cip latest technologies, typical errors and cip assurance...pi pi cip return cip return ti fi ci ti...
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■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
CIP – Latest Technologies, Typical Errors and CIP Assurance
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Influences on Cleaning (Sinner)
Source: Natursteinpflege24.de
Action
Time
Temperature
Chemicals
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Applied Agents
• Caustic cleaner (NaOH)
• Combined cleaner (NaOH + detergent or hypochlorite)
• Phosphoric acid or nitric acid (up to 5 %), better for
environment: lactic acid or citric acid
• Peracetic acid or hydrogen peroxide, chlorine
dioxide, salicylic acid, etc. as disinfectant
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Detergents
Surfactants
decrease of surface tension
lower adhesion of dirt to surfaces
better swelling of dirt
possibility of wetting gaps and cracks
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Penetration Behaviour of Liquids with different Surface Tensions
water 72 mN/m
milk 52 mN/m
beer 43 mN/m
quats 24...34 mN/m
microorganism
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Disinfectants
• type and degree of contamination
• efficiency of disinfectant
• temperature
• nature and condition of the surface
• time
A proper disinfection is dependent on:
Disinfectants are chemical compounds which
are able to inactivate microorganisms due to
different modes of action.
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Disinfectant Mode of Action Features Structure
Peroxides e.g. peracetic acid
Oxidation effect Sensitive to organic soilsand copper, attacsrubber,
Aldehydes Reaction with carbonyl-,amino-, hydroxyl- andsulfhydryl groups of cellproteins
Sensitive to organicsoils, limkted action onGram-neg. MO
Salicylic Acid Attacs membranes, replacespantothenic acid, no CoAcan be synthesized
Stable, insensitiveagainst organics, oftenused with acids
MonobromaticAcid
Reaction with SH-groups ofenzyme proteins
Stable, insensitiveagainst organics, oftenused with acids
Quats Destruction of semi-permeability of cell wall bylowering the charge andsurface tension
Non-corrosive; stable athigh temperatures
Guanidines Similar to Quats Deposits at pH 12; nosurface activity
Hypochlorite Oxidation effect Sensitive to org. soils; instable at high temp.
NaOCl
Iodophores Oxidation effect Problematic with copperand rubber
N R
R
R
R1
1
2
1 N
N
R
R
R
N
R1
2
1
2
X X X
a b c
+ -
+
-+
-
CH3 C
O
O OH
OC
H
H
C C
O
OH
H
Br
H
C NN
NHR
R1
R2
R3
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Disinfectants - Oxidants
Peracetic acid; H2O2:
• Release of O-radicals (nascent oxygen)
reaction with proteins and lipids of cell wall
penetration of cell wall and denaturation of
proteins
• Mostly in final rinsing water
• Also applied as cleaning booster (cracking)
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Wort Cooler – Cracking
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Deep Cleaning – Once a Year
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Sodium Hypochlorite
Mode of action: NaOCl NaCl + O
Besides disinfection very good for periodic intensive deep cleaning
To avoid corrosion (!):
• pH of the cleaning solution > 11 (always in NaOH)
• Concentration not above 5 %
• Temperature not above 65 °C resp. 149 °F
• Maximum contact time 1 hour
• Unsuitable for rubber-containing gasket materials
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Disinfectants - Chlorine Dioxide
4 HCL + 5 NaClO2 4 ClO2 + 5 NaCl + 2 H2O
• Application in water disinfection
brewing water
bottle washer (cold water zone)
bottle rinser (after crowning)
belt lubricants
• Organic residuals weaken the efficiency
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Source: GrundfossSource: Dr. Wolf GmbH
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
CIP-PLANTS
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Disinfectant
concentrate
LI
TI
LI
LI
LI
TI
LI
LI
LI
TI
LI
LI
LI
TI
LI
LI
LI
TI
LI
LI
Water
Acid
concentrate
Caustic soda
concentrate
Freshwater
Dis-infectant
Acid Hotcaustic
Returnwater
CI CI CI
Steam
Condensate
Steam
Condensate
TICTIC
Steam
Condensate
Steam
Condensate
CIP
to plant
CIP
to plant
TIC
TIC
TI
TI
PI
PI
CIP
Return
CIP
Return
CITI FI
CITI FI
CLEANING-IN-PLACE (CIP) INSTALLATION
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
• Cleaning times
• Flow velocities
• Conductivities
• Temperatures
• Cleaning of safety fittings and mountings
• Cleaning of sample drawers
• Frequency of jet cleaners if existent
• Checking the change of medias
Controlling CIP - Operations
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
CIP – Control System
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Mechanical Impact in CIP Systems
