Dairy Australia / NCDEA webinar

CIP for Hot Surfaces

Webinar
August 1st
2014

Robert Ellis B Sc(hons) MRACI CChem

Technical Support Coordinator

Food & Beverage Division

Content

Why clean at all?

The Equipment being cleaned

Types of detergents

CIP fundamentals

CIP program options

Common mistakes with CIP

Validation

Why clean at all?

Definition:
a soil is something that is not where it belongs.
Dairy type soils, including milkstone usually contain
combinations of, or all of the following:

Proteins

Fats

Carbohydrates

Minerals

Why clean at all?

The main purposes for cleaning are to:

Sanitise
Achieve Plant Efficiencies
If surfaces are not clean, sanitation is a waste of time
and money.

Heating and cooling efficiency

Removal of burnt on soils from the heating surfaces.

Milkstone has 1 / 20th of the heat transfer rate of stainless steel.

e.g. reduced efficiency of UHT heat exchanger

Why clean at all?

The longer the soil remains, removal is more difficult.

Heated surfaces have the most difficult to remove soils

Scale is put down in layers, thus removal can be similar.

Heavy duty regimes are usually employed.

Soils & scale provide homes for microbes - spoilage

organisms.

The Soils
Soils left on heated surfaces are different
from those left on cold surfaces

Proteins

Denature with temperature

Develop cross links which reduce solubility

Fats

Burn onto surfaces

Combine with other soil types

Carbohydrates

Carbonise and become less soluble

Minerals

Precipitate out of solution at high temperatures

The Equipment
Soils left on heated surfaces can vary with
the type of equipment used

Evaporators

Pasteurisers

UHT / Sterilisers

Holding tubes

The Equipment
Evaporator
Key considerations

The temperature at which the product

was run, the higher the temperature
the harder it is to remove the soil

The % solids coming off the final effect,

the higher the solids the tougher the
soil

How long the evaporator ran, 10 hours,

19 hours or up to 50 hours

The Equipment
UHT sterilisers and Pasteurisers
Key considerations

The temperature profile within

the system

The product type

e.g. Holding tubes 140C

e.g. Heat exchange 80C

Skin vs Full Cream vs Flavoured milk

Length of run

Full clean
Intermediate cleans
Flavour changes

Detergent Types
Common cleaning chemicals

Alkali

Caustic Detergents remove:

Fats
Oils
Carbohydrates
Proteins

Acids

Acid Detergents remove:

Minerals
Milkstone

Detergent Types
Alkaline detergent types

Raw Caustic (Sodium Hydroxide)

Advantages

Low cost commodity

Disadvantages
Poor soil removal/penetration
Increased CIP time
High impact on waste treatment
Have to use at high levels for any performance

Detergent Types
Alkaline detergent types

Fully built alkaline detergents containing

Surfactants and Wetting Agents
Chelating Agents
Emulsifiers
e.g. Glissen, Avoid, Enviro CIP

Advantages
Better for soil removal/penetration
Decreased CIP time
Reduced caustic levels required
Reduced impact on waste treatment

Disadvantages

Additional cost of cleaning chemicals

Detergent Types
Alkaline detergent types
Additive

program with bulk Caustic

Mix additives with caustic on site

e.g. Duplex, Stabilon CIP

Advantages
Better for cost / efficiency ratio
Provide fit for purpose on site formulated detergents for
different areas throughout the process area.
Decreased CIP time
Reduced caustic levels required
Reduced impact on waste treatment

Disadvantages
Some additional cost of chemicals (cf commodity only)
Additional requirements for bulk storage/mixing equipment

Detergent Types
Acid detergent types
Acids

can be use as raw acids or blended.

