cip latest technologies, typical errors and cip assurance...pi pi cip return cip return ti fi ci ti...

■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■

CIP – Latest Technologies, Typical Errors and CIP Assurance

Influences on Cleaning (Sinner)

Source: Natursteinpflege24.de

Action

Temperature

Chemicals

Applied Agents

• Caustic cleaner (NaOH)

• Combined cleaner (NaOH + detergent or hypochlorite)

• Phosphoric acid or nitric acid (up to 5 %), better for

environment: lactic acid or citric acid

• Peracetic acid or hydrogen peroxide, chlorine

dioxide, salicylic acid, etc. as disinfectant

Detergents

Surfactants

decrease of surface tension

lower adhesion of dirt to surfaces

better swelling of dirt

possibility of wetting gaps and cracks

Penetration Behaviour of Liquids with different Surface Tensions

water 72 mN/m

milk 52 mN/m

beer 43 mN/m

quats 24...34 mN/m

microorganism

Disinfectants

• type and degree of contamination

• efficiency of disinfectant

• temperature

• nature and condition of the surface

• time

A proper disinfection is dependent on:

Disinfectants are chemical compounds which

are able to inactivate microorganisms due to

different modes of action.

Disinfectant Mode of Action Features Structure

Peroxides e.g. peracetic acid

Oxidation effect Sensitive to organic soilsand copper, attacsrubber,

Aldehydes Reaction with carbonyl-,amino-, hydroxyl- andsulfhydryl groups of cellproteins

Sensitive to organicsoils, limkted action onGram-neg. MO

Salicylic Acid Attacs membranes, replacespantothenic acid, no CoAcan be synthesized

Stable, insensitiveagainst organics, oftenused with acids

MonobromaticAcid

Reaction with SH-groups ofenzyme proteins

Stable, insensitiveagainst organics, oftenused with acids

Quats Destruction of semi-permeability of cell wall bylowering the charge andsurface tension

Non-corrosive; stable athigh temperatures

Guanidines Similar to Quats Deposits at pH 12; nosurface activity

Hypochlorite Oxidation effect Sensitive to org. soils; instable at high temp.

Iodophores Oxidation effect Problematic with copperand rubber

Disinfectants - Oxidants

Peracetic acid; H2O2:

• Release of O-radicals (nascent oxygen)

reaction with proteins and lipids of cell wall

penetration of cell wall and denaturation of

proteins

• Mostly in final rinsing water

• Also applied as cleaning booster (cracking)

Wort Cooler – Cracking

Deep Cleaning – Once a Year

Sodium Hypochlorite

Mode of action: NaOCl NaCl + O

Besides disinfection very good for periodic intensive deep cleaning

To avoid corrosion (!):

• pH of the cleaning solution > 11 (always in NaOH)

• Concentration not above 5 %

• Temperature not above 65 °C resp. 149 °F

• Maximum contact time 1 hour

• Unsuitable for rubber-containing gasket materials

Disinfectants - Chlorine Dioxide

4 HCL + 5 NaClO2 4 ClO2 + 5 NaCl + 2 H2O

• Application in water disinfection

brewing water

bottle washer (cold water zone)

bottle rinser (after crowning)

belt lubricants

• Organic residuals weaken the efficiency

Source: GrundfossSource: Dr. Wolf GmbH

CIP-PLANTS

Disinfectant

concentrate

Caustic soda

concentrate

Freshwater

Dis-infectant

Acid Hotcaustic

Returnwater

CI CI CI

Condensate

TICTIC

Condensate

to plant

Return

CITI FI

CLEANING-IN-PLACE (CIP) INSTALLATION

• Cleaning times

• Flow velocities

• Conductivities

• Temperatures

• Cleaning of safety fittings and mountings

• Cleaning of sample drawers

• Frequency of jet cleaners if existent

• Checking the change of medias

Controlling CIP - Operations

CIP – Control System

Mechanical Impact in CIP Systems

Spraying Equipment for Tanks

Spray Ball Jet Cleaner

Atmospheric

pressure

re liq

Course of pressure in pipe

Pressure Loss in Pipes

Pressure and Cleaning Effect

Highest mechanical effect

In sump

mechanical effect low

Too low pressure no

mechanical Effect no

sufficient film at surface

Sufficient flow rate results in

a consistent liquid film on

the walls surface

Too high pressure rebound

Consistent Showering of the

Vessel Wall *

* Zürcher, Dresdner Brauertag 2003

for a falling film thickness 1 mm turbulent flow

set point value: 25 – 30 l / (m * min)

showering [ l /(m * min) ] =

flow rate [ hl / h ] * 100 / 60 / circumference [ m ]

Flow Showering

hl/h l/m x min

80 11.7

171 25.0

200 29.2

Influences of CO2 on the Process

Tank - CO2 - Removal – Why?

1. Loss of alkalinity by neutralization

2. Risk of vacuum formation

3. Precipitations interfering with the process

4. Pit corrosion (Hypochlorite)

Insufficient CO2-Removal - Carbonates

2 NaOH + CO2 NaHCO3 + H2O

Example: 3000 hl tank filled with 2500 hl

500 hl head space

At pop = 0.6 bar ≈ 80 m3 CO2 = 160 kg CO2

neutralization of 291 kg NaOH possible!

Vacuum II

Carbonate Precipitations – Insufficient CO2-Removal before Caustic Cleaning

Pre-Cleaning with Caustic-Shot

No pre-rinsing

No de-aeration

Source: Sopura

1. Shot NaOH

Source: Sopura

1. Shot NaOH

1. Defined rest

Source: Sopura

1. Shot NaOH

1. Defined rest

2. Shot NaOH

Source: Sopura

1. Shot NaOH

1. Defined rest

2. Shot NaOH

2. Defined rest

Source: Sopura

1. Shot NaOH

1. Defined Rast

2. Shot NaOH

2. Defined rest

3. Shot NaOH

Source: Sopura

1. Shot NaOH

1. Defined rest

2. Shot NaOH

2. Defined rest

3. Shot NaOH

3. Defined rest

Source: Sopura

1. Shot NaOH

1. Defined rest

2. Shot NaOH

2. Defined rest

3. Shot NaOH

3. Defined rest

Intermediate rinsing

Source: Sopura

Empty tank

After acid

cleaning

1. Shot 2. Shot

Intermediate

rinsing with fresh

water after shots

3. Shot

Source: Sopura

Spray Shadows

Spray Shadows!

Before Cleaning:

After Cleaning:

Spray Shadows!

Absurd Installations!

Opening the Tank peels the Eyes

Blocked Sprayballs

Wrongly inserted Conus Gasket

ImproperWelding Seams

Improper Welding Seams

Endoscope

• Endoscopy is a minimally invasive diagnostic medical procedure that is used to assess the interior surfaces of an organ by inserting a tube into the body. (Wikipedia)

• Endoscope of the VLB:Pixel: 500 x 582Light sensitiveness: 0.5 LuxObjective: f = 2,3 mm, F = 1,2Picture angle: 120°Light source: 12 white LEDsProtection: waterproof acc. IP 68Temperature range: -10 - 50 °C,Wire with distance marks: Length: 20 mDiameter: 6 mm

Source: Pahl; VLB -FMV

■■ VLB Berlin, D. Bilge ■■ ■■■ CBC 2016 - Philadelphia ■■■Source: Pahl; VLB -FMV

Dead Ends

Placing of no-return Valves

Wrong Position of no-return Valve

Cleaning with closed Connecter Valves

Cleaning with closed Connectors and broken Gaskets

cip latest technologies, typical errors and cip assurance...pi pi cip return cip return ti fi ci ti...

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