Principles Of Cleaning And CIP - Alfa Laval

Principles of cleaning and CIPAlyce Hartvigsen CIP in the brewery (and food and beverage applications)29/04/2020 Alfa Laval1 www.alfalaval.com

What we’ll talk about today Agenda Principles of cleaning and CIP CIP in the brewery (and food and beverage applications) Technologies for tank cleaning Optimization of CIP process Automated CIP solutions from Alfa Laval Brewery Systems29/04/2020 Alfa Laval2 www.alfalaval.com

Purpose of cleaning and CIP Why do we clean? Maintenance of product purity, quality and safety Prevention of product contamination (e.g.,spoilage) Prevention of cross-contamination (e.g., ingressof one product into another) Maximization of equipment uptime and productioncapacity (fastest possible resumption ofproduction after completed batch) Maintenance of control of the production process29/04/2020 Alfa Laval3 www.alfalaval.com

Principles of cleaningTACT – Sinners CircleTimeTemperatureChemicalsAction29/04/2020 Alfa Laval Sinners Circle represents thescope of a given cleaning task The combined elements of the circle(temperature, action, chemicals,time) accomplish the task Larger share of one or moreelements allow smaller shares of theothers (e.g., higher temperatureallows less time, or more actionallows less time, lower temperature,less chemicals)4 www.alfalaval.com

Mechanical cleaning (action) Requirements for mechanical cleaning in the brewery For pipes: minimum fluid velocity 1.5 m/secto generate sufficient turbulence to achievethe desired cleaning effect For tanks: cleaning machines generatinggeometric reach of all interior surfaces (coverage)and sufficient impact force on the surfaces For special equipment (e.g., separators and plateheat exchangers): clearly defined cleaningprocedures and specifications to ensure optimumcleaning effect29/04/2020 Alfa Laval5 www.alfalaval.com

Mechanical cleaning Minimum flow rates in pipesPipe sizeMinimum flow rateVelocityDN 2530 hl/h1.7 m/sDN 4080 hl/h1.8 m/sDN 50120 hl/h1.7 m/sDN 65200 hl/h1.7 m/sDN 80300 hl/h1.6 m/sDN 100400 hl/h1.4 m/s Alfa Laval29/04/2020 Alfa LavalSlide 66 www.alfalaval.com

Chemicals used in CIP Main types of cleaning chemicals and their purposeCleaning mediaChemicalcompoundsWaterH2 OPre-rinses, intermediate rinses and final rinses remove solidresidues and flush away chemical residues.Caustic ( 2%) at85oC or 35oCNaOH, KOHDissolves and removes organic residues like yeast and hops.Requires a CO2-free atmosphere to prevent carbonateformation.Acid ( 0.5–1%)HCl, H3PO4,CH3CO3HDissolves and removes inorganic residues like beer stone.Can be combined with disinfectant in a single step.DisinfectantClO2, O3, H2O2Kills bacteria, spores and hardy microorganisms that survivecaustic wash. Can be combined with acid in a single step.WaterH2 OPre-rinses, intermediate rinses and final rinses remove solidresidues and flush away chemical residues.29/04/2020 Alfa LavalFunction7 www.alfalaval.com

Automated Cleaning-in-Place (CIP) What is it? Enables cleaning of tanks, piping and other processequipment without dismantling or manual cleaningprocesses Typically consists of tank cleaning machines installedinside the tanks Involves cleaning stages using water and chemicals thatcirculate through the CIP system to the equipment forthorough cleaning and disinfection Proceeds through the entire sequence of cleaning stepswithout requiring human intervention29/04/2020 Alfa Laval8 www.alfalaval.com

Tank cleaning technology Characteristics of tank cleaning machinesStatic spray ballEasy-to-clean tasksMax. diameter: 3 mPressure: 1–2 barCleaning costs: HighCleaning efficiency: LowFor small tanks, water, CIP29/04/2020 Alfa LavalRotary spray headModerate cleaning tasksMax. diameter: 5 mPressure: 2–3 barCleaning costs: MediumCleaning efficiency: MediumFor small process tanksRotary jet headDifficult cleaning tasksMax. diameter:15 mPressure: 5–7 barCleaning costs: LowCleaning efficiency: HighFor fermenters and large tanks9 www.alfalaval.com

