rwr presentation to retort manufacturers updated eco innovation … · 2015-05-28 · history &...
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![Page 1: RWR presentation to Retort Manufacturers updated Eco Innovation … · 2015-05-28 · History & context-2009 : We commissioned in VDN a innovative Retort cooling Water Recycling System](https://reader034.vdocument.in/reader034/viewer/2022042116/5e932d0458e5083c1100df5d/html5/thumbnails/1.jpg)
RECOWATER PROJECTRetort Water Recycling
Dissemination via retorts manufacturers
24242424thththth & 30& 30& 30& 30thththth of July 2013of July 2013of July 2013of July 2013
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ParticipantsParticipantsParticipantsParticipants
Christophe Crouzet : Composite project leader
Gebhard Kregel : Global R&D, responsible for dissemination
Philippe Frickert : ERN chief Engineer, local project leader
Christophe Mathey : ERN maintenance manager
2
Christophe Mathey : ERN maintenance manager
Yann Weissgerber : Steriflow
Jean Patrick Roumagnac : Steriflow
Gerd Werner : Scholz (Separate meeting 30/07/2013)
Frank Funke : Scholz (Separate meeting 30/07/2013)
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12:00 – 12:30 Welcome on Site and a first introduction Philippe Frickert
12:30 – 13:30 Lunch in the cafeteria All
13:30 - 14:00 Retort Process Steam Air and the special requirements Gebhard Kregel
14:00 – 14:45 Detail technical presentation of the RWR Christophe Crouzet
14:45 – 15:00 Break
Agenda of the dayAgenda of the dayAgenda of the dayAgenda of the day
3
15:00 – 16:30 intensive and detailed factory tour All
16:30 – 17:00 Quality requirements for a successful operation Philippe Bernard
17:00 – 17:30 Question & Answer Session Gebhard, Christophe and Philippe
17;30 Return to the Hotel Petite France in Strasbourg
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Content of this presentationContent of this presentationContent of this presentationContent of this presentation
1) History
2) Dissemination
3) Technical description
4) Results & challenges
4
4) Results & challenges
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History & contextHistory & contextHistory & contextHistory & context
- 2009 : We commissioned in VDN a innovative Retort cooling Water Recycling System based on
fine filtration, UV light, ozone, saving 95% water and keeping water quality on potable level
-Early 2010 : Based on this success, we decided to roll out to European factories equipped with
steam air retorts : ERN & GAR with the support of European Union (MEL & BRK stepped out for strategic & economical reasons)
5
- October 2010 : Contract with EU was signed to get subsidies from them to help us
implementing the replications, as far as will disseminate this project outside.
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DisseminationDisseminationDisseminationDissemination
-> From the initial contract, we were asked to disseminate via the following channels :
European
food
industry/
public
MARS Commercial → Subcontractor
6
-> Due to time & resources constraints we downscaled the scope to retorts manufacturers only
-> Therefore we would need your help to fulfil the contract terms :
(We have)...”also approached the major European retort and filter producers and currently discusses the option of including information on the project e.g. in their newsletters. That way, approximately 60% of all food producing companies within Europe could be reached”
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Principle of the RWRPrinciple of the RWRPrinciple of the RWRPrinciple of the RWR
• Coarse filter to remove solids, avoid debris build up & reduce COD level
Here is the principle :Retort Coarse
FilterWater check & rejectstation
Raw WaterTank
FineFilter
UV Treatment
Weekend cleaning system
Police disinfection
Clean Water Tank
7
• Online checking station for incoming water, with rejection of water > 10 NTU
• Raw-water buffer tank and pumps
• Self cleaning filter (size 20-30µm) to prevent that any debris or build-up of substances in the system becomes nutrients for bacterial growth.
• UV light for water disinfection, as it will not impact the water chemistry nor require special safety protections/training of operators deal with hazardous substances.
• Ozone police disinfection via ozone injection to keep the system clean after the UV treatment and provide verification of chemical sanitation
• Clean water buffer tank and pumps
• Automatic CiP system to provide weekly cleaning and sanitation of the whole recycling system
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Cold
water
PT100
Heat-
V2
Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortStart
empty retort
8
T
Control
valve
Condensat
Pump 2x
Heat-
exchanger
2x
P2A
P2B
V3
VD1
V7
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Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortCondensate
(C.U.T and Sterilisation)
CP2
CP1
Venting
Cold
waterPT100
PS1
Heat-
V2
Flow direction away from the van
Flow direction to the van
9
T
Condensat
Steam
Pressure
air
Pump 2x
Heat-
exchanger
2x
P2A
P2B
V3
Condensate(300 - 350 ltr.)
100 mmVD1
V7
N0∑300 - 350 ltr.
N3
N1
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Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retort
Cold
water
Pre-Cooling
valve
Heat-
V2 V1
Flow direction away from the van
Flow direction to the van
Pre-Cooling water
from 125°C to ~95°C
10
N0
Condensat
Pump 2x
Heat-
exchanger
2x
P2A
P2B
V3
Cold water
injection
VD1
V7
250 mm∑1.300 ltr
Pre-Cooling water
(1.000 ltr.)
N3
N1
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Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retort
Cold
water
Heat-
V2 V1
Additional water to reach the
correct level for circulation pump
11
Condensat
Pump 2x
Heat-
exchanger
2x
P2A
P2B
V3
Cold
water
VD1
V7
Additional water
(few hundred ltr.)