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Spraying Equipment for Tanks
Spray Ball Jet Cleaner
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Atmospheric
pressure
To
tal p
ressu
re liq
uid
Course of pressure in pipe
Pre
ssu
re
of p
um
p
Pressure Loss in Pipes
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Pressure and Cleaning Effect
Highest mechanical effect
In sump
mechanical effect low
Too low pressure no
mechanical Effect no
sufficient film at surface
Sufficient flow rate results in
a consistent liquid film on
the walls surface
Too high pressure rebound
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Consistent Showering of the
Vessel Wall *
* Zürcher, Dresdner Brauertag 2003
for a falling film thickness 1 mm turbulent flow
set point value: 25 – 30 l / (m * min)
showering [ l /(m * min) ] =
flow rate [ hl / h ] * 100 / 60 / circumference [ m ]
Flow Showering
hl/h l/m x min
80 11.7
171 25.0
200 29.2
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Influences of CO2 on the Process
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Tank - CO2 - Removal – Why?
1. Loss of alkalinity by neutralization
2. Risk of vacuum formation
3. Precipitations interfering with the process
4. Pit corrosion (Hypochlorite)
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Insufficient CO2-Removal - Carbonates
2 NaOH + CO2 NaHCO3 + H2O
Example: 3000 hl tank filled with 2500 hl
500 hl head space
At pop = 0.6 bar ≈ 80 m3 CO2 = 160 kg CO2
neutralization of 291 kg NaOH possible!
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Vacuum II
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Carbonate Precipitations – Insufficient CO2-Removal before Caustic Cleaning
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
Pre-Cleaning with Caustic-Shot
No pre-rinsing
No de-aeration
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
1. Shot NaOH
Pre-Cleaning with Caustic-Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
1. Shot NaOH
1. Defined rest
Pre-Cleaning with Caustic-Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
1. Shot NaOH
1. Defined rest
2. Shot NaOH
Pre-Cleaning with Caustic-Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
1. Shot NaOH
1. Defined rest
2. Shot NaOH
2. Defined rest
Pre-Cleaning with Caustic-Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
1. Shot NaOH
1. Defined Rast
2. Shot NaOH
2. Defined rest
3. Shot NaOH
Pre-Cleaning with Caustic-Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
1. Shot NaOH
1. Defined rest
2. Shot NaOH
2. Defined rest
3. Shot NaOH
3. Defined rest
Pre-Cleaning with Caustic-Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Steps
1. Shot NaOH
1. Defined rest
2. Shot NaOH
2. Defined rest
3. Shot NaOH
3. Defined rest
Intermediate rinsing
Pre-Cleaning with Caustic-Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Empty tank
After acid
cleaning
1. Shot 2. Shot
Intermediate
rinsing with fresh
water after shots
3. Shot
Source: Sopura
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Spray Shadows
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Spray Shadows!
Before Cleaning:
After Cleaning:
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Spray Shadows!
Absurd Installations!
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Opening the Tank peels the Eyes
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Blocked Sprayballs
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Wrongly inserted Conus Gasket
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
ImproperWelding Seams
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Improper Welding Seams
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Endoscope
• Endoscopy is a minimally invasive diagnostic medical procedure that is used to assess the interior surfaces of an organ by inserting a tube into the body. (Wikipedia)
• Endoscope of the VLB:Pixel: 500 x 582Light sensitiveness: 0.5 LuxObjective: f = 2,3 mm, F = 1,2Picture angle: 120°Light source: 12 white LEDsProtection: waterproof acc. IP 68Temperature range: -10 - 50 °C,Wire with distance marks: Length: 20 mDiameter: 6 mm
Source: Pahl; VLB -FMV
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■Source: Pahl; VLB -FMV
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Dead Ends
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Dead Ends
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Placing of no-return Valves
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Wrong Position of no-return Valve
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Wrong Position of no-return Valve
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Cleaning with closed Connecter Valves
■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■
Cleaning with closed Connectors and broken Gaskets