CIP and Manual cleaning

CIP Cleaning

1. Manual and CIP Cleaning Physical removal of food soils, brushing, scraping and rinsing Mrs. Arjunan Kanchchana B.Sc in Agri (Hons ) M.Sc in ENS Lecturer Department of Food Technology SLGTI

2. Application of Cleaners Manual Cleaning *Equipment manually disassembled *Hand scrubbing and washing Semi-automatic OPC (open plant cleaning) *High pressure washing and rinsing *Foaming Mechanical (Clean-in-place or CIP) *Automated cleaning process

3. Cleaning methods in Food industry 1. Manual & Mechanical - Wet & Dry 2. Immersion cleaning 3. COP 4. CIP 5. High Pressure sprays

4. This is how Foam is Generated H 2 30 - 50 psi Chemical Air 40 - 60 psi a. Mechanical Wet Cleaning - Foam / Gel Technology Use of high foaming solution to increase the retention time on the vertical surfaces Gels are used to further increase over foam the retention time on the vertical surface 1. Mechanical Cleaning and Sanitation

5. Foam Cleaning - Cling Time Foaming Techniques • Pre-rinse to remove loose soil and residues. • Foam up, rinse down. • Work in small sections. • Allow foam to remain on surface 10 to 15 min. Be aware of surfaces susceptible to corrosion. No advantage in foaming hot solutions. Wear protective equipment (goggles, gloves, suit and boots).

6. Advantages of Foam Cleaning Process Mechanized Cleaning Process Applied at Low pressures High chemical / soiling contact time Safe for operators as little aerosol is formed Hence more aggressive chemicals can be used Uses significantly less water than pressure cleaning Reduces cleaning time Minimizes risk of cross contamination Improved Cleaning efficiency Better cleaning economy Improved working environment Satisfied cleaning personnel Better environmental accountability

7. Centralised Foam Cleaning systems No concentrated chemicals in production area. Less handling of chemicals. One setting of concentration De centralized Foam Cleaning System Operators can select rinse, foam or disinfection. Detergent at each cleaning point

8. b. Mechanical – Dry Cleaning Manual or Automated Use of Brooms/ Shovels Use of automated Vacuum cleaners Process used where wet cleaning is not possible Areas manufacturing water sensitive products

9. 2. Immersion Cleaning This is the type of cleaning in which the parts to be cleaned are placed in the cleaning solutions to come in contact with the entire surface of the parts. Immersion cleaning is preferred for parts that must be placed in baskets and for processes requiring a long soaking time because of the type of contamination to be removed or the shape of the parts to be cleaned.

10. It is the most effective method, even if not the fastest one, and can be used with any type of cleaner for any process, heated or at room temperature. Immersion washers, can be portable or stationary; single or multi-compartment; and available with a variety of options, controls and valve configurations including CIP capability.

11. The important aspects during design of immersion washer should be To minimize cycle time Lower chemical usage Reduce water and utility costs Performance for immersion cleaning can be improved by moving the parts within the liquid or with agitation of the liquid, mechanically or with the addition of ultrasonic energy.

12. 3. COP (Cleaning Out Of Place - Mechanical) Cleaning Out of Place is defined as a method of cleaning equipment items by removing them from their operational area and taking them to a designated cleaning station for cleaning. It requires dismantling an apparatus, washing it in a central washing area using an automated system, and checking it at reassembly. Automated controls: - Contact Time - Temperature

13. COP Mechanical Action (agitation) Side Jet Action Push - Pull Action Combination

14. Advantages of COP Cleaning Usually lower investment than CIP systems Delivers consistent results Provides a cost savings over manual cleanings, saves on time, chemical, and water usage Minimizes operator exposure to high temperatures and strong chemical concentration

15. Disadvantages to cop systems: In situations where a CIP system could be used, certainly more labor intensive (disassembly and reassembly) Loading / unloading the COP washer

16. 4. CIP (Cleaning in place - Mechanical) Clean-in-place: Cleaning internal surfaces of production equipment without disassembly Cleaning in place can be described as the cleaning of equipment and vessels at the same place without movement of them to a different place. The cleaning agents can be transferred to the vessel or equipment types either thorough fixed piping or flexible hoses.

