cip - ingles

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

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Page 1: Cip - Ingles

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

Page 2: Cip - Ingles

Content

Why clean at all?

The Equipment being cleaned

Types of detergents

CIP fundamentals

CIP program options

Common mistakes with CIP

Validation

Page 3: Cip - Ingles

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.”

Page 4: Cip - Ingles

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

Page 5: Cip - Ingles

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.

Page 6: Cip - Ingles

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

Page 7: Cip - Ingles

The Equipment

Evaporators

Pasteurisers

UHT / Sterilisers

Holding tubes

Soils left on heated surfaces can vary with

the type of equipment used

Page 8: Cip - Ingles

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

Page 9: Cip - Ingles

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

Page 10: Cip - Ingles

Detergent Types

Alkali Caustic Detergents remove:

Fats Oils Carbohydrates Proteins

Acids Acid Detergents remove:

Minerals Milkstone

Common cleaning chemicals

Page 11: Cip - Ingles

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

Page 12: Cip - Ingles

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

Page 13: Cip - Ingles

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

Page 14: Cip - Ingles

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

Page 15: Cip - Ingles

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

Page 16: Cip - Ingles

CIP Systems

Factors affecting cleaning performance

Water Quality Hardness, salts, iron, pH

Soil Type

Soil Condition

Type of Equipment

Effluent Constraints

CIP fundamentals

Page 17: Cip - Ingles

CIP Systems

Simple single use CIP system

Page 18: Cip - Ingles

CIP Systems

Solution recovery system

Page 19: Cip - Ingles

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

Page 20: Cip - Ingles

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

Page 21: Cip - Ingles

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

Page 22: Cip - Ingles

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

Page 23: Cip - Ingles

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

Page 24: Cip - Ingles

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

Page 25: Cip - Ingles

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

Page 26: Cip - Ingles

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

Page 27: Cip - Ingles

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

Page 28: Cip - Ingles

Common mistakes with CIP

Page 29: Cip - Ingles

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

Page 30: Cip - Ingles

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

Page 31: Cip - Ingles

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

Page 32: Cip - Ingles

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

Page 33: Cip - Ingles

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

Page 34: Cip - Ingles

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

Page 35: Cip - Ingles

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

Page 36: Cip - Ingles

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

Page 37: Cip - Ingles

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

Page 38: Cip - Ingles

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

Page 39: Cip - Ingles

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

Page 40: Cip - Ingles

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

Page 41: Cip - Ingles

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

0

10

20

30

40

50

60

70

80

90

22:50 23:00 23:10 23:20 23:30 23:40 23:50 0:00 0:10 0:20 0:30 0:40

Time

Tem

pera

ute

r /

Co

nd

ucti

vit

y /

Tu

rbid

ity

0

2

4

6

8

10

12

14

pH

Temperature Conductivity Turbidity pH

Page 42: Cip - Ingles

Topics covered

Why clean at all?

Types of detergents

CIP fundamentals

CIP program options

Common mistakes with CIP

Validation