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CLEANING AND SANITATIONCLEANING AND SANITATION
ofof
PROCESSING EQUIPMENTPROCESSING EQUIPMENT
Huub Lelieveld
FSM Chicago November 2004
CLEANING and SANITATIONCLEANING and SANITATION
OBJECTIVESOBJECTIVES
• PREVENTING PRODUCT CONTAMINATION BY:
• ENSURE CONTINUED CORRECT OPERATION OF THE EQUIPMENT, AVOIDING:
- DEPOSITS (PRODUCT ON FREEZERS AND HEATERS)
- INHOMOGENEITY OF PRODUCTS (LUMPS, FLAKES)- MECHANICAL DAMAGE (PUMPS, VALVES, SEALS, …)- HAMPERING PRODUCT FLOW (PASTEURISERS)
• IMPROVE PRODUCTION EFFICIENCY
- MICROORGANISMS
- ALLERGENS- FOREIGN MATERIAL
CLEANINGCLEANING
REMOVALREMOVAL OF SOIL
MAJOR CAUSES OF FOULINGMAJOR CAUSES OF FOULING
• CHEMICAL REACTION AT THE PRODUCT CONTACT SURFACE
• CRYSTALLISATION FOLLOWED BY DEPOSITION
• SEDIMENTATION OF PARTICLES
• BIOFILM FORMATION
• SOLIDIFICATION OF PRODUCT COMPONENTS ON THE SURFACE
HEAT CHANGES THE SOIL, OFTEN MAKING IT MORE DIFFICULT TO REMOVE:
CLEANINGCLEANING
REMOVALREMOVAL OF SOIL
- DENATURING OF PROTEINS
- POLYMERISATION OF FATS
- REACTION PRODUCTS OF PROTEINS, FATS AND SUGAR
AVOID HIGH TEMPERATURES AS MUCH AS POSSIBLE ALSO DURING CLEANING
CLEANINGCLEANING
REMOVAL REMOVAL OF SOIL
FACTORS AFFECTING CLEANING
• DESIGN OF EQUIPMENT AND PROCESS LINE
• TYPE OF SOIL (PRODUCT RESIDUES)
DETERMINING THE TIME, TEMPERATURE and CHEMICALS NEEDED
• MECHANICAL ENERGY (LIQUID VELOCITY)
RESIDUAL LEVEL AFTER EFFECTIVE CLEANINGMIC
RO
OR
GA
NIS
MS
/SO
IL
TIME
MAXIMUM ACCEPTABLE CONCENTRATION
CLEANING NEEDED
EXTENSION OF PRODUCTION TIME DUE TO EFFECTIVE CLEANING
POOR CLEANING
CLEANING NEEDED
CLEANING NEEDED
START OF PRODUCTION
RESTART OF PRODUCTION
CLEANINGCLEANING
REMOVAL REMOVAL OF SOIL
DELIVERING THE REQUIRED MECHANICAL and THERMAL ENERGY TO THE LOCATION OF THE SOIL
KEEPING REMOVED NON-SOLUBLE SOIL SUSPENDED
DEPENDING ON THE TYPE OF SOIL: DELIVERING THE REQUIRED CHEMICALS TO THE SOIL
REMOVAL OF THE SOIL AND CHEMICALS FROM THE EQUIPMENT
CLEANINGCLEANING
REMOVALREMOVAL OF SOIL
PLATE HEAT-EXCHANGER OPENED FOR INSPECTION AFTER CLEANING
CLEANINGCLEANING
SOIL CHEMICALS
SUSPENSION OF SOIL PARTICLES AND PREVENTING REDEPOSITIONING
SURFACTANTS ANIONICS
- BASED ON FATTY ACIDS- FOAMING- NOT AFFECTED BY HARD WATER
CATIONICS
- QUATERNARY AMMONIUM COMPOUNDS- LESS GOOD- BENEFIT: ANTIMICROBIAL
NONIONICS
- LOW FOAMING- GOOD WETTING- EFFECTIVE ON OIL
CLEANINGCLEANING
SOIL CHEMICALS
FAT and PROTEINS