17. The CIP process can consist of the following elements: Supply pump Return pump Heat exchanger with Black/Plant steam supply Chemical tanks i.e Acid, Alkali tanks Supply Pressure gauge or transmitter Supply temperature sensors Conductivity meter with sensor

18. C.I.P. Basic Requirements

19. Advantages of a CIP cleaning system : Minimizes the cleaning time and reduces manual labor involved in cleaning Increased economy in use of cleaning detergents, which helps in cutting the operational costs (Effectively helps to manage water and chemical costs) Automated systems clean better than manual systems due to their consistency (Much faster than manual cleaning) Automated cleaning increases the level of equipment/storage space utilization ( Less labor intensive, no disassembly or reassembly)

20. CIP systems enhance safety at the processing plant since people do not come into direct contact with the cleaning detergents (Safer for workers, less chemical exposure) CIP systems can reach and effectively clean places, which you cannot reach by any other means Enaced efficiency will definitely improve productivity at the plant. There will be efficient use of water and detergents

21. Disadvantages of a CIP cleaning system Expensive to install Needs a professional personnel to operate. Experienced operators are not very cheap Once you start cleaning, you cannot stop the process, otherwise you will compromise the hygiene. CIP systems use a constant volume of water even if you just needed to clean one pipe in the system

22. 5. High Pressure cleaning (Mechanical) Useful for walls, floors, large equipment and tables. Spray can form aerosols mist from irritating chemicals. Atomization can spread soil and microorganisms. Pressures used: ¤ Low Pressure: <15 bar ¤ Medium Pressure: 15 to 30 bar ¤ High Pressure: 30 to 150 bar • Recommended: < 45 bar

23. Use of High pressure spray device assists in the removal of soil High Pressure Advantages Good for Removal of Difficult or burnt soil Lowest Water Usage Works Against Broad Range of Soils

24. Manual Cleaning (Topic 10) Pads, brushes and brooms should be: 1. Dedicated to tasks for which they are designed. • Optimizes cleaning effectiveness; and • Minimizes cross-contamination between areas of the plant 2. Designed for the task. • Brushes—proper stiffness; • Pads—proper cutting properties; and • Pressure spray—moderate pressure. • Cleaning aids that retain water, such as sponges, wiping cloths, and mops should not be used for routine cleaning

25. 3. Do not mix uses. For example, never : • Use floor brooms / floor squeegees on tables • Use green pads used for cleaning waste barrels on grading or packing tables • Use the same brush to clean floors on any food contact surface.

26. Manual and Mechanical - Wet Cleaning Methods Manual - Wet mopping One/two bucket systems, apply detergent solution to emulsify/absorb dissolved dirt. Longer dry time Manual Scrubbing Single disc /water tank e.g. Stripping coated floorings Automatic Scrubbing Machine scrub/dry floor in one operation. Cleaning of medium to large areas. Wet vaccum cleaning Pick-up residual liquids /water, drying floor

27. A manual dishwashing sink consists three compartment sink

28. Manual cleaning Advantages and Disadvantages Manual Cleaning Advantages Parts can be cleaned without complete immersion in the cleaning solution. Additional cleaning equipment, such as wash and rinse tanks, is not necessary. Manual Cleaning Disadvantages It is a labor-intensive process, R equire additional time to complete. Cleaning efficacy is less Cleaning Solution consumption is higher, Limitation on use of aggressive chemical.

29. A general soil Types and removal characteristics Fat-based Soils Fat usually is present as an emulsion and can generally be rinsed away with hot water above the melting point. More difficult fat and oil residues can be removed with Surfactants / Alkaline detergents , which have good emulsifying or saponifying ingredients.

30. Protein-based Soils In the food industry, proteins are the most difficult soils to remove. In fact, casein (a major milk protein) is used for its adhesive properties in many glues and paints. Food proteins range from more simple proteins, which are easy to remove, to more complex proteins, which are very difficult to remove. Heat-denatured proteins can be extremely difficult to remove.

31. Generally, a highly alkaline detergent with peptizing or dissolving properties is required to remove protein soils . Wetting agents can also be used to increase the wettability and suspendability of proteins. Protein films require alkaline cleaners that have hypochlorite in addition to wetting agents.

