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REDUCING SODIUM HYDROXIDE IN PROCESS CLEANINGUMASS LOWELL - TURI
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OUTLINEREDUCING SODIUM HYDROXIDE IN PROCESS CLEANING
B k d• Background• Method• Preliminary results• Preliminary results• Potential recommendations• Next Steps• Next Steps• Acknowledgements
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BACKGROUND
• Sodium hydroxide (NaOH) is widely used in combination with hydrogen peroxide (H2O2) as an effective FCS cleaner.
• NaOH (Caustic Soda) is classified as toxic chemical by• NaOH (Caustic Soda) is classified as toxic chemical by Toxic Use Reduction Act (TURA).
• When used in large quantity it pose significant chemicalWhen used in large quantity it pose significant chemical hazards to the processed food, employees and the environment
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OBJECTIVES
1 E t bli h i i t ti f N OH/ H O• 1. Establish a minimum concentration of NaOH/ H2O2 for cleaning-in-place (CIP) at Kettle Cuisine (KC).
• 2. Identify and test green alternatives of caustic soda for CIP processes. p
• 3. Reduce down-time, energy and labor cost for CIP processes.
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METHOD
Scaling and weight: place stainless steel (SS)316 coupons in Mac & Cheese heat at 180°F for 3 hoursCheese, heat at 180 F for 3 hours.
Cleaning with NaOH/ H2O2 and g / 2 2 weight: different concentration
and temperature.
Physical scrubbing with diluted phosphoric acid.
QC ‐ ATP measurement
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QC ‐ ATP measurement
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MEASUREMENT
• Dry weight changes among different steps• QC ATP test• QC – ATP test
– ATP, the energy molecule found in all living things, making it a perfect indicator to determine if a surface is clean or not.
– To ensure no product contamination or biofilm development presents on SS surface.
– The amount of ATP present in the sample providingThe amount of ATP present in the sample, providing information on the level of contamination.
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PRELIMINARY RESULTS
Table 1. Alternative experiments associated with concentration of NaOH/H2O2 and p / 2 2descaling temperature. 100% = simulated KC’s application (250 gallons of H2O, 8 lbs of HCL‐5000, 2 lbs of H2O2). Size of coupon: 1.5 inch x 1.5 inch.
TemperatureConc. Of NaOH/H2O2
100% 75% 50%
82°C √ √ √
75°C √
65°C √
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PRELIMINARY RESULTS – DOSE
DE‐SCALE RATIO ATP TEST
101102103
atio
DE SCALE RATIO
10
12
14
LU)
ATP TEST
‐‐ 82°C ‐‐ 82°C
96979899100
idue
Rem
oval Ra
4
6
8
10
ATP values (R
L
939495
100% 75% 50%
Resi
Concentration of NaOH/H2O2
0
2
100% 75% 50%Concentration of NaOH/H2O2Concentration of NaOH/H2O2 Concentration of NaOH/H2O2
Figure 1. (A) Weight removal test and (B) ATP test of SS316 coupons under 82 °C cleaning temperature RLU: relative light unit 0‐10 RLU: good; 11‐30 RLU: caution; over
(A) (B)
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cleaning temperature. RLU: relative light unit. 0 10 RLU: good; 11 30 RLU: caution; over 30 RLU: failure.
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PRELIMINARY RESULTS - TEMPERATURE
14
ATP TEST ‐‐ 75% NaOH/H2O2
8
10
12
lues (R
LU)
2
4
6
ATP va
082°C 75°C 65°C
Concentration of NaOH/H2O2
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RESULTS
Cl i ff t f 75% N OH/H O ith 82 °C 75 °C• Cleaning effect of 75% NaOH/H2O2 with 82 °C, 75 °C, and 65 °C is able to pass ATP test.
• Cleaning effect of 50% NaOH/H2O2 with 82 °C is able to pass ATP test, but its ATP values are higher than that p gof 75% NaOH/H2O2 .
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POTENTIAL RECOMMENDATIONS
• In 2015 44,662 lbs of sodium hydroxide was used in the l icleaning process.
• It was anticipated that by 2017 taking production growth into account an additional 9 379 pounds per year wouldinto account, an additional 9,379 pounds per year would be used.
• Results show using 75% NaOH, considered as the new dosing concentration, about 15% (3.5 Tons) can be reduce annually while achieving same ATP results as 100%.
• Reduce CIP temperature to 65oC = savings on energy bill!
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NEXT STEPS
• Continuing to evaluate the concentration of NaOH/H2O2(50%) ith t t 82°C d 50°C(50%) with temperature 82°C and 50°C.
• Screening alternatives will investigate the following: Phix XIVPhix XIV Chlorine Materials Hydrogen peroxideHydrogen peroxide Ozone Peracetic acid/peroxyacetic acidPeracetic acid/peroxyacetic acid Phosphoric acidPotassium hydroxide
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Potassium hydroxide
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T i U R d i I i• Toxics Use Reduction Institute
• Kettle Cuisine; AlanACKNOWLEDGEMENTS
• Xiaobo Liu, Manyun Yang,
D i K jDuniya Kajang
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