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CLEANING AND SANITATION of PROCESSING EQUIPMENT

CLEANING AND SANITATION of PROCESSING EQUIPMENT. Huub Lelieveld. FSM Chicago November 2004. CLEANING and SANITATION. OBJECTIVES. PREVENTING PRODUCT CONTAMINATION BY:. - MICROORGANISMS - ALLERGENS - FOREIGN MATERIAL. ENSURE CONTINUED CORRECT OPERATION OF THE EQUIPMENT, AVOIDING:.

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CLEANING AND SANITATION of PROCESSING EQUIPMENT

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  1. CLEANING AND SANITATION of PROCESSING EQUIPMENT Huub Lelieveld FSM Chicago November 2004

  2. CLEANING and SANITATION OBJECTIVES • PREVENTING PRODUCT CONTAMINATION BY: - MICROORGANISMS - ALLERGENS - FOREIGN MATERIAL • 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

  3. CLEANING REMOVAL OF SOIL MAJOR 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

  4. CLEANING REMOVAL OF SOIL HEAT CHANGES THE SOIL, OFTEN MAKING IT MORE DIFFICULT TO REMOVE: - DENATURING OF PROTEINS - POLYMERISATION OF FATS - REACTION PRODUCTS OF PROTEINS, FATS AND SUGAR AVOID HIGH TEMPERATURES AS MUCH AS POSSIBLE ALSO DURING CLEANING

  5. CLEANING REMOVAL OF SOIL FACTORS AFFECTING CLEANING • DESIGN OF EQUIPMENT AND PROCESS LINE • TYPE OF SOIL (PRODUCT RESIDUES) • MECHANICAL ENERGY (LIQUID VELOCITY) DETERMINING THE TIME, TEMPERATURE and CHEMICALS NEEDED

  6. MAXIMUM ACCEPTABLE CONCENTRATION POOR CLEANING CLEANING NEEDED CLEANING NEEDED MICROORGANISMS/SOIL RESIDUAL LEVEL AFTER EFFECTIVE CLEANING TIME CLEANING NEEDED RESTART OF PRODUCTION START OF PRODUCTION EXTENSION OF PRODUCTION TIME DUE TO EFFECTIVE CLEANING CLEANING REMOVAL OF SOIL

  7. CLEANING REMOVAL OF SOIL DELIVERING THE REQUIRED MECHANICAL and THERMAL ENERGY TO THE LOCATION OF THE SOIL DEPENDING ON THE TYPE OF SOIL: DELIVERING THE REQUIRED CHEMICALS TO THE SOIL KEEPING REMOVED NON-SOLUBLE SOIL SUSPENDED REMOVAL OF THE SOIL AND CHEMICALS FROM THE EQUIPMENT

  8. PLATE HEAT-EXCHANGER OPENED FOR INSPECTION AFTER CLEANING

  9. CLEANING 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

  10. CLEANING SOIL CHEMICALS FAT and PROTEINS STRONG ALKALINE SOLUTIONS SODIUM HYDROXIDE POTASSIUM HYDROXIDE ORTHOSILICATE METASILICATE

  11. CLEANING SOIL CHEMICALS INORGANIC SCALE ACID SOLUTIONS PHOSPHORIC NITRIC SULPHAMIC GLUCONIC CITRIC

  12. CLEANING SOIL CHEMICALS METALS (Ca, Mg) SEQUESTRANTS PHOSPHATES EDTA GLUCONATE

  13. CLEANING SOIL CHEMICALS PREVENTING DEPOSITION OF HARD WATER SALTS AFTER CLEANING SEQUESTRANTS IN LOW CONCENTRATIONS (5-20 mg/kg)

  14. CLEANING 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

  15. wetting agents • surfactants • sequestering agents • threshold agents CLEANING 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

  16. COMPARISON

  17. SINGLE STAGE / FORMULATED PRODUCTSDIFFERENCES • Increased costs for cleaning materials • Shorter cleaning time and thus reduced down time • Less energy • Less water • Lower overall costs

  18. DUAL STAGE CLEANING

  19. SINGLE STAGE CLEANING

  20. Blue slides borrowed from: Lammert Baas lammert.baas@johnsohndiversey.com

  21. SANITATION CLEAN SURFACES ARE EASY TO SANITISE • BY HEAT • BY CHEMICALS • BY COMBINATIONS

  22. SANITATION • BY HEAT PASTEURISATION - INACTIVATES MOST VEGETATIVE MICROBES, INCLUDING PATHOGENS STERILISATION - INACTIVATES ALL MICROBES, INCLUDING (HEAT RESISTANT) SPORES

  23. SANITATION • BY CHEMICALS or COMBINATIONS INACTIVATES SOME OR MANY OR ALL MICROBES, INCLUDING PATHOGENS AND PATHOGENS, DEPENDING ON CHEMICALS and TEMPERATURE

  24. SANITATION IMPORTANT DISINFECTANTS • ACTIVE CHLORINE COMPOUNDS - SLIGHTLY ALKALINE HYPOCHLORITE - CHLORINE DIOXIDE • IODOPHORS • QUATERNARY AMMONIUM COMPOUNDS • PEROXY COMPOUNDS - HYDROGENPEROXIDE - PERACETIC ACID • ACIDS AND ALKALIS AT ELEVATED TEMPERATURE

  25. Emulsion picture by Jo Janssen, 1993

  26. Thank you for your attention!

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