32. Carbohydrate-based Soils Simple sugars are readily soluble in warm water and are quite easily removed. Starch residues, individually, are also easily removed with mild detergents. Starches associated with proteins or fat can usually be easily removed by highly alkaline detergents.

33. Mineral Salt-based Soils Mineral salts can be either relatively easy to remove or be highly troublesome deposits or films. Calcium and magnesium are involved in some of the most difficult mineral films. Under conditions involving heat and alkaline pH, calcium and magnesium can combine with bicarbonates to form highly insoluble complexes. Other difficult deposits contain iron or manganese.

34. Salt films can also cause corrosion of some surfaces. Difficult salt films require an acid cleaner (especially organic acids that form complexes with these salts) for removal. Sequestering agents such as phosphates or chelating agents are often used in detergents for salt film removal.

35. Microbiological Films Under certain conditions, micro orgranisms (bacteria, yeasts, and molds) can form invisible films (biofilms) on surfaces. Biofilms can be difficult to remove and usually require cleaners as well as sanitizers with strong oxidizing properties.

36. Lubricating Greases and Oils These deposits (insoluble in water, alkali, or acid) can often be melted with hot water or steam, but often leave a residue. Surfactants can be used to emulsify the residue to make it suspendable in water and flushable

37. Other Insoluble Soils Inert soils such as sand, clay, or fine metal can be removed by surfactant-based detergents. Charred or carbonized material may require organic solvents.

38. Factors affecting the removal of food soils 1. Quantity of Soil It is important to rinse food-contact surfaces prior to cleaning to remove most of the soluble soil. Heavy deposits require more detergent to remove. Improper cleaning can actually contribute to build-up of soil.

39. 2. The Surface Characteristics The clean ability of the surface is a primary consideration in evaluating cleaning effectiveness. Included in surface characteristics are the following: 1.Surface Composition Stainless steel is the preferred surface for food equipment and used by many industry For example, 3-A Sanitary Standards (equipment standards used for milk and milk products applications) specify 300 series stainless steel or equivalent.

40. Other grades of stainless steel may be appropriate for specific applications (i.e., 400 series) such as handling of high fat products, meats, etc. For highly acidic, high salt, or other highly corrosive products, more corrosion resistant materials (i.e., titanium) is often recommended.

41. O ther "soft" metals (aluminum, brass, copper, or mild steel), or nonmetallic surfaces (plastics or rubber) are also used on food contact surfaces. Surfaces of soft metals and nonmetallic materials are generally less corrosion-resistant and care should be exercised in their cleaning. Aluminum is readily attacked by acids as well as highly alkaline cleaners.

42. Hard wood (maple or equivalent) or sealed wood surfaces should be used only in limited applications such as cutting boards or cutting tables, provided the surface is maintained in good repair. Avoid using porous wood surfaces.

43. 2.Surface Finish Equipment design and construction standards also specify finish and smoothness requirements. With high-fat products, a less smooth surface is used to allow product release from the surface.

44. 3. Surface Condition Misuse or mishandling can result in pitted, cracked, corroded, or roughened surfaces. Such surfaces are more difficult to clean or sanitize, and may no longer be cleanable. Thus , care should be exercised in using corrosive chemicals or corrosive food products.

45. 3. Environmental Considerations Detergents can be significant contributors to the waste discharge ( effluent) of primary concern is pH. Many publicly owned treatment works limit effluent pH to the range of 5 to 8.5. So it is recommended that in applications where highly alkaline cleaners are used, that the effluent be mixed with rinse water (or some other method be used) to reduce the pH.

46. Recycling of caustic soda cleaners is also becoming a common practice in larger operations. Other concerns are phosphates, which are not tolerated in some regions of the U.S., and the overall soil load in the waste stream that contributes to the chemical oxygen demand (COD) and biological oxygen demand (BOD).

