clean-in-place: how to ensure food safety while maintaining equipment effectiveness
TRANSCRIPT
#DWwebinar
#DWwebinar
q This webinar will be available afterwards at www.designworldonline.com & email
q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar
Before We Start
#DWwebinar
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
#DWwebinar
#DWwebinar
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
#DWwebinar
Brief introduction Baumer
#DWwebinar
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
CIP Webinar 2015 BADK, tjh
#DWwebinar
Slide: 8
Baumer Global coverage
© Baumer 2014
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
#DWwebinar
Statistics The importance of food safety
#DWwebinar
CIP Webinar 2015 BADK, tjh The importance of food safety
Worst news!
#DWwebinar
CIP Webinar 2015 BADK, tjh The importance of food safety
Impact in the US alone
#DWwebinar
CIP Webinar 2015 BADK, tjh The importance of food safety
Contamination throughout the chain
#DWwebinar
The importance of food safety US Recalls over time
CIP Webinar 2015 BADK, tjh
#DWwebinar
The importance of food safety Cost of recalls (direct cost, loss of profit only)
CIP Webinar 2015 BADK, tjh
#DWwebinar
CIP Webinar 2015 BADK, tjh The importance of food safety
Food processing contamination reasons
#DWwebinar
CIP Webinar 2015 BADK, tjh The importance of food safety
Types of food contamination
#DWwebinar
Objectives and aspects of cleaning The importance of CIP
#DWwebinar
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.
CIP Webinar 2015 BADK, tjh
#DWwebinar
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.
CIP Webinar 2015 BADK, tjh
#DWwebinar
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.
CIP Webinar 2015 BADK, tjh
#DWwebinar
CIP Webinar 2015 BADK, tjh
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
#DWwebinar
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
#DWwebinar
CIP Webinar 2015 BADK, tjh
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
#DWwebinar
Baumer process sensors CIP optimization possibilities
#DWwebinar
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.
#DWwebinar
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.
#DWwebinar
CIP optimization possibilities CIP equipment overview
CIP Webinar 2015 BADK, tjh
#DWwebinar
CIP Webinar 2015 BADK, tjh The importance of food safety
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
#DWwebinar
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
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
Temperature monitoring
Level Point detection max/min
Media recovery
Concentrate
dosing of chemicals
End of cycle (CIP)
Dry run protection
Continuous level
measurement
CIP Webinar 2015 BADK, tjh
#DWwebinar
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.
Temperature monitoring
Level Point detection max/min
Media recovery
Concentrate
dosing of chemicals
End of cycle (CIP)
Dry run protection
Continuous level
measurement
CIP Webinar 2015 BADK, tjh
#DWwebinar
CIP optimization possibilities Tank temperature monitoring
To ensure maximal cleaning effect, the temperature of the detergent inside the tank must be precisely monitored.
CombiTemp
Temperature monitoring
Concentrate dosing of chemicals
Phase separation of detergents &
water
Cleanness measurement
of rinsing water
Level Point detection max/min
Dry run protection
Continuous level
measurement
CIP Webinar 2015 BADK, tjh
TER8
#DWwebinar
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
Temperature monitoring
Level Point detection max/min
Concentrate dosing of chemicals
Cleanness measurement
of rinsing water
Phase separation of detergents &
water
Dry run protection
Continuous level
measurement
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
Concentrate dosing of chemicals
Cleanness measurement
of rinsing water
Phase separation of detergents &
water
Temperature monitoring
Level Point detection max/min
Continuous level
measurement
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
Level Point detection max/min
Continuous level
measurement
Concentrate dosing of chemicals
Cleanness measurement
of rinsing water
Phase separation of detergents &
water
Temperature monitoring
Dry run protection
CIP Webinar 2015 BADK, tjh
#DWwebinar
Page: 37
Display modes:
Touch screen
Value only
Bar graph
Analogue
Tank illustration
Flashing in warning mode
CIP optimization possibilities Display features
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
CIP Webinar 2015 BADK, tjh
#DWwebinar
CIP optimization possibilities CIP portfolio Overview
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
CIP Webinar 2015 BADK, tjh
#DWwebinar
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
#DWwebinar
q This webinar will be available at designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com
Don’t Forget!
#DWwebinar