clean-in-place: how to ensure food safety while maintaining equipment effectiveness

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q  This webinar will be available afterwards at www.designworldonline.com & email

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Before We Start

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Meet your Speakers

MODERATOR

FEATURED SPEAKER Thomas Hedemark Industry Segment Specialist Baumer

Leslie Langnau Managing Editor Design World

FEATURED SPEAKER Christ Makris Product Marketing Manger Baumer

Using Baumer temperature, pressure, level and conductivity sensors

Improved CIP performance

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The importance of food safety Today`s topics

•  Baumer in brief •  The importance of food safety

•  The importance of CIP •  CIP optimization possibilities

•  Questions

CIP Webinar 2015 BADK, tjh

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Brief introduction Baumer

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Slide: 7

Baumer An international family-owned enterprise

•  Headquarter in Frauenfeld, Switzerland

•  Around 2.300 employees worldwide •  37 locations in 19 countries •  Turnover $400 Mio •  Re-invest more than 18% of

turnover into R&D. (250 engineers) •  More than 25 years of supplying

quality sensors for the food and beverage industry

© Baumer 2014


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Slide: 8

Baumer Global coverage

© Baumer 2014


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CIP Webinar 2015 BADK, tjh The importance of food safety

F&B Megatrends 1.  Steady growth in global population

Continuously rising demand for food and energy Volume growth potential everywhere, but especially in Asia

2.  Urbanization / Expansion of middle class Growing quality requirements for foodstuffs Higher demand for aseptic filled processed food and drinks

3. Ricing energy costs / environmental regul. Growing interest in efficient production processes Energy saving machines and processes. Optimization through intelligent engineered products

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Statistics The importance of food safety

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Worst news!

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Impact in the US alone

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Contamination throughout the chain

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The importance of food safety US Recalls over time


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The importance of food safety Cost of recalls (direct cost, loss of profit only)


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Food processing contamination reasons

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Types of food contamination

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Objectives and aspects of cleaning The importance of CIP

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The importance of CIP Aspects of cleaning 1.  Trade obligation

Good, wholesome, clean products that keep well and are free from health hazards are obviously good for trade; customers will buy the same product again.


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The importance of CIP Aspects of cleaning 2. Moral obligation

Most of the customers who consume the products never see the factory or how the products are handled. They trust the company, rely on its reputation.


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The importance of CIP Aspects of cleaning 3. Legal obligation

The law attempts to protect the customer and purchaser in respect of health and quality. Failure to meet legal obligations, national or local, can result in very severe action, and prosecution proceedings can be very costly.


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1.  Physical cleanliness Removal of all visible dirt from the surface

2.  Chemical cleanliness Removal not only of all visible dirt but also of microscopic residues which can be detected by taste or smell but are not visible to the naked eye

3. Bacteriological cleanliness Attained by disinfection

4.  Sterile cleanliness Destruction of all micro-organisms

The importance of CIP Cleanliness

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CIP Webinar 2015 BADK, tjh The importance of CIP

F&B industry CIP savings 1.  Reduce cycle time

Preparation of CIP solutions, cleaning & disinfection steps, rinsing steps

2.  Reduce water consumption Preparation of chemical / hot water solutions, rinsing steps 3. Reduce chemical consumption Alkaline, acid, disinfectant 4.  Reduce overall energy costs Heating and cooling 5.  Reduce waste of product

Product recovery before CIP cycle

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1.  Survey from industry leaders on sustainability priorities of food & beverage and consumer products industries

The importance of CIP F&B industry general sustainability priorities

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Baumer process sensors CIP optimization possibilities

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CIP Webinar 2015 BADK, tjh CIP optimization possibilities

Parameters1/2 1.  Modifying chemicals

New chemicals can be tested. Concentration of existing chemicals can be altered to see if cleanliness is achieved more easily.

2.  Altering cleaning times Increasing or decreasing the time taken for rinse or for chemical solution cycles may result in some efficiency gains.

3.  Adjusting water temperature Increasing the temperature of water to decrease the cleaning time or decreasing the temperature to lower energy costs are also possible options.

4.  Reconfiguring settings A study of CIP lines usage can be a useful way to improve production efficiency. For example if line 1 is at 100% capacity and line 2 is rarely used, a simple re-balancing would be to move some equipment cleaning to line 2.

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CIP Webinar 2015 BADK, tjh CIP optimization possibilities

Parameters 2/2 5. Maximizing chemical effectiveness

The introduction of enzyme-based detergents to speed up chemical reactions or membranes to filter chemicals and enable them to be re-used for longer helps save resources.

