OptiCIP New approach to optimize CIP-cleaning

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Noel Gilbert
8 years ago
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1 OptiCIP New approach to optimize CIP-cleaning PPA 12 Februari 2015 Godelieve Bun NIZO food research Rob van den Bos Schneider Electric

2 NIZO food research 65 proud years of open innovation Why Good food needs good science How Science Hub for projects in a global food network What Flavor, Texture or Health Process improvement From lab to pilot plant Where HQ in the Dutch Food Valley Sales offices in USA, France & Japan Who 180 professionals Research Centre Application & Processing Centre

Process improvement From lab to pilot plant Where HQ in the Dutch Food Valley Sales

3 Who are the Companies that invite us Co-Create (and allow us to tell)

4 OptiCIP Approach to optimize CIP-cleaning CIP Cleaning - some general aspects The NIZO / Schneider Electric approach

5 Cleaning in Place (CIP) Before you start, know your enemy and know what you re doing during CIP

6 Cleaning-In-Place (CIP) Automatic cleaning of equipment tanks, piping, pasteurizers filling machines, An example of a cleaning cycle: a first water rinse a caustic wash a second water rinse an acid wash a third water rinse

example of a cleaning cycle: a first water rinse a

7 CIP Process Automation key information to follow Counters: Valves command <> Conductivity Counters: supply flow <> return flow Object: Low level

8 CIP The Sinner circle Titer Chemistry 40% Addition to result Mechanical energy 30% Turbulence Fouling Turbidity removal Time Time 15% Temperature 15% Temperature 5T s

Cleaning optimization NIZO experience CIP procedures often based on worst case scenario s» too intensive and extended Cleaning time Evaporators 1.5 to 2 hours Plate heat exchangers 0.

9 Cleaning optimization NIZO experience CIP procedures often based on worst case scenario s» too intensive and extended Cleaning time Evaporators 1.5 to 2 hours Plate heat exchangers 0.5 to 1 hour Dryers (cleaned wet) 3 to 6 hours Membranes 1 2 hours * strongly depends on product formulations & process settings!! if you want to optimize measuring is essential Possible savings*: Average 15% reduction of cleaning time (range 10 30%) Reduced use of: energy cleaning agents water * Cost savings dependent on cost structure customer

5 to 1 hour Dryers (cleaned wet) 3 to 6 hours Membranes 1 2 hours * strongly depends on product formulations & process settings!

10 JOINT APPROACH OPTICIP SCHNEIDER ELECTRIC / NIZO

11 Joint approach: Combined expertise Your automation system

collection Monitoring Cleaning Process data input from process automation system.

12 Approach - OptiCIP Science based Combined strength Customer Preparation Data acquisition Troubleshooting Optimization Validation measurement Walkthrough audit Installation measuring equipment Link for data collection Monitoring Cleaning Process data input from process automation system. Microbial (optional) Optimization software / equipment Process adjustments Verification + final adjustment Implementing CIP monitoring Advice & reporting

13 1. Walk-through Audit Walk-through CIP Audit and / or Detailed CIP Audits Detailed Audit Detailed Audit Detailed Audit Detailed Audit Steam Piping Program Recipe Water Electricity Utilities Tanks Instrument. Safety Supervision Recipe Processefficiency Product/ process interaction Energies Process Automation Foulingremoval Walk-through Audit

14 2. OptiCIP tool Meten = Weten Continuous monitoring of 5T s: Temperature Time Turbulence Titer Turbidity Result: Continuous tracking and tracing Optimization Your automation system

15 CIP Traceability and Optimization Detailed Analysis based on trend tools Expert Analysis Line occupation diagrams

16 3. Operator interface

17 3. Analyst interface Conductivity Temperature Flow (calculated) Sequence 70 Golden CIP for Caustic & Acid recipe

18 3. Troubleshooting Define Golden CIP

19 CIP The Sinner circle Titer Chemistry 40% Addition to result Mechanical energy 30% Turbulence Fouling Turbidity removal Time Time 15% Temperature 15% Temperature 5T s

20 Ca2+ (ppm) troebelheid (-) Turbidity Monitoring fouling removal 2000 reinigen pasteurisatie N250 Ca2+ troebelheid vs loog tussenspoelen zuur naspoelen 1200 riool circuleren riool circulere n riool tijd (min)

6 vs loog tussenspoelen zuur naspoelen 1200 riool circuleren

21 4. Optimization

22 4. Optimization and validation of CIP-recipe Results before and after optimization

23 OptiCIP by Schneider Electric & NIZO Cost savings and increased: Food safety and Utilisation of production processes Easy assessment by the operators, and easy analysis by technologists per individual CIP-sequence Assistance by experts of both Schneider Electric and NIZO food research (on site and/or by remote access) Other Products by NIZO & Schneider Electric will be developed!!

24 Questions & Answers

Executive summary. by Benjamin Jude and Eric Lemaire

Executive summary. by Benjamin Jude and Eric Lemaire 998-2095-12-09-13AR0. by Benjamin Jude and Eric Lemaire Executive summary Existing clean-in-place (CIP) processes are time intensive and waste large amounts of energy, water, and chemicals. New innovations