Principles of cleaning – tank cleaning machines Effect of cleaning machine type on required cleaning parameters according to the Sinners CircleTemperatureActionChemicalsTimeStatic spray ball29/04/2020 Alfa LavalRotary spray headRotary jet head10 www.alfalaval.com

Alfa Laval TJ40G Best-in-class for rotary jet head tank cleaning with hygienic design and self-cleaningEnhanced self-cleaning features of TJ40G1Self-cleaning of body2Self-cleaning of nozzles3Self-cleaning of cone12329/04/2020 Alfa Laval11 www.alfalaval.com

Alfa Laval TJ40G Self-cleaning demonstration using yogurt as the test media29/04/2020 Alfa Laval12 www.alfalaval.com

Challenging cleaning task Fermenter yeast ring29/04/2020 Alfa Laval13 www.alfalaval.com

Static spray ball for fermenter yeast ring Fast wetting but low action: inefficient and expensive cleaning Low cleaning action Long cleaning time High operating cost29/04/2020 Alfa Laval14 www.alfalaval.com

Rotary jet head High-impact cleaning Fast effective wettingHigh cleaning actionFast cleaning timeLow operating cost29/04/2020 Alfa Laval15 www.alfalaval.com

Development of TJ40G cleaning pattern TRAX simulation of time, wetting intensity and cleaning fluid consumption TRAX program illustrates wettingintensity in all areas of tankduring the cleaning cycle Examples show wetting andwater consumption after 2 minutes(1 cycle) and 16 minutes(8 cycles 1 full pattern) Tank diameter: 4.6 m Cylinder height: 5.5 m TJ40G: 4 x 7.3 mm nozzles29/04/2020 Alfa Laval16 www.alfalaval.com

Alfa Laval TJ40G Burst Fast-wetting AND high-impact cleaningCut29/04/2020 Alfa Laval17 www.alfalaval.com

Standard TJ40G versus TJ40G BurstStandard TJ40GTJ40G BurstLess caustic is necessary to wet the tank surface using TJ40G Burstas there is no need to build up a dense cleaning pattern29/04/2020 Alfa Laval18 www.alfalaval.com

Savings Standard spray ball CIP with caustic recoveryStepsCIP programRe-use factor %MinutesEUR1Water rinse01026.252Caustic re-circulation856026.2531 x water rinse (1 cycle)5056.5648 x sterilant continues re-circulation90209.3351 x final rinse (2 cycles)10060.00Total per year per fermenter101EUR 2,529Five cleanings per monthFlow rate: Spray ball 350@hl/h29/04/2020 Alfa Laval19 www.alfalaval.com

Savings Burst spray ball CIP without caustic recoveryStepsCIP programRe-use factor %Minutes01.5EUR11 x ambient caustic burst2Wait time31 x ambient caustic burst4Wait time51 x ambient caustic burst6Wait time71 x ambient caustic burst8Wait time91 x water rinse5056.56108 x sterilant continues re-circulation90209.33111 x final rinse10060.00Total per year per fermenter29/04/2020 Alfa Laval4.38501.54.38501.54.38501.56.13557EUR 2,109Five cleanings per monthFlow rate: Spray ball 350@hl/h20 www.alfalaval.com

Savings TJ40G Burst CIP without caustic recoveryStepsCIP programRe-use factor %Minutes01EUR11 x ambient caustic burst2Wait time31 x ambient caustic burst4Wait time51 x ambient caustic burst6Wait time91 x water rinse5021.43108 x sterilant continues re-circulation90205.07111 x final rinse10040.0044EUR 789Total per year per fermenter2.225012.225012.225Five cleanings per monthFlow rate: TJ40G Burst 190@hl/h29/04/2020 Alfa Laval21 www.alfalaval.com

Comparison Summary of savingsSpray ball withcaustic recoverySpray ball withoutcaustic recoveryTJ40G Burst withoutcaustic recoveryWater73 hl15 hl3 hlCaustic52 hl35 hl9 hlSterilant12 hl12 hl6 hl2,530 EUR2,100 EUR789 EURYearly operation cost29/04/2020 Alfa Laval22 www.alfalaval.com

Optimizing burst cleaning Trials to find appropriate number of repetitions1st burst of 60 seconds29/04/2020 Alfa Laval2nd burst of 60 seconds3rd burst of 60 seconds23 www.alfalaval.com

Optimizing burst cleaningEvaluate andanalyze thecleaning results!29/04/2020 Alfa LavalBeforeAfter24 www.alfalaval.com