∑1.500 ltr
N3
N1
N0
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Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retort
Cold
water
Heat-
V2 V1
Start cooling over heat exchanger
from 95°C to 35°C
12
Condensat
Pump 2x
Heat-
exchanger
2x
P2A
P2B
V3
VD1
V7
Condensate
recyclingN3
N1
N0
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Pouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retortPouch sterilisation in Steam/Air retort
Cold
water
PT100
Heat-
V2
Empty the retort
(Drain the water)
to the drain water and waste it
A)
send the water to the RWR system for reuse
B)
or
13
Condensat
Pump 2x
Heat-
exchanger
2x
P2A
P2B
V3
VD1
V7
Drain
N3
N1
N0
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Retort Recirculation Cooling Water Retort Recirculation Cooling Water Retort Recirculation Cooling Water Retort Recirculation Cooling Water Treatment System Treatment System Treatment System Treatment System
TI
P
roM
aq
ua
®
Pro
Min
en
t®
Coarse Filter > 1 mm
Pro
Min
en
t®
From the Retorts
45 m3/h
QIS FI
P
PD
2
Potable water conn.
Failure Indication
Berkefeld-Filter
Stö
rungsm
eld
ung
UV
Ca
taly
tic
rem
ain
ing
ozo
n a
nnih
ilato
r
34
5
67
21
P
CIP- Pipe
P
P
DN 100
DN 40
DN 40DN 40
DN 65
DN 50
P
23
min. 1 m infeed lenght
1
Ozon-Injection25
01
02 04
11
LIC
05
LIC
06
2726
Pro
Min
en
t®
Pro
Min
en
t®
Pro
Min
en
t®
Failure Indication
Ozon
DN
100
DN 40
TI
03
optional
Lf
00
Pro
Min
en
t®P
roM
ine
nt®
Conductivity Turbidity
TemperatureFlow
Redox
Flow
Ozone
pH
LevelLevel
Temperature
14
UV-Lamp
QIS
FT
FIC
FU
P
P
Ozon rH QIS-
Ra
w w
ate
r-ta
nk
Pro
ce
ss w
ate
r-ta
nk
SAC pH
P Fine filtration10 µm
P
8
9 10
1112
13
14
21
18
19
22
CIP-Base 50 %
P2
P3
P1
P
treated coolingwater
Emptying pipes
20
P
to the Retorts56 m3/h
DN
50
DN
40
DN 40DN 40
DN 50DN 65
DN 50
15
23
24
DN 100
FT
FIC
P4
08 09 10
12 13 14
Zirculation pipe to
avoid switch off the UV-lamps
LSA-
15
LSA-
16
Flu
shin
g A
ir
DN 50
16
PP
DN
50
P
Flushing tank
PPP
PP
PP
P
P
P
LSA-
16
P
to Waste Water
d P
FlowFlow Level
SpectralAbsorption
Coefficient
pH
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Agenda of the dayAgenda of the dayAgenda of the dayAgenda of the day
12:00 – 12:30 Welcome on Site and a first introduction Philippe Frickert
12:30 – 13:30 Lunch in the cafeteria All
13:30 - 14:00 Retort Process Steam Air and the special requirements Gebhard Kregel
14:00 – 14:45 Detail technical presentation of the RWR Christophe Crouzet
14:45 – 15:00 Break
15:00 – 16:30 intensive and detailed factory tour All
15
15:00 – 16:30 intensive and detailed factory tour All
16:30 – 17:00 Quality requirements for a successful operation Philippe Bernard
17:00 – 17:30 Question & Answer Session Gebhard, Christophe and Philippe
17;30 Return to the Hotel Petite France in Strasbourg
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ContentContentContentContent
1 - General project overview
2 – From idea to pilot
3 – Technical overview & deep dive on key elements
16
4- Reco summary
5- Achieved results
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1111---- Project CharterProject CharterProject CharterProject Charter
• OBJECTIVE : Recycle retort cooling water (steam air retorts) to reduce dramatically
potable/softened water usage, and keep water quality on Q&FS standards
• SCOPE :
• 11 retorts in ERN (300m3 water/day) , 21 retorts in GAR (500m3 water/day)• Conversion to “water through process” in ERN, and full emptying in GAR
• PROJECT KEY DATA :
• 1 turnkey supplier for the core treatment system• Local suppliers for environing systems/interfaces
17
• Local suppliers for environing systems/interfaces• ERN : 0,8 M€ project, actual commissioning July 2011• GAR : 1,6 M€ project, actual commissioning October 2011
• KEY SUCCESS FACTORS :
KPI Measure
Retort fresh water consumption reduction -90% on basis of equivalent portofio/volume
CFU at system outlet <100 bacts/ml
Coliforms & enterococci at system outlet 0
Impact on retort cycle time 0
Workload to operate & maintain the system Max 4h/weekStandalone for 1 week
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2 2 2 2 ---- Why such a system ?Why such a system ?Why such a system ?Why such a system ?
The project started from blank sheet and different options were studied for water treatment :
1) Physical treatment : RO/Ultra filtration Filtration CapabilitiesReverse Osmose (RO)Reverse Osmose (RO)Reverse Osmose (RO)Reverse Osmose (RO) Flow DirectionNanofiltrationNanofiltrationNanofiltrationNanofiltration (NF)(NF)(NF)(NF) Ultrafiltration (UF)Ultrafiltration (UF)Ultrafiltration (UF)Ultrafiltration (UF) Mikrofiltration (MF)Mikrofiltration (MF)Mikrofiltration (MF)Mikrofiltration (MF)No No No No poresporesporespores
18
+ : bacteria avoidance, chemical-free, no impact on material/product
- : Low efficiency (less savings), prefiltration needed to cope with pollution, possible re-infection after system
Viruses
Bacteria, parasitesanorganic substances
Highly molecular org.substances
Org. Substances with medium size
Low molecular org. Substances
Polyvalent ions
Univalent ions
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2222---- Why such a system ?Why such a system ?Why such a system ?Why such a system ?
2) