605-04 3-A® Accepted Practices for Permanently Installed Product and Solution Pipelines and Cleaning Systems Used in Milk and Milk Product Processing Plants, Number 605-04 Formulated by JImernational association of Food Industry Suppliers (LA FS) International Association for Food Protection (LAP) United States Public Healt Service (USPHS) The Dairy Industry Comittee (DIC) tis the purpose of the JAFIS, IAFP, USPHS, and DIC in connection with the development ofthe 3-A Sanitary Standards program co allow and encourage full freedom for inventive geaius or new developments, Practices for permanently installed product and solution pipelines and cleaning systems specifications heretofore or hereafter developed which so Lifer in design. materials, and construction, oF therise, as not to conform to the following practices but which in the manufacturers or fabricators opinion, are equivalent or better may be submitted for joint consideration ofthe IAFIS. IAPPS, USPHS and DIC at any time, NOTE: Use current revisions of editions ofall referencod documents cited herein ‘Standard English is the official language of 3-A Sanitary Standards and 3-A. Accepted Practices. A SCOPE, B DEFINITIONS. Al These 3-A Accepted Practices provide for BL CIP (Cleaned-tn-Place) Mechanical the instalation and mechanical cleaning and Cleansing: Shall denote cleaning solely by sanitizing of rigid pipelines used for milk circulation and/or flowing, chemical and milk processing systems in whieh the detergent solutions and water rinses onto and connections are welded or are provided with ‘over the surfaces to be cleaned, by ppeemanenaly instal 3-A Aceepied Pra sd CIP fitngs, These ‘mechanical means also specify materials, fabrication and other requirements B2 Pipelines forthe rigid cleaning solution lines and For the mechanical cleaning (CIP) unit which B21 Permanently installed Produet Pipelines: circulates the pre-inse. rinse. cleaning ‘Shall mean rigid pipelines which have solutions and post-inse liquids used for welded joints or permanently installed C cleaning and sanitizing the praduet pipelines fiwings and are designed foe CIP cleaning and process equipment. The mechanical and which are used for milk and mill cleaning and sanitizing of individual ftems of products equipment may be found in the 3 Standards covering the specific equi 82.2 Permanently Installed Solution Pipelines: This practice does not pertain to cleaning Shall mean rigid pipelines which have systems used on dairy farms, nor to large ‘welded joints or have permanently installed diameter piping used for conveying dry CIP ype fittings and are used exclusively for product in milk drying or instantizing the supply’ and recirculation of eleaning, systems. (See Appendix, Section P for an and/or sanitizing solutions. except those example of a mechanical (CIP) cleaning used to supply concentrated cleaning and/or unit) ssinitizing materials to the poiat of use. B3_— Permanently Installed CIP Fitings: Shall ‘mean welded or gasketed fitings designed s 5 : 5BY Bo 87 BS Bo. 9.1 BOL 89.1.2 89.13 Bold BOLLS B9.1.6 9.1.7 B92 for CIP cleaning wich form substantially smooth, flush interior surfaces Produet: Shall mean mill and milk products Product Comaet Surfaces: Shall mean all surfaces that are exposed to the product or from which liquids may drain, drop. oF be drawn into the product. Solutions: Shall mean those solutions used Tor flushing. cleaning, rinsing, and sanitizing, Solution Contact Surfaces: Shell mean the imerior surfaces of the system which sre used exclusively for supply and recirculation of cleaning andior sanitizing solutions. except those used to supply concentrated cleaning and/or sanitizing materials to the point of use Nonproduet Contact Suefaces: Shall mean all other exposed surfaces. Mechanical Cl ning (CIP) Un Mechanical Cleaning (CIP) Unit: Shall ‘mean equipment assembled as a unit dedicated fo and used exclusively for supply. and recirculation of cleaning and/oc sanitizing solutions. This equipment may include but isnot Fimited to the following: Solution Pumps. Solution Tanks): Solution Supply and Rewn Valves) andl Valve Manifolds, Pings; Solution Contaet Heat Exchangers) or Steam Injectorts Insirument Finingls) and Swainers. ‘The mechanical cleaning (CIP) unit does not 605-04 include utility piping. BLO Tungsten Inert Gas (TIG) Method: Shall mean electric welding with a tungsten electrode shielded by an inert gas, 10 produce a but fusion weld. BIL Non CIP Appurtenances: Shalt mean those appurtenances such as plug valves. sample cocks, instrument fitings. pumps and parts Daving the same functional purposes and not ‘designed for mechanical cleaning. B12 Usity Piping: Shall mean oiher system service piping such asthe steam supply line Lup to and including the steam supply valve: chemical injection lies up to and including the chemical shut-off device: water supply fines up to and including the water shut-of valve, © MATERIALS Cl The materials of equipment included in the product and solution pipelines and ‘mechanical cleaning units for which there ‘ore applicable 3-A Sanitary Standards or ‘Accepted Practices shall comply with the ‘material erteria ofthe applienble Standards or Practices, C2 Alloher product and solution contact surfaces shall be of stainless siel ofthe American Tron and Stee! Institute (AISI) 300 Series! or corresponding Alloy Cast Institute (ACH? types (See Appendix, Section 1.) or metal which under conditions of intended use is at least as corrosion resistant as stainless steel of the foregoing types and is, nontoxic and nonabsorbent, or heat-resistant lass piping, except that: C21 Rubberand rubber-like materials may be used for gaskets, seals and short take-down jumpers. "re dt arte senes are conse nthe AISI Ste! Proaets ‘Maria, Sales & Het Ressing Sil, December 1974, Table ‘20 Ave fem te Fen and Se! Soret. 185. ye lead, Warrendale, PA S089 (724179400 * Alay Casing nesta Divo, Sts Founders Saeey of ‘Ameren, Cast Met Foleaton Bg 488 Sate St, Des Plies, T0016 705) 29.8860 nora npost23 ca 63 ca DI DB Rubber and rubber-like materials shall ‘comply with the applicable provisions ofthe 3-A Standards for Rubber and Rubber-Like Materials Used as Product Contact Surfaces in Daicy Equipment, Number 18 Plastic materials may be used for gaskets, seals, sight ports and shor take-down jumpers. Plastic materials shall comply with the applicable provisions of the 3-A Standards {or Moltiple-Use Plastic Materials Used as Product Contact Surfaces for Dairy Equipment, Number 20. Utity piping need not be stainless steel Paper gaskets shall not be used. FABRICATION ‘The fabrication erteria of equipment included in the permanently installed product and solution pipelines for which ‘there are applicable 3-A Sanitary Standards or Accepted Practices shall be those of the applicable 3-A Sanitary Standard or Accepted Practice. All other product contact surfaces shall have a finish at least as smooth as a No, 4 ground ish on stainless steel sheets, and be free of ‘imperfections such as pits, folds and crevices in the inal fabricated form. (See Appendix Section J.) Al solution contact surfaces shall be a least as smooth as a No. 4 ground finish on stainless steel sheets, except for those of castings for solution heat exchanger(sVsteam injectors) and pumps. This does not preclude the use of a No. 2B finish for solution contact surfaces ‘The solution contact surfaces of castings for heat exchangers(sV/steam injector(s) and for pumps shal be a leat as smooth as ACI Surface Indicator Seale SIS-1 (See Appendix, Section ML) 605-04 D4 Product Fines shall eomply withthe provisions of 3-A Standards for Polished “Metal Tubing for Dairy Products, Number DS Product and solution lines and equipment shall have permanently installed CIP fitings cor welded joints. Gasketed CIP fitings shall be readily demountable for inspection. DS Welded joins shall be smooth and free from pis, folds, crevices, cracks. inclusions. or other defects. (See Section G.) D7 Removable tings may be used with or Without gaskets and shall be ofsuch design so form substantially sh interior joints 7.1 Gaskets, when used. shall be selpositioning and form a substantially Mush interior join. DS Power operated solution valves shall have an open space of al least Lin. (25 mm), clear For nspection, between the actuator and the valve. D9 Non CIP appurtenances, such as plug valves. instrument fitings, sample cocks, pumps and parts having the same functional purposes ‘hich have product or sofution contact surfaces shall be readily demountable and easily disassembled for manval cleaning and sanitizing, DIO Radi DIO.1 All internal angles of 135° or less on product ‘contact and solution contact surfaces shall (of 1/4 in, (6 mm) except Ihave axinimum ra ‘that DIO.L.1 The radi in gasket retaining grooves except for those for standard 1/4 in (6 mm) and smaller O-Rings, shall be not Tess than 1/8 in. (3 mm). 10.1.2 Smaller radii may be used when they are required for essential functional reasons, such as those in pump impelters. In no ease shall radi be less than 1/32 in. (1 mm). The angle must be readily accessible for cleaning and inspection, E g 0D10:1.3 The radi in grooves for standard 1/4 in. (6 1am) O-Rings shall be not less than 3/32 in. (2 mm) and for standard 1/8; in. (3 mm) (O-Rings shall be not lass than 1/32 in, (1 am). II Allproduct contact and solution contact surfaces shall be cleanable, ether when in an assembled position or when removed. System appurtenances shall be accessible for inspection DI2 Lines and fitings forthe application of ai under pressure shall comply’ with the applicable provisions of 3-A Accepted Practices for Supplying Air Under Pressure jn Contact with Milk, Milk Products and Product Contact Surfaces. Number 604, DIZ Nonproduct contact surfaces shall be smooth, fee of pockels and ereviees and be readily cleanable DI4 There shall beno threads on product contact surfaces or on solution contact surfaces DIS Information Plate Cleaning solution pumps designed and used solely for CIP recirculation shall be provided with an information plate permanently affixed to the pump, next tothe ame plate stating: "This pump shall be used solely for pumping cleaning and/or sanitizing solutions." 5 INSTALLATION el ines shall be supported so that they remain in alignment and position. The support system shall be designed so as to preclude electrolytic action between suppor(s) and pipeline(s). E2 Bach separate cleaning circuit, including product and solution lines, shall be provided. \with 2 sufficient number of access points, such as valves, fittings, or removable sections to make possible adequate inspection and examination of representative interior surfaces BB 605-04 Pipelines shall be drainable or self-draining and pitched to dain points. Upon completion of welded pipeline installations and prior to use all interior ine and wold areas shall be subjected 10 circulation of cleaning solution of 0.5 10 1% alkalinity a a minimum of 160° F (71.1° C) for 30 minutes, followed by an adequate post rinse, followed by circulation of 0.5% 1um and 1% maximum phosphoric oF nitric acid solution at 150° F (65.6°C) 0 180° F (82.2° C) for 10 minutes to clean all interior surfaces of ferric impurities. (This is ‘no intended for passivation.) This treatment shall be followed by an adequate rinse, LAYOUT AND ENGINEERING REQUIREMENTS Prior to installation, a drawing or equivalent plan shall be made avaitable tothe regulatory agency by the processor for each installation, or subsequent addition or ‘modification, showing each permanent cirevit to be cleaned, The mechanical cleaning unit shall be designed so thatthe suction intake of the primary circulating pump shall be flooded at all times during the cleaning cycle. Solution temperature shall be automatically contolled by the use of temperature contro! system with a response range of + 5° F (+ 3° o., The mechanical cleaning unit shall be provided with 2 recording thermometer or ilar device complying with these ations ora recording device which has been reviewed by the FDA snd found o provide efficient information to adequately evaluate the cleaning and sanitizing regimen and which is approved by the local regulatory agency shal be installed in the ‘c{um solution line or ather appropriate areas to record the temperature and time during which the line oF equipment is ‘exposed to cleaning and sanitizing solutions, Tine Seale range shall be: 60° F 10 180° F (16 10 83° C) with extensions of scale on eramven pau sy 2 fo unr snpetas a ny 0Ps G a cither side permissible: graduated in time-scale divisions of not more than 15, ‘minutes. Above 110° F (44° C), the chart is to be graduated in femperature divisions of ‘not more than 2° F (1° C) spaced not less ‘than 0.0625 in. (0.159 mm) apart, Provided that the temperature-scale divisions of 2° F (1° C) spaced not less than 0.40 in, (1 mim) Apart are permitted when the ink line is thin enough to be easily distinguished from the printed line. Temperatures shal be accurate within 2° F (1° C) plus or minus, when above 110° F (44° C). The per-arm setting doviee shal be easily accessible and simple to adjust. The pen and chart paper shall be designed o make a line not over 0.025 ja, (0.635 mm} wide and be easy to maintain, ‘The stem Ging shall have a pressuce-tight scat against the inside wall of pipe and no threads shall be exposed to solution. The ‘sensor shall be protected against damage at 212° F (100° C), Circular chars shall make ‘one revolution in not more than 24 h. Strip ‘charts shall not move less than | in. (25 mm) per h, More than one record of the cleaning ‘operation shall not overlap the same section of the chat for either circular or siip-type charts, All connections between any solution circuit, and any product circuit shall be effectively separated to positively prevent the commingling of the product and solution during processing. (See Appendix, Section ND There shal be no cross-connection(s) bewveen the sale water supply and any unsafe of questionable water supply or any source of pollution through which the safe ‘water supply might become contaminared For example, a connection between the ‘water supply piping and make-up: tank unless protected by an air gap or eff backeflow preventer constitutes a vilation of this practice. INSTALLATION WELDING REQUIREMENTS, All welding of sanitary product pipelines nd solution lines shall be made by the TG au ai as Gia ais Gis oy 605-04 method or an equally satisfactory method. Te following precautions shall be taken: Inert back-up gas shall be used to provect and control the interior of the weld. ‘The welding surface (interior, face and exterior) shall be cleaned and freed of all Foreign matter and surface oxide before welding, Iron-free abrasive shall be used ‘when cleaning surfaces All tube and fitting ends shall be square cut and debured, Welding procedures shall assure uniform and complete penetration of the weld at all All welds having pts, craters, ridges, or imbedded foreign materials shall be removed and the joins shal be property re-wekded. Internal and external grinding and/or polishing of pipeline welds is not required, (f grinding and/or polishing of external weld surfaces is desired by either the insialler or the user, such finishing shall be delayed until after inspection and acceptance of the ‘welding by the applicable regulatory agencies unless intemal weld surfaces are easily accessible for inspection. An acceptable sample weld piece shall be provided when required, ‘A borascope or other acceptable inspection device shall be available to use to inspect representative welds, CLEANING AND SANITI PROCEDURES, NG ‘A mechanical Nushing, cleaning, rinsing and ‘sanitizing regimen which has been demonstrated to be effective shall be employed. Because of the possibilities of corrasion. the recommendations of the cleaning compound manufacturer shall be followed with respect tothe time, temperature and the concentration of specifie acid or alkaline solutions and ans rams ont (oreTsT3G) Sanny wesunuL fy porngtserd2 1B Ha sanitizers. To insure proper strength of solution and to avoid corrosion, the cleaning ‘compound shall be completely dissolved or Aispersed prior 1 circulation. (See Appendix, Section © for one regimen found to be satisfactory.) Pulsing ofall product outing valves shall be done during each phase of cleaning cycle. ie. rinse. wash, rinse sanitize, A description of the cleaning regimen which has been demonstrated tobe effective for ‘each circuit shall he made available by the processor. Reverse osmosis permente or cow water (condensed vapors removed from liquid dairy praduets by vacuum evaporation) produced in compliance with Appendix D-V of the Pasteurized Milk Ordinance where applicable may only be used as a drain and to make up cleaning solutions. but used as the final rinse or to make ing solutions APPENDIX. NOTE: This appendix is an adjunct to the preceding sections of these practices. Its purpose isto provide information and guidance in the design, fabrication and Installation of rigid pipelines and cleaning systems, 605-04 STAINLESS STEEL MATERIALS Stainless steel conforming to the applicable ‘composition ranges established by AISI for ‘wrought products, or by ACI for eas. produets, should be considered in ‘compliance with the eequirements of Section C.2 herein, Where welding is involved. the carbon content af the stainless stel should rot exceed 0.08%, The reference cited in (C.2 sets forth the chemical ranges and limits of accopiable stainless stels ofthe 300, series. Cast grades of slainless steed equivalent to types 303, 304, and 316 are designated CF-I6P. CF-8, and CF-8M, respectively. These cast gras are covered by ASTM’ specifications A351/A351M, AT43/743M and A744/744M, PRODUCT CONTACT SURFACE FINISH Surface finish equivalent to 150 grit or beter as obtained with silicon carbide, properly applied on stainless steel sheets is considered in compliance with the requirements of Sections D.2 FLOW RATES A circulating unit, consisting of a motor {riven pump and solution nk, should be ‘provided and deliver a minimum Now rate of 5 Nuper sec (FPS) per line when cleaning, In ‘split flow arrangements, a pressure Lifferential should be maintained or flow should be sequenced through multiple paths to.ascure a minimum flow rate of 5 FPS (1.5 ‘meter per second [MPS}). In all cases, sufficient flow should be maintained to assure thatthe lines are fully Nooded at all times. Table gives examples of minimum recommended Mow rates for CIP systems co meet the 5 FPS (1.5 MPS) mean flow velocity. ® vale fe ASTI, 100 Bat Hatbr Drive, West CConshasken. Pa 194262958. Phone (610) 832-2500 € ag) sseanng ens a pabonTASTaTABLE 1: Recommended flow rates to achieve 5 FPS or 1.3 MPS, Sanitary Tube Size Flow Rate 1p Op 1D in. om GPM LPM 10 0.875 2. 94 35.6 13 1375 38 350 © 240-908 20 1875 Sl 47S 3.0 163.0, 23 2373 64 6.033 69.0 261.0 30 2875 76 7303 1020 386.0 40 3.850 10.0 9.779 1820 689.0 Lt 12 MI ‘These flow rates are usually adequate for cleaning pipelines which handle milk and ther relatively low-fat products. Howvever, for more viscous products such as crear, ice eream mix, or concentrated mill produets, it may be necessary to change ‘hese velocities and/or other cleaning variables. Other variables to be considered are time, temperature, and concentration of cleaning formulations. ‘TYPES OF WELDS Automate Weld: A fally automatic weld is that made by equipment which starts and completes the weld. strikes, and conteols the are vith no manual adjustment of control during the welding cycle and will consistently make repetitive welds Semi-auiomatie Weld: semi-automatic ‘weld is that made by equipment wich requires manual strike and/or manual control during the welding cycle and will consistently make repetitive welds. Hand Weld: A weld in which the positioning of the are is manually controled. SPECI |ONS FOR VISUAL INSPECTION OF CAST SURFACE FINISH Because RMS (root mean square) values are applicable stretly to machined surfaces, iis essential to use a scale oFcast surfaces in designating the general surface smoothness desired on castings. The reason for establishing 2 visual standard is to overcome M2 NI 605-04 the obvious inadequacy ofany arithmetical ‘or geometrical measuring system when applied to the surface ofa casting. The ACI SURFACE INDICATOR SCALE is the one to be used for the surfaces of castings for pumps or other appurtenances (See subsection D.3. 