Considerations for retrofit to TJ40G Rotary Jet Head Insertion of machine into tank Most static spray balls are 100 mm in diameter Insertion flanges for these on tank tops aretherefore typically 100 mm or smaller TJ40G Rotary Jet Head requires an opening of180–200 mm to insert the machine It is not therefore feasible to use existing staticspray balls flange openings to insert the head Ideal design for a TJ40G insertion flange wouldinclude the Alfa Laval Rotacheck validationinstrument on the flange29/04/2020 Alfa Laval25 www.alfalaval.com

SCANDI BREW top plate with TJ40G and Rotacheck Insertion flange for TJ40G with optimal placement of Rotacheck validation instrument already mounted29/04/2020 Alfa Laval26 www.alfalaval.com

Considerations for retrofitting with a rotary jet head Required capacity for CIP-Forward pump Static spray balls typically require high flowrates but low inlet pressure ( 2 bar at inlet) Rotary jet heads have lower flow requirements,but higher inlet pressure (5 bar at inlet) CIP-F pump capacity must be verified prior toretrofitting, particularly with respect to headpressure Typical requirement 7.5 bar at CIP-F pumpdischarge29/04/2020 Alfa Laval27 www.alfalaval.com

Process considerations for use of rotary jet head Risk: Gas flow through rotary jet head during pressurization and emptying Typical fermenter design: Cleaning-in-Place/CO2line with non-return valve (NRV) NRV should allow gas to flow out of tank duringfilling and fermentation – and into tank duringemptying and pressurization NRV is closed during CIP, driving CIP liquid tothe rotary jet head (RJH) Gas flows that are too high gas duringpressurization can also close the NRV, forcingthe gas through the RJH Dry run of RJH causes high vibrations and heatgeneration, which can rapidly lead to damageand failure of the RJH29/04/2020 Alfa Laval28 www.alfalaval.com

Process considerations for rotary jet head Improved design of fermenter CIP-CO2 system for rotary jet head (RJH) applications Non-return valve is replaced withtwo automated butterfly valves During filling, emptying,pressurization and fermentation:valve to RJH closed, valve onCIP/CO2 line open During cleaning: valve to RJH open,valve on CIP/CO2 line closed29/04/2020 Alfa Laval29 www.alfalaval.com

Process piping design for cleanability Avoiding dead legs in piping branchesButterfly valveMore dead legPoor cleanability29/04/2020 Alfa LavalButterfly valve with drainSingle seat valveUnique Mixproof valveNo dead legOptimal cleanability30 www.alfalaval.com

Optimizing CIP of valves and piping Water and chemical savings with Alfa Laval Unique Mixproof valvesPasteurizedmilkCIP freshwater Optimizing valve configuration andoperation results in savings of waterand chemicals Valve configuration determines themethod of cleaning the valve (e.g.external valve CIP or seat lift Valve operation, such as seat lifttiming and frequency, determinesboth timing as well as water andchemicals consumptionCIP freshwater29/04/2020 Alfa Laval31 www.alfalaval.com

Seat lift CIP versus external valve CIPSeat lift cleaning More hygienic solution 70% savings of water andchemicals Same investment cost Fewer pipe installations Less equipment tomaintain Additional I/O points29/04/2020 Alfa LavalExternal cleaning Standard offering(e.g., SPX and GEA) Cheaper solution fromSPX and GEA Clean without CIPin pipe installations32 www.alfalaval.com

Case story: Unique Mixproof seat lift cleaning Influence of CIP supply pressure on wall shear stress and cleaning efficiencyFlow through Unique Mixproof valve (seat lift)Pressure (bar)Wall shear stress opening (Pa)Wall shear stress laminar (Pa)Kv (m 3/h)Flow rate (m 3/h)Seat lift time (seconds)Volume per seat lift (litres)SizeISO/DINKv valueUpper seat lift [m 3/h]Lower seat lift [m 3/h]Air consumptionUpper seat lift * [n litre]Lower seat lift * [n litre]Main movement * [n litre]Kv value – SpiralCleanSpindle CIP [m 3/h]External CIP of leakage chamber [m 3/h]29/04/2020 Alfa 9DN/OD63.576.1Higher CIP supply pressure gives strongerpulsations, which clean the opening more efficiently.This results in higher wall shear stress, whichincreases overall tank cleaning 0.860.21.10.860.120.250.120.2510012515033 www.alfalaval.com