Cleaning Methodologies - DeLaval Cleaning Solutions

Cleaning Methodologies
A Discussion on the Various ways to most
effectively clean Interior & Exterior Surfaces
Internal
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Cleaning Methodologies
Categories of Cleaning
• Basically two overall approaches to cleaning:
• Internal Process Cleaning
• External Process Cleaning
Internal
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Cleaning Methodologies
Categories of Cleaning
• CIP – Clean in Place
• Foam Cleaning
• COP Cleaning
• Manual/Automated
• Spray Cleaning – High Pressure/Medium Pressure
• Parts Washers
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Batch
Conveyorized
Vats / Totes / Bins
Cabinet Washers
• Fogging
• Manual – Hand Detailing/Scrubbing
Internal
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What Do Manual, Cabinet Washers, COP and CIP
Have in Common?
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T
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W
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Cleaning requires both physical and
ime
chemical processes.
ction
hemistry / Concentration
emperature
Time
ater
Action
ndividual
Temperature
ature of Soil
Concentration
urface to be cleaned
/Chemistry
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?
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?
Clean-In-Place
Designing for Food Safety
Purpose of CIP:
Provides for:
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Safe Foods
Quality Foods
CIP - Part of the Process
Effective Cleaning
Efficient Cleaning
Clean and Sanitized Process Equipment
Regulatory Compliance
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
What is the most important
component in a CIP system?
What is the most important design
criteria for a CIP system?
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.
Basic CIP Steps
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Preparation
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Critical
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Equipment connections / set-up
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Pre-rinse heavy soils / solids
CIP Pre-Rinse Step
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Water – the best cleaning agent
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Remove easily rinsed soils
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Temper for fats / oils / greases
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Product Recovery?
Wash Step
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Detergent / concentration
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Time / Temp
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Flow / Pressure
Post-Rinse Step
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Rinse to pH setpoint / conductivity
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Water recovery
Sanitize Step
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Concentration
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Contact
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Time
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Temp
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.
CIP SYSTEM TYPES
Single Use
Single-Use
Rinse Recovery
Re-Use 3 Tank
Ultra-Flow
CIP
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
Disadvantages
• Multiple cleaning regimens
• Minimize thermal shock
• Minimize potential cross
contamination
• Smaller tank and footprint
• Lower cost CIP system
• Detergent concentrations can
be metered
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Longer heat-up times
Higher chemical usage
Higher water usage
Higher steam usage
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
Disadvantages
• Multiple cleaning regimens
• Minimize potential cross
contamination vs. re-use
• Reduce water usage vs.
single-use CIP systems
• Improved pre-rinse vs.
single-use
• Longer heat-up times than
re-use
• Higher chemical usage vs.
re-use CIP
• Higher steam usage vs.
re-use CIP
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
Disadvantages
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• 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
Reduce chemical cost
Reduce water usage
Reduce steam usage
Simple to operate
Shorter heating times and
CIP cycles
• Increase production time
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
Disadvantages
• Multiple cleaning regimens
• Minimize thermal shock
• Eliminate cross
contamination
• Smallest tank and footprint
• Detergent concentrations
can be metered
• Eliminate return pumps
• Minimize water pooling
• 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
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
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
Disadvantages
• Multiple applications
• Eliminates air relief valves
• Self priming (after initial
pump flooding)
• Good evacuation of tanks
• Return from multiple
locations
• Low NPSH requirements
• 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
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
Disadvantages
• Good evacuation of tanks
• Eliminates multiple return
pumps
• Eliminates air relief valves
• Self priming
• Return from multiple
locations
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Requires large return lines
High initial equipment cost
Limited temperature ranges
Motive tanks are unsanitary
Hydraulic problems are
masked
Fixed Spray Devices
Rotary Spray Devices
Sani-Matic Conveyor Spray
Image courtesy of Lechler
____________________________________________Image courtesy of Alfa-Laval
Images courtesy of Alfa-Laval
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:
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)
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.
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.
Detergent Injection
• How to Dispense
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Timed - Continuous
Pulsed
Conductivity Controlled
Metered
• Recommended Injection Locations
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Return Manifold
Suction Manifold (Sanitizer)
CIP Tank / Fresh Water Tank
Chemical Loop
• Cleaners, Additives, Sanitizers
Recommended CIP Solution
Strength/Temperature
EQUIPMENT
CLEANING
CYCLE TIME @
TEMP
ALKALINITY PER
CENT
TEMPERATURE(
DEGREES F)
Bulk Trucks
Bulk Tankers
5 – 10 Min
10 Min
.15 - .20
.15 - .20
135 – 145
135 - 145
Raw Storage Lines 15 Min
Raw Milk Lines
10 – 15 Min
.15 - .20
.20
140 – 145
155
H.T.S.T. (Conven.)
Alkali Wash
Acid Wash
60 Min
30 Min
1.00 – 1.50
pH 2.5 - 3
180
165
Finished Product
Lines
20 Min/Spur
.15 - .20
155
Finished Product
Tanks
10 – 15 Min
.15 - .20
145 – 155
CIP Cleaning
DeLaval Product Suggestions
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CIP Cleaning
DeLaval Product Suggestions
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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?
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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?
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•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?
• 10 – 15 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
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•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.
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•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
• 10 – 15 minutes on horizontal surfaces such as belts, tables, floors, etc.
• Rinse with boosted/high pressure water from the bottom up
• Why?
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Foam Cleaning
DeLaval Suggested Products
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Foam Cleaning
DeLaval Suggested Products
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COP Cleaning
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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
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Recommended COP Solution
Strength/Temperature
EQUIPMENT
CLEANING
CYCLE TIME @
TEMP
C.O.P. Tanks
30 – 45 Min.
(General usage for
parts)
ALKALINITY PER
CENT
TEMPERATURE(
DEGREES F)
.10 - .20
155
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?
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Spray Cleaning
DeLaval Suggested Products
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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
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Fogging
What is This Approach?
1. What Sanitizers are best to Use?
2. Quats, PAA, CLO2
3. Insecticides
4. Why not Chlorine?
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Fogging
DeLaval Suggested Products
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MUCHAS GRACIAS/THANK
YOU
PREGUNTAS/QUESTIONS?