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1 Advancements in Cleaning Technologies Coatings and Coating Equipment Cleaner with Chematic Formulated Detergents
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Advancements in Cleaning Technologies
Coatings and Coating Equipment
Cleaner with ChematicFormulated Detergents
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Agenda
• Cleaning Coatings• T.A.C.T• How do we clean• Know your residue• Opadry• Eudragit• Cleaning techniques• Value
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Coatings Color and Time release
• What are we cleaning?– Coating pans, Fluid beds, Mixers, Pumps,
Hoses• How are they currently cleaned
– Manual scrubbing, Sprayers, CIP, COP• What are the problems
– Time consuming– Repeatable results– Worker safety– Disassembly of equipment– HAZE Left behind
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Where do you Start?
The GoldenGolden Rule of Cleaning
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T.A.C.T The Variables of cleaning
Time
Action
Concentration/Chemistry
Temperature
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Understanding the Cleaning
TACT
imectiononcentration/Chemistryemperature
Critical Process Parameters for Cleaning
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Removal Mechanisms of Formulated Detergents
– Wetting– Solubilization– Sequestration
– Saponification
– Chelation
– Emulsification– Degradation
Modifying surface tensionIncreasing solubilityReacting with ions to prevent insoluble by-products (e.g., soap scum)Formation of water soluble salts (alkali hydrolysis)Using - charges to form stable complexes with + metal ionsCreating a stable oil / water mixtureInactivation through a number of means, usually hydrolysis or oxidation
Each detergent constituent has one or more rolesto play in the removal of soil…:
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HowPeople Clean
• Manual
• Clean-Out-Of-Place –COP
• Clean-In-Place – CIP
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Cleaning better with T.A.C.T
How do we clean better
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Understand you goalsNature of Soil
• Opadry®– TiO2 based, HPMC
Talc, Zinc oxide
– Temperature effect
– Leaves haze
– Hand wiping
– Disassembled needed
– Pans designed
• Eudragit®– Polymer based
– pH Dependent
– Several application
– Manual cleaning
– Temperature effect
– Layered
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Improving cleaningOpadry II® & Eudragit®
• Reduce haze and residue
• Limit hand wiping & scraping
• Decrease disassembly
• Reduce cleaning Time
• Improve reliability
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Opadry®Key Factors of cleaning
• Temperature– Hot water is Bad– Cold water removes residue better
• Cleaning Process– Pre-rinse
• Separates soil can be problematic– Impingement
• Increased spray or agitation will improve removal– Detergent application
• Multiple applications maybe needed• Formulation is critical to
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Detergents SelectionChematic 400 series
• Chematic 410 & 405– Two years in
development
– Formulated to remove Opadry II products
– Limits need for wiping
– Reduces disassembly
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The Opadry II® cleaning process
• Opadry II®• White, Gray, YellowYellow, Orange, Blue
– 5% Chematic 410 at 30°C for 45 minutes– 5% Chematic 410 at 37°C for 45 minutes– Rinse - 37°C– Rinse - 30°C
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The Opadry II® cleaning process (con)
• Opadry II® Brown
– 5% Chematic 405 at 33°C for 45 minutes– 5% Chematic 405 at 37°C for 45 minutes– Rinse - 37°C– Rinse - 30°C
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Lab trial results
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Results after Chematic Cleaning
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Conclusion
• Limit wiping and disassembly with new Chematic 405 & 410
• Temperature is critical to maintain the product bond
• Hot water will reduce cleaning• Impingent helps in the cleaning process.• Do not let product dry in lines.
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Cleaning Eudragit®
Time release coating
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Eudragit® Cleaning key factors
• Dependent on pH• Layered batches• Addition of other
materials changes cleaning
• Manual cleaning• Requires scraping• Time consuming• Use of solvents
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Cleaning Studies guidelines• Eudragit® L-100, L-100-55, L-30-55
– Chematic 82CIP Spray Applications: • Concentration: 2-10% v/v, depending on
application Temperature: 60-70ºC • Manual Cleaning: Concentration: 2% v/v
Temperature: 50-60ºC
• Eudragit® RS-P0, RS-100, RS-30D– Chematic 453Concentration:
• 10% v/v Temperature: 70ºC• 70ºCPost rinse should be Hot (70-80ºC) water
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Results
• Using proper chemistry and Application
• Cleaning time reduced for 24 hrs to 3 hrs
• Simple application
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Chematic 400 seriesChematic 405 & 410 & 453
• Mild pH• Low foaming• Detectable Method
– IMS (Ion Mobility Scan)– HPLC – TOC
• Application– CIP– COP– Manual
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Things to consider
• Eudragit formulation
– Adding plasterers, talc, est.. will change cleaning
– Number of layer will increase cleaning time
– Temperature is critical to cleaning
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Value of cleaning improvements
What is it worth?
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Value of cleaning
• Reduce cleaning time– Labor cost– Increased production
time– Reduce safety
concerns– Easy validation– Simpler Reliable
cleaning
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Coating pan Cleaning
Not Quantified
Value of Recovered Production Time
$425,000Value to Customer in Man Hours
3,125 / yrTotal Saving in Cleaning Hours
1.5 hrsChematic 410 Cleaning
6.5 hrsPrevious Cleaning
16Number of Coating Pans
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E quipm ent O ptim ization
O ld M ethod C lean ing T im e Personnel M anhoursM JC T im e 13.45 2 26.9 58.6%M IC T im e 2 1.5 3 6.5%R un T im e 7.4 1.5 11.1 24.2%Setup T im e 3.25 1.5 4.875 10.6%
45.875C am paign (lo ts ) 7 .5
ave Per lo t 3 .526666667
N ew M ethodM JC T im e 8 2 16 45.7%M IC T im e 2 1.5 3 8.6%R un T im e 7.4 1.5 11.1 31.7%Setup T im e 3.25 1.5 4.875 13.9%
34.975C am paign (lo ts ) 14
ave Per lo t 2 .428571429
Average per lo t 1 .098095238
Equipm ent N o . o f Lo ts Equipm ent (hr)022 Lots per m onth 35 38.43333333022 Lots per year 420 461.2Increase in Production (Lots) 62.32Percent Increase in Production 14.8%
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Conclusion
• Achieve better cleaning faster through new technologies and science
• Understand the T.A.C.T and it uses
• Understand the value of cleaning
• Set goals and value