1 ofthese Practices.) The seale provides a measure of'the degree ‘of general smoothness which can be attained on alloy castings by currently available ses, There are four surftces shown on Copies of the SPECIFICATIONS FOR VISUAL INSPECTION OF CAs SURFACE PINISH as well as the SURFACE INDICATOR SCALE can be obtained from the Alloy Casting Institute Division, Stcel Founders’ Society of America, Cast Metal Federation Bldg. 455 State Si, Des Plaines, IL 60016, (708-299-9160) SEPARATION OF CLEANING AND PROCESSING CIRCUITS During processing, pipelines and equipment used f9 contain oF conduct milk and milk products shall be effectively separated from {anks or circuits containing cleaning and/or sanitizing solutions (See Section F.3). This cean be accomplished by ‘A-complete physica! separation ofall tanks. pipelines and eireuits: oF ‘Separation is by at least wvo automatically ‘controlled valves with a drainable opening to the atmosphere between the valves. The ‘opening tothe atmosphere should be equal to the largest pipeline size and the valves sould be position detectable, The installation of such valves shall include an ‘automatic fail sale system to prevent product contamination with cleaner and/or sanitizing solutions. “The design of the product and cleaning and/or sanitizing Solution pipedine system should provide forthe permanent installation ‘af as much ofthe pipeline as possible WIG awueens mY pOSIANTT Tey EIEN PENTA z a soy 6 pain ssraNB Na on ons os All unnecessary bypass and retura ‘connections should be eliminated. ‘The piping configuration should enable all processing to be completed without piping ‘changes and yet permit quick conversion to cleaning circuits, except for those changes required for separation of Grade A products and non-Grade A products, CLEANING AND SANIIZING EXAMPLE All solution and product contact surfaces such as dovin tubes fill tubes. manhole gaskets. petcocks, plug valves, check valves, instrument fitings and air purgers not designed for mechanical cleaning and sanitizing procedures should be cleaned and sanitized manually lnmediately after concluding the day's operations. all connections between eleaned-in-place lines and processing equipment wich are not included in the cleaning ireuit should be removed, the openings capped. by-pass connections made, tnd the lines Nlushed thoroughly with tempered water (not to exceed 120° F oF 49° CC entering circuit) continuously discarding the rinse water aear the downstream end of the solution return line until the discarded ceMuent is elea. Circulate an effective detergent solution for ‘ period of time at a concentration and temperature capable of effectively removing the sol residue in the circuit ‘Thoroughly rinse the detergent solution from the circuit, Circulate an acid detergent, when needed. 2s a supplement to the routine circulation, Follow this acid detergent treatment with a ols. o1s3 605-04 thorough rinse anitize all product contact surfaces immediately before use with one ora combination ofthe following commonly used methods: CCireulation of water at a minimum {temperature of 170° F(76.6° C) (atthe discharge end) through the eireuit for $ minutes and drained Pumping ofan approved chemical sanitizer solution of acceptable strength and recommended temperature through product Tines and equipment for at least | minute and drained, Halogen based sanitizers (chlorine and iodine) allowed to remain on surfaces For longer than necessary may cause Exposure fo steam for atleast 15 minutes after the temperature of the drainage a the ‘outlet has reached 170° F(76.7° C) or for 5 minutes after the (emperature ofthe drainage ‘tthe outlet has reached 200° F (93.3° C) NOTE: Approved sanitization procedures and related recommendations are provided in detail inthe Grade “A Pasteurized Mill. Ordinance Recommendations of the US, Public Health Service/Pood und Drug Administeation. SCHEMATIC EXAMPLES OF MECHANICAL CLEANING (CIP) UNIT These amended accepted practices shall become effective August 20, 1994, at which time the A Accepted Practices for Permanently Installed Sanitary Product-Pipelines and Clean Systems, with Anyendment, Number 605-03 are rescinded and ‘become null and void. yun asn +, a2& 605-04 & MECHANICAL CLEANING CIP UNIT z S050 sem otp soutien : LOUTH ARE LOUTARY GUKKCLAMP 0 CADET COMMAETONE 4 SuPpLy 5 eee is 2 «s 2 Sea 3S : a : CIP SOLUTION RETURN WATER s at ow z S00 5 i mr ; ui Eee cH) 2 E 7 Pou dog ; 7 eee 5 i veranotat Te oni Fetus ans re a i eee ee en ; i Hey oH Wa : tt tou toon & . Ae dla Alo du Ae i Lane 1 4 a “tle Wo os i ox Bec 7 a than i a 2 ee EE : Fosse rcatrencroment coisas | SWaREITCMENANE. g Ricmimceuen: Ee NUaeE, eee Seas aay i & i ° i