New

technology products include wetting agents and

surfactants for improved cleaning with reduced
concentrations.
Phosphoric
Hydrochloric
Sulphuric
Nitric
Sulfamic
Organic

e.g. Formula 507A

ensure inhibitor is used e.g. Acidblend H300
e.g. Envirocid Plus
inhibitor recommended e.g. Super Stonekleen
e.g. DS 88
e.g. Ultrasil 73

CIP Systems
CIP fundamentals
Four key factors for cleaning
Concentration

Time
Temperature

Concentration

Cleaner and sanitiser

Mechanical

action

Flow and pressure

Temperature
Mechanical
Action
Time

CIP Systems
CIP fundamentals
Factors affecting cleaning performance

Water Quality

Hardness, salts, iron, pH

Soil Type

Soil Condition

Type of Equipment

Effluent Constraints

CIP Systems
Simple single use CIP system

CIP Systems
Solution recovery system

CIP Systems
CIP types

Single Use

All solutions used once.

All used cleaning solutions go to drain

Solution recovery

Rinse solutions are reclaimed for pre-rinse at next CIP.

Full Re-Use

High soil load portions of cleaning solutions are dumped

Low soil load solutions are reclaimed and adjusted for
concentration
Post rinses reclaimed for pre-rinsing at next CIP.

CIP Systems
CIP types features and benefits

Single Use
Advantages

Equipment cost is low

Flexible CIP regimes to suit individual requirements

Disadvantages

High use of CIP chemicals

High impact on waste treatment

Solution (rinse) recovery

Advantages

Reduce water use (recovered rinses)

Improve initial rinse (pre rinse)

Disadvantages

Some additional equipment cost cf single use

High use of CIP chemicals
High impact on waste treatment

CIP Systems
CIP types features and benefits
Full Re-Use
Advantages
Reduced CIP chemical cost (recovered cleaning solution)*
Reduce water use (recovered rinses)
Improve initial rinse (pre rinse)
Lower impact on waste treatment*

Disadvantages

High initial equipment cost

Reduced or no flexibility of chemical concentrations*

* Full re-use systems are locked into a specific chemical concentration.

Need to separate hot and cold surface CIP sets for cleaning cost and
sustainability.
e.g. CIP by equipment functionality not production area.

CIP Systems
CIP line flow rates

1.5 m/s required

for turbulent flow
System restrictions

Changing pipe sizes

Identify dead legs

Hard to clean

Cleaning through pumps & valves

Changes in pipe sizes can restrict flow in the circuit.

Restrictions in flow

Vertical rises & elbows

CIP supply head pressure knowledge required

CIP Programs for heated surfaces

Typical Full Clean Program
1.

Rinse

2.

Caustic clean

3.

Rinse

4.

Acid clean

5.

Rinse

6.

Sanitise (heat or chemical)

CIP Programs for heated surfaces

Typical Intermediate Program
1.

Rinse

2.

Caustic clean

3.

Rinse

4.

Sanitise (heat or chemical)

Usually performed in conjunction with the Full Clean program

Alternating sequence depends on

Soil type and condition

Cleaning chemistry use of EDTA additives extends acid clean intervals

CIP Programs for heated surfaces

Pre-treatment Programs
1.

Rinse

2.

Alkaline clean cycle

a)
b)

Pre-treatment
Caustic clean (override)

3.

Rinse

4.

Acid clean (cycle as required)

5.

Rinse

6.

Sanitise (heat or chemical)

CIP Programs for heated surfaces

Why the different CIP programs
Full CIP Clean
Advantages

Good soil removal organics and scale

Disadvantages

Long CIP time

High impact on waste treatment

Intermediate CIP
Advantages
Shorter CIP time
Reduced chemical and water use
Lower impact on waste treatment

Disadvantages

No complete removal of scale gross soil reduction only

CIP Programs for heated surfaces

Why the different CIP programs
Single Phase CIP
With EDTA based additives

Advantages

Shorter CIP time no acid step

Reduced chemical and water use
Lower impact on waste treatment

Disadvantages

Still required remedial acid clean (weekly/monthly)

No always best at organic soil removal

Pre treatment CIP Clean

Advantages
Excellent soil removal organics and scale
Shorter CIP time
Lower impact on waste treatment (reduced caustic use)

