commodity Disadvantages Poor soil removal/penetration Increased CIP time High impact on waste treatment Have to use at high levels for any performance

12 Detergent Types Alkaline detergent types Fully built alkaline detergents containing Surfactants and Wetting Agents Chelating Agents Emulsifiers e.g. Glissen, Avoid, Enviro CIP Advantages Better for soil removal/penetration Decreased CIP time Reduced caustic levels required Reduced impact on waste treatment Disadvantages Additional cost of cleaning chemicals

13 Detergent Types Alkaline detergent types Additive program with bulk Caustic Mix additives with caustic on site e.g. Duplex, Stabilon CIP Advantages Better for cost / efficiency ratio Provide fit for purpose on site formulated detergents for different areas throughout the process area. Decreased CIP time Reduced caustic levels required Reduced impact on waste treatment Disadvantages Some additional cost of chemicals (cf commodity only) Additional requirements for bulk storage/mixing equipment

14 Detergent Types Acid detergent types Acids can be use as raw acids or blended. New technology products include wetting agents and surfactants for improved cleaning with reduced concentrations. Phosphoric Hydrochloric Sulphuric Nitric e.g. Formula 507A ensure inhibitor is used e.g. Acidblend H300 e.g. Envirocid Plus Sulfamic e.g. DS 88 Organic e.g. Ultrasil 73 inhibitor recommended e.g. Super Stonekleen

15 CIP Systems CIP fundamentals Four key factors for cleaning Time Temperature Concentration Cleaner and sanitiser Mechanical action Flow and pressure Concentration Mechanical Action Temperature Time

16 CIP Systems CIP fundamentals Factors affecting cleaning performance Water Quality Hardness, salts, iron, ph Soil Type Soil Condition Type of Equipment Effluent Constraints

17 CIP Systems Simple single use CIP system

18 CIP Systems Solution recovery system

19 CIP Systems CIP types Single Use All solutions used once. All used cleaning solutions go to drain Solution recovery Rinse solutions are reclaimed for pre-rinse at next CIP. Full Re-Use High soil load portions of cleaning solutions are dumped Low soil load solutions are reclaimed and adjusted for concentration Post rinses reclaimed for pre-rinsing at next CIP.

20 CIP Systems CIP types features and benefits Single Use Advantages Equipment cost is low Flexible CIP regimes to suit individual requirements Disadvantages High use of CIP chemicals High impact on waste treatment Solution (rinse) recovery Advantages Reduce water use (recovered rinses) Improve initial rinse (pre rinse) Disadvantages Some additional equipment cost cf single use High use of CIP chemicals High impact on waste treatment

21 CIP Systems CIP types features and benefits Full Re-Use Advantages Reduced CIP chemical cost (recovered cleaning solution)* Reduce water use (recovered rinses) Improve initial rinse (pre rinse) Lower impact on waste treatment* Disadvantages High initial equipment cost Reduced or no flexibility of chemical concentrations* * Full re-use systems are locked into a specific chemical concentration. Need to separate hot and cold surface CIP sets for cleaning cost and sustainability. e.g. CIP by equipment functionality not production area.

22 CIP Systems CIP line flow rates 1.5 m/s required for turbulent flow System restrictions Changing pipe sizes Changes in pipe sizes can restrict flow in the circuit. Identify dead legs Hard to clean Cleaning through pumps & valves Restrictions in flow Vertical rises & elbows CIP supply head pressure knowledge required

23 CIP Programs for heated surfaces Typical Full Clean Program 1. Rinse 2. Caustic clean 3. Rinse 4. Acid clean 5. Rinse 6. Sanitise (heat or chemical)

24 CIP Programs for heated surfaces Typical Intermediate Program 1. Rinse 2. Caustic clean 3. Rinse 4. Sanitise (heat or chemical) Usually performed in conjunction with the Full Clean program Alternating sequence depends on Soil type and condition Cleaning chemistry use of EDTA additives extends acid clean intervals

25 CIP Programs for heated surfaces Pre-treatment Programs 1. Rinse 2. Alkaline clean cycle a) Pre-treatment b) Caustic clean (override) 3. Rinse 4. Acid clean (cycle as required) 5. Rinse 6. Sanitise (heat or chemical)