47. 4. Chemistry of Detergents Detergents and cleaning compounds are usually composed of mixtures of ingredients that interact with soils in several ways: Physically active ingredients alter physical characteristics such as solubility or colloidal stability. Chemically active ingredients modify soil components to make them more soluble and, thus, easier to remove. In some detergents, specific enzymes are added to catalytically react with and degrade specific food soil components

48. Physically Active Ingredients The primary physically-active ingredients are the surface active compounds termed surfactants. These organic molecules have general structural characteristic where a portion of the structure is hydrophilic (water-loving) and a portion is hydrophobic (not reactive with water). Such molecules function in detergents by promoting the physical cleaning actions through emulsification, penetration, spreading, foaming, and wetting.

49. The classes of surfactants are as follows: Ionic surfactants that are negatively charged in water solution are termed anionic surfactants. Conversely , positively charged ionic surfactants are termed cationic surfactants. If the charge of the water soluble portion depends upon the pH of the solution, it is termed an amphoteric surfactant. These surfactants behave as cationic surfactants under acid conditions, and as anionic surfactants under alkaline conditions . Ionic surfactants are generally characterized by their high foaming ability.

50. Nonionic surfactants, which do not dissociate when dissolved in water, have the broadest range of properties depending upon the ratio of hydrophilic/hydrophobic balance. This balance are also affected by temperature. For example, the foaming properties of nonionic detergents is affected by temperature of solution. As temperature increases, the hydrophobic character and solubility decrease. At the cloud point (minimum solubility), these surfactants generally act as defoamers , while below the cloud point they are varied in their foaming properties.

51. It is a common practice to blend surfactant ingredients to optimize their properties. However , because of precipitation problems, cationic and anionic surfactants cannot be blended.

52. Chemically Active Ingredients Alkaline Builders Highly Alkaline Detergents (or heavy-duty detergents) use caustic soda (sodium hydroxide) or caustic potash (potassium hydroxide). An important property of these highly alkaline detergents is that they saponify fats: forming soap. These cleaners are used in many CIP systems or bottle-washing applications.

53. Moderately Alkaline Detergents include sodium, potassium, or ammonium salts of phosphates, silicates, or carbonates. Tri-sodium phosphate (TSP) is one of the oldest and most effective . Silicates are most often used as a corrosion inhibitor. Because of interaction with calcium and magnesium and film formation, carbonate-based detergents are of only limited use in food processing cleaning regimes.

54. Acid Builders Acid Detergents include organic and inorganic acids. The most common inorganic acids used include phosphoric, nitric, sulfamic , sodium acid sulfate, and hydrochloric. Organic acids, such as hydroxyacetic , citric, and gluconic , are also in use. Acid detergents are often used in a two-step sequential cleaning regime with alkaline detergents. Acid detergents are also used for the prevention or removal of stone films (mineral stone, beer stone, or milk stone).

55. Water Conditioners Water conditioners are used to prevent the build-up of various mineral deposits (water hardness, etc.). These chemicals are usually sequestering agents or chelating agents. Sequestering agents form soluble complexes with calcium and magnesium. Examples are sodium tripolyphosphate , tetra-potassium pyrophosphate, organo -phosphates, and polyelectrolytes. Chelating agents include sodium gluconate and ethylene diamine tetracetic acid (EDTA).

56. Oxidizing Agents Oxidizing agents used in detergent application are hypochlorite (also a sanitizer) and—to a lesser extent—perborate. Chlorinated detergents are most often used to clean protein residues.

57. Enzyme Ingredients Enzyme-based detergents, which are amended with enzymes such as amylases and other carbohydrate-degrading enzymes, proteases, and lipases, are finding acceptance in specialized food industry applications. The primary advantages of enzyme detergents are that they are more environmentally friendly and often require less energy input (less hot water in cleaning ).

58. Uses of most enzyme cleaners are usually limited to unheated surfaces (e.g ., cold-milk surfaces). However , new generation enzyme cleaners (currently under evaluation) are expected to have broader application

59. Fillers Fillers add bulk or mass, or dilute dangerous detergent formulations that are difficult to handle. Strong alkalis are often diluted with fillers for ease and safety of handling. Water is used in liquid formulations as a filler. Sodium chloride or sodium sulfate are often fillers in powdered detergent formulations.

60. Miscellaneous Ingredients Additional ingredients added to detergents may include corrosion inhibitors, glycol ethers, and butylcellosolve (improve oil, grease, and carbon removal).