cip - ingles
DESCRIPTION
eeeeeeeTRANSCRIPT
Webinar
August 1st
2014
Dairy Australia / NCDEA webinar
CIP for Hot Surfaces
Robert Ellis B Sc(hons) MRACI CChem
Technical Support Coordinator
Food & Beverage Division
Content
Why clean at all?
The Equipment being cleaned
Types of detergents
CIP fundamentals
CIP program options
Common mistakes with CIP
Validation
Why clean at all?
Dairy type soils, including milkstone usually contain combinations of, or all of the following:
Proteins
Fats
Carbohydrates
Minerals
Definition: “a soil is something that is not where it belongs.”
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 / 20th of the heat transfer rate of stainless steel. e.g. reduced efficiency of UHT heat exchanger
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.
The Soils
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
Soils left on heated surfaces are different
from those left on cold surfaces
The Equipment
Evaporators
Pasteurisers
UHT / Sterilisers
Holding tubes
Soils left on heated surfaces can vary with
the type of equipment used
The Equipment
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
Evaporator
The Equipment
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
UHT sterilisers and Pasteurisers
Detergent Types
Alkali Caustic Detergents remove:
Fats Oils Carbohydrates Proteins
Acids Acid Detergents remove:
Minerals Milkstone
Common cleaning chemicals
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
Alkaline detergent types
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
Alkaline detergent types
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
Alkaline 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 e.g. Formula 507A
Hydrochloric ensure inhibitor is used e.g. Acidblend H300
Sulphuric e.g. Envirocid Plus
Nitric inhibitor recommended e.g. Super Stonekleen
Sulfamic e.g. DS 88
Organic e.g. Ultrasil 73
Acid detergent types
Detergent Types
CIP Systems
Four key factors for cleaning
Time
Temperature
Concentration Cleaner and sanitiser
Mechanical action Flow and pressure
Concentration
Temperature
Time
Mechanical
Action
CIP fundamentals
CIP Systems
Factors affecting cleaning performance
Water Quality Hardness, salts, iron, pH
Soil Type
Soil Condition
Type of Equipment
Effluent Constraints
CIP fundamentals
CIP Systems
Simple single use CIP system
CIP Systems
Solution recovery system
CIP Systems
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.
CIP types
CIP Systems
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
CIP types – features and benefits
CIP Systems
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.
CIP types – features and benefits
CIP Systems
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
CIP line flow rates
CIP Programs for heated surfaces
1. Rinse
2. Caustic clean
3. Rinse
4. Acid clean
5. Rinse
6. Sanitise (heat or chemical)
Typical Full Clean Program
CIP Programs for heated surfaces
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
Typical Intermediate Program
CIP Programs for heated surfaces
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)
Pre-treatment Programs
CIP Programs for heated surfaces
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
Why the different CIP programs
CIP Programs for heated surfaces
“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
Why the different CIP programs
Common mistakes with CIP
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
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
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
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
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
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
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
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
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
Validation of the cleaning process
If you do not achieve the required result,
however many resources you have spent,
then all the time, effort & money was to no avail.
The Measure of Success
Validation of the cleaning process
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!
Know your system
Validation of the cleaning process
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)
Manually validating CIPs
Validation of the cleaning process
Common CIP parameters measured over time include
Conductivity
Temperature
pH
Turbidity
Additional data
Flow rates
Pump and valve operation
Set points and variation
Automatic validation of CIPs
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Temperature Conductivity Turbidity pH
Topics covered
Why clean at all?
Types of detergents
CIP fundamentals
CIP program options
Common mistakes with CIP
Validation