26 CIP Programs for heated surfaces Why the different CIP programs Full CIP Clean Advantages Good soil removal organics and scale Disadvantages Long CIP time High impact on waste treatment Intermediate CIP Advantages Shorter CIP time Reduced chemical and water use Lower impact on waste treatment Disadvantages No complete removal of scale gross soil reduction only

27 CIP Programs for heated surfaces Why the different CIP programs Single Phase CIP With EDTA based additives Advantages Shorter CIP time no acid step Reduced chemical and water use Lower impact on waste treatment Disadvantages Still required remedial acid clean (weekly/monthly) No always best at organic soil removal Pre treatment CIP Clean Advantages Excellent soil removal organics and scale Shorter CIP time Lower impact on waste treatment (reduced caustic use) Disadvantages Some increase in chemical cost

28 Common mistakes with CIP

29 Cleaning Failures Blue Sheen on Metal Protein film incomplete clean cycle incorrect choice of chemical used for cleaning protein gel formation (hot caustic solutions) Temperature shock hot water on cold tank water temperature to high Magnesium deposits in water (12ppm) Water softener needs recharging

30 Cleaning Failures Build-Up of white(soft) film Cleaning solution low in active alkalinity Incorrect choice of cleaning chemical more surfactants required for soil penetration more builders required to prevent redeposition of soil Failure to rinse properly and thoroughly after wash step

31 Cleaning Failures Build-Up of white(hard) film Hard water used at high temperature (> 70C) Cleaner allowed to dry on surface before rinsing Cleaner used at too high temperature

32 Cleaning Failures Deterioration of gaskets Excessive cleaner strength Excessive cleaning temperature Particularly with nitric acid products Sanitizing with chlorine solution too long in advance of equipment being used Failure to follow cleaning with adequate rinse

33 Cleaning Failures Corrosion and pitting Delays in rinsing when emptied Excessive use and concentration of cleaning chemicals and sanitizers Use of non-inhibited nitric acid Surface not cool when sanitizing Prolonged contact with chlorine or heat still present Improper and inadequate rinse after cleaning Stainless steel not passivated

34 Cleaning Failures Unclean sections of pipe Failure to include the pipe in the CIP circuit Inadequate velocity (>1.5 m/s) Cleaning solution strength inadequate Cleaning wash temperature inadequate Cleaning cycle time inadequate Processing valves washed within the circuit not operating properly or not programmed

35 Cleaning Failures Unclean portions of tank surface Spray device plugged with debris Distribution holes incorrectly spaced/located Inadequate flow rate to spray device Inadequate detergent concentration Inadequate wash temperature Inadequate wash cycle time Spray device position to high or low from top of vessel Product allowed to dry on surface before CIP cycle is run Pressure of cleaning solution through spray device too high causing solution to aerosol

36 Cleaning Failures Ring of soil in lower part of the tank/vessel Return pump capacity not sufficient to correctly evacuate or return solution to CIP system Return pump air bound Inadequate detergent concentration or improper temperature Constant rinse allowing soil to float Rinse times inadequate

37 Cleaning Failures Air valve on processing tank not clean Failure to pulsate Improper frequency rate during pulsation If valve cannot be pulsed during wash cycle, valve was not manually operated or cleaned

38 Validation of the cleaning process The Measure of Success If you do not achieve the required result, however many resources you have spent, then all the time, effort & money was to no avail.

39 Validation of the cleaning process Know your system Do you know what is going on in your CIP Set? Do you only know what it is supposed to do? Make sure what you think happens is happening, and only then will you get good CIP results!

40 Validation of the cleaning process Manually validating CIPs Recommended parameters to be measured include Cycle times Temperature (supply & return) Flow rates Vessel low level Pressure Number of CIP's Concentration (make-up & return) Confirmation of delivery (detergent & sanitiser) Detergent / sanitiser usage Total Cost per Clean (bench marking)

41 Temperauter / Conductivity / Turbidity ph Validation of the cleaning process Automatic validation of CIPs Common CIP parameters measured over time include Conductivity Temperature ph Turbidity Additional data Flow rates Pump and valve operation :50 23:00 23:10 23:20 23:30 23:40 23:50 0:00 0:10 0:20 0:30 0:40 Time Temperature Conductivity Turbidity ph Set points and variation

42 Topics covered Why clean at all? Types of detergents CIP fundamentals CIP program options Common mistakes with CIP Validation