6. Implementing eco-friendly solutions

Bio-decontaminants eliminate the need for the use of harsh chemicals and can help reduce the amount of energy, time and water for the cleaning process.

7.  Equipment upgrades & maintenance

Disconnecting or removing redundant pipework. Change valves, nozzles, sensors (conductivity, temperature, pressure, level, flow) to achieve a higher degree of effectiveness and reliability.

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CIP optimization possibilities CIP equipment overview


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Baumer process sensors 1.  Avoidance of hazards

•  Food industry approved lubricants •  Free of cleaning residues

•  Corrosion resistant materials

2.  Hygienically designed components •  No sharp edges or dirt traps •  Easily cleaned and sanitized •  Continues to work perfectly after cleaning

3.  Industry standards and directives

•  FDA approved materials •  Approved to 3A standards •  Approved to EHEDG standards

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CIP optimization possibilities Media recovery

CombiLyz

Product recovery before CIP cycle to ensure valuable product does not end up in drainage.

Temperature monitoring

Level Point detection max/min

Media recovery

Concentrate

dosing of chemicals

End of cycle (CIP)

Dry run protection

Continuous level

measurement


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CIP optimization possibilities Concentrate dosing of chemicals

To control the concentrate dosing of acid or caustic in the circulation loop, CombiLyz measures the specified concentration accurately to always ensure the right mix between water and chemicals.

CombiLyz



Media recovery

Concentrate

dosing of chemicals

End of cycle (CIP)

Dry run protection

Continuous level

measurement


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CIP optimization possibilities End of cycle (CIP) CombiLyz

Final CIP step (return). To avoid unnecessary spillage of water it is important to measure exactly when the rinsing water is running clear of chemicals. This step also to avoid chemicals in the continued manufacturing process.



Media recovery

Concentrate

dosing of chemicals

End of cycle (CIP)

Dry run protection

Continuous level

measurement


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CIP optimization possibilities Tank temperature monitoring

To ensure maximal cleaning effect, the temperature of the detergent inside the tank must be precisely monitored.

CombiTemp


Concentrate dosing of chemicals

Phase separation of detergents &

water

Cleanness measurement

of rinsing water


Dry run protection

Continuous level

measurement


TER8

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CIP optimization possibilities Level point detection

Fast and reliable sensor to detect the maximum and minimum tank levels. The CleverLevel can be used in all harsh environments and media. Can be set-up to ignore or detect foam.

CleverLevel





of rinsing water


water

Dry run protection

Continuous level

measurement


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CIP optimization possibilities Dry run protection

The CleverLevel protects the pump from running dry during filling and emptying of the tank or pipe. Especially in processes where foam can occur the sensor must decide if the media is just foam or liquid. Conventional sensors have problems detecting these conditions.

CleverLevel

Dry run protection



of rinsing water


water



Continuous level

measurement


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CIP optimization possibilities Continues level measurement

To measure continuous level of liquid in the tank, Baumer offers a variety of sensors for all needs. With hydrostatic technology the PLC will receive constant level information even under extreme temperature conditions up to 200 °C in permanent operation.

CombiPress


Continuous level

measurement



of rinsing water


water


Dry run protection


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Page: 37

Display modes:

Touch screen

Value only

Bar graph

Analogue

Tank illustration

Flashing in warning mode

CIP optimization possibilities Display features


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CIP optimization possibilities Process connections and fixings

•  Hygienic process connections

ISO Clamp Varivent N DIN 11851 SMS 1145

•  Also available with a varity fixing accessories:

Union nuts Clamp rings O-rings & gaskets


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CIP optimization possibilities Welding parts and adapters

Tank Thin wall tank Pipes (T) Angled

•  Adapters

G½” to G1” Industry adapter Industry adapter

•  Hygienic welding parts


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CIP optimization possibilities CIP portfolio Overview


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CIP optimization possibilities Your benefits at a glance

Reduce CIP operation costs: Efficient resource and material utilization, higher productivity

Simplify CIP System Easy sensor configuration,

ready to fit process adapters and design variants

Support from an experienced partner: Convenient sourcing from a

comprehensive portfolio, access to premium sensor technology

know how

Food Safety: Precise cleaning process control and process safety with sensors

Optimize field operations:

Clear and field proven status indication using your individual

terminology


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Thomas Hedemark Industry Segment Specialist Baumer [email protected] @BaumerGroup

Christ Makris Product Marketing Manger Baumer [email protected] @BaumerGroup

Leslie Langnau Managing Editor Design World [email protected] @DW_3DPrinting

Questions?

MODERATOR

FEATURED SPEAKER

FEATURED SPEAKER

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