STRONG ALKALINE SOLUTIONSSODIUM HYDROXIDEPOTASSIUM HYDROXIDEORTHOSILICATEMETASILICATE
CLEANINGCLEANING
SOIL CHEMICALS
INORGANIC SCALE
ACID SOLUTIONSPHOSPHORICNITRICSULPHAMICGLUCONICCITRIC
CLEANINGCLEANING
SOIL CHEMICALS
METALS (Ca, Mg)
SEQUESTRANTSPHOSPHATESEDTAGLUCONATE
CLEANINGCLEANING
SOIL CHEMICALS
PREVENTING DEPOSITION OF HARD WATER SALTS AFTER CLEANING
SEQUESTRANTS IN LOW CONCENTRATIONS (5-20 mg/kg)
CLEANING PROCEDURE - MILKCLEANING PROCEDURE - MILK
• DUAL STAGE WITH RAW MATERIALS– Pre rinse– Alkali dosing (1,5 - 3 % NaOH) ! Gross soil removal drain– Circulation– Intermediate rinse– Acid dosing ( 1 - 3 % Acid) ! Gross soil removal drain– Circulation– Final rinse
CLEANING PROCEDURE - MILKCLEANING PROCEDURE - MILK
• SINGLE STAGE WITH FORMULATED PRODUCT– Pre rinse– Alkali dosing (0,5 - 1 % NaOH) ! Gross soil removal drain– Adjunct dosing– Circulation– Final rinse
• Acid step periodically
• wetting agents• surfactants• sequestering agents• threshold agents
COMPARISONCOMPARISON
Cleaning step Dual stage Cleaning step Single stagePre rinse 20 Pre rinse 20Alkali step 70 Pre clean 30Rinse 25 Alkali step 50Acid step 50 Rinse 20Rinse 15Total cleaning time 180 min. 120 min.
SINGLE STAGE / FORMULATED PRODUCTSSINGLE STAGE / FORMULATED PRODUCTS
DIFFERENCESDIFFERENCES
• Increased costs for cleaning materials• Shorter cleaning time and thus
reduced down time• Less energy• Less water• Lower overall costs
DUAL STAGE CLEANINGDUAL STAGE CLEANING
SINGLE STAGE CLEANINGSINGLE STAGE CLEANING
SANITATIONSANITATION
CLEAN SURFACES ARE EASY TO SANITISECLEAN SURFACES ARE EASY TO SANITISE
• BY HEAT
• BY CHEMICALS
• BY COMBINATIONS
SANITATIONSANITATION
• BY HEAT PASTEURISATIONPASTEURISATION
- INACTIVATES MOST VEGETATIVE
MICROBES, INCLUDING PATHOGENS
STERILISATIONSTERILISATION
- INACTIVATES ALL MICROBES,
INCLUDING (HEAT RESISTANT) SPORES
SANITATIONSANITATION
• BY CHEMICALS or COMBINATIONS
INACTIVATES SOME OR MANY OR ALL MICROBES, INCLUDING PATHOGENS AND PATHOGENS, DEPENDING ON CHEMICALS and TEMPERATURE
SANITATIONSANITATION
IMPORTANT DISINFECTANTSIMPORTANT DISINFECTANTS
• ACTIVE CHLORINE COMPOUNDS
• IODOPHORS
• QUATERNARY AMMONIUM COMPOUNDS
• PEROXY COMPOUNDS
• ACIDS AND ALKALIS AT ELEVATED TEMPERATURE
- SLIGHTLY ALKALINE HYPOCHLORITE
- CHLORINE DIOXIDE
- HYDROGENPEROXIDE
- PERACETIC ACID
Emulsion picture by Jo Janssen, 1993
Thank you for your Thank you for your attention!attention!