1. CLEANING AND SANITATION of PROCESSING EQUIPMENT Huub Lelieveld FSM Chicago November 2004

2. CLEANING and SANITATION OBJECTIVES PREVENTING PRODUCT CONTAMINATION BY: ENSURE CONTINUED CORRECT OPERATION OF THE EQUIPMENT, AVOIDING: - DEPOSITS (PRODUCT ON FREEZERS AND HEATERS) - INHOMOGENEITY OF PRODUCTS (LUMPS, FLAKES) - MECHANICAL DAMAGE (PUMPS, VALVES, SEALS, …) - HAMPERING PRODUCT FLOW (PASTEURISERS) IMPROVE PRODUCTION EFFICIENCY - MICROORGANISMS - ALLERGENS - FOREIGN MATERIAL

3. CLEANING REMOVAL REMOVAL OF SOIL MAJOR CAUSES OF FOULING CHEMICAL REACTION AT THE PRODUCT CONTACT SURFACE CRYSTALLISATION FOLLOWED BY DEPOSITION SEDIMENTATION OF PARTICLES BIOFILM FORMATION SOLIDIFICATION OF PRODUCT COMPONENTS ON THE SURFACE

4. HEAT CHANGES THE SOIL, OFTEN MAKING IT MORE DIFFICULT TO REMOVE: CLEANING REMOVAL REMOVAL OF SOIL - DENATURING OF PROTEINS - POLYMERISATION OF FATS - REACTION PRODUCTS OF PROTEINS, FATS AND SUGAR AVOID HIGH TEMPERATURES AS MUCH AS POSSIBLE ALSO DURING CLEANING

5. CLEANING REMOVAL REMOVAL OF SOIL FACTORS AFFECTING CLEANING DESIGN OF EQUIPMENT AND PROCESS LINE TYPE OF SOIL (PRODUCT RESIDUES) DETERMINING THE TIME, TEMPERATURE and CHEMICALS NEEDED MECHANICAL ENERGY (LIQUID VELOCITY)

6. RESIDUAL LEVEL AFTER EFFECTIVE CLEANING MICROORGANISMS/SOIL TIME MAXIMUM ACCEPTABLE CONCENTRATION CLEANING NEEDED EXTENSION OF PRODUCTION TIME DUE TO EFFECTIVE CLEANING POOR CLEANING CLEANING NEEDED START OF PRODUCTION RESTART OF PRODUCTION CLEANING REMOVAL REMOVAL OF SOIL

7. DELIVERING THE REQUIRED MECHANICAL and THERMAL ENERGY TO THE LOCATION OF THE SOIL KEEPING REMOVED NON-SOLUBLE SOIL SUSPENDED DEPENDING ON THE TYPE OF SOIL: DELIVERING THE REQUIRED CHEMICALS TO THE SOIL REMOVAL OF THE SOIL AND CHEMICALS FROM THE EQUIPMENT CLEANING REMOVAL REMOVAL OF SOIL

8. PLATE HEAT- EXCHANGER OPENED FOR INSPECTION AFTER CLEANING

9. CLEANING SOILCHEMICALS SUSPENSION OF SOIL PARTICLES AND PREVENTING REDEPOSITIONING SURFACTANTS ANIONICS - BASED ON FATTY ACIDS - FOAMING - NOT AFFECTED BY HARD WATER CATIONICS - QUATERNARY AMMONIUM COMPOUNDS - LESS GOOD - BENEFIT: ANTIMICROBIAL NONIONICS - LOW FOAMING - GOOD WETTING - EFFECTIVE ON OIL

10. CLEANING SOILCHEMICALS FAT and PROTEINS STRONG ALKALINE SOLUTIONS SODIUM HYDROXIDE POTASSIUM HYDROXIDE ORTHOSILICATE METASILICATE

11. CLEANING SOILCHEMICALS INORGANIC SCALE ACID SOLUTIONS PHOSPHORIC NITRIC SULPHAMIC GLUCONIC CITRIC

12. CLEANING SOILCHEMICALS METALS (Ca, Mg) SEQUESTRANTS PHOSPHATES EDTA GLUCONATE

13. CLEANING SOILCHEMICALS PREVENTING DEPOSITION OF HARD WATER SALTS AFTER CLEANING SEQUESTRANTS IN LOW CONCENTRATIONS (5-20 mg/kg)

14. CLEANING PROCEDURE - MILK DUAL STAGE WITH RAW MATERIALS –Pre rinse –Alkali dosing (1,5 - 3 % NaOH) –  ! Gross soil removal  drain –Circulation –Intermediate rinse –Acid dosing ( 1 - 3 % Acid) –  ! Gross soil removal  drain –Circulation –Final rinse

15. CLEANING PROCEDURE - MILK SINGLE STAGE WITH FORMULATED PRODUCT –Pre rinse –Alkali dosing (0,5 - 1 % NaOH) –  ! Gross soil removal  drain –Adjunct dosing –Circulation –Final rinse Acid step periodically wetting agents surfactants sequestering agents threshold agents

16. COMPARISON

17. SINGLE STAGE / FORMULATED PRODUCTS DIFFERENCES Increased costs for cleaning materials Shorter cleaning time and thus reduced down time Less energy Less water Lower overall costs

18. DUAL STAGE CLEANING

19. SINGLE STAGE CLEANING

20. Blue slides borrowed from: Lammert Baas lammert.baas@johnsohndiversey.com

21. SANITATION CLEAN SURFACES ARE EASY TO SANITISE BY HEAT BY CHEMICALS BY COMBINATIONS

22. SANITATION BY HEATPASTEURISATION - INACTIVATES MOST VEGETATIVE MICROBES, INCLUDING PATHOGENS STERILISATION - INACTIVATES ALL MICROBES, INCLUDING (HEAT RESISTANT) SPORES

23. SANITATION BY CHEMICALS or COMBINATIONS INACTIVATES SOME OR MANY OR ALL MICROBES, INCLUDING PATHOGENS AND PATHOGENS, DEPENDING ON CHEMICALS and TEMPERATURE

24. SANITATION IMPORTANT DISINFECTANTS ACTIVE CHLORINE COMPOUNDS IODOPHORS QUATERNARY AMMONIUM COMPOUNDS PEROXY COMPOUNDS ACIDS AND ALKALIS AT ELEVATED TEMPERATURE - SLIGHTLY ALKALINE HYPOCHLORITE - CHLORINE DIOXIDE - HYDROGENPEROXIDE - PERACETIC ACID

25. Emulsion picture by Jo Janssen, 1993

26. Thank you for your attention!