Disadvantages

Some increase in chemical cost

Common mistakes with CIP

Cleaning Failures
Blue Sheen on Metal

Protein film
incomplete clean cycle
incorrect choice of chemical used for cleaning
protein gel formation (hot caustic solutions)

Temperature shock
hot water on cold tank
water temperature to high

Magnesium deposits in water (12ppm)

Water softener needs recharging

Cleaning Failures
Build-Up of white(soft) film
Cleaning solution low in active alkalinity
Incorrect choice of cleaning chemical

more surfactants required for soil penetration

more builders required to prevent redeposition of soil

Failure to rinse properly and thoroughly after wash step

Cleaning Failures
Build-Up of white(hard) film
Hard water used at high temperature (> 70C)
Cleaner allowed to dry on surface before rinsing
Cleaner used at too high temperature

Cleaning Failures
Deterioration of gaskets
Excessive cleaner strength
Excessive cleaning temperature

Particularly with nitric acid products

Sanitizing with chlorine solution too long in advance of

equipment being used
Failure to follow cleaning with adequate rinse

Cleaning Failures
Corrosion and pitting
Delays in rinsing when emptied
Excessive use and concentration of cleaning chemicals and
sanitizers
Use of non-inhibited nitric acid
Surface not cool when sanitizing
Prolonged contact with chlorine or heat still present
Improper and inadequate rinse after cleaning
Stainless steel not passivated

Cleaning Failures
Unclean sections of pipe
Failure to include the pipe in the CIP circuit
Inadequate velocity (>1.5 m/s)
Cleaning solution strength inadequate
Cleaning wash temperature inadequate
Cleaning cycle time inadequate
Processing valves washed within the circuit
not operating properly or not programmed

Cleaning Failures
Unclean portions of tank surface
Spray device plugged with debris
Distribution holes incorrectly spaced/located
Inadequate flow rate to spray device
Inadequate detergent concentration
Inadequate wash temperature
Inadequate wash cycle time
Spray device position to high or low from top of vessel
Product allowed to dry on surface before CIP cycle is run
Pressure of cleaning solution through spray device too high
causing solution to aerosol

Cleaning Failures
Ring of soil in lower part of the tank/vessel
Return pump capacity not sufficient to correctly evacuate or return
solution to CIP system
Return pump air bound
Inadequate detergent concentration or improper temperature
Constant rinse allowing soil to float
Rinse times inadequate

Cleaning Failures
Air valve on processing tank not clean
Failure to pulsate
Improper frequency rate during pulsation
If valve cannot be pulsed during wash
cycle, valve was not manually operated or
cleaned

Validation of the cleaning process

The Measure of Success

If you do not achieve the required result,

however many resources you have spent,
then all the time, effort & money was to no avail.

Validation of the cleaning process

Know your system

Do you know what is going on in your CIP Set?

Do you only know what it is supposed to do?

Make sure what you think happens is happening,

and only then will you get good CIP results!

Validation of the cleaning process

Manually validating CIPs
Recommended parameters to be measured include

Cycle times

Temperature (supply & return)

Flow rates

Vessel low level

Pressure

Number of CIP's

Concentration (make-up & return)

Confirmation of delivery (detergent & sanitiser)

Detergent / sanitiser usage

Total Cost per Clean (bench marking)

Validation of the cleaning process

Automatic validation of CIPs
Common CIP parameters
measured over time include
Conductivity
Temperature

pH

Turbidity

Additional data

14

80
12

70
10
60

50

pH

90

Temperauter / Conductivity / Turbidity

40

30
4
20

Flow rates

Pump and valve operation

Set points and variation

10

0
22:50

23:00

23:10

23:20

23:30

23:40

23:50

0:00

0:10

0:20

0:30

Time
Temperature

Conductivity

Turbidity

pH

0
0:40

Topics covered

Why clean at all?

Types of detergents

CIP fundamentals

CIP program options

Common mistakes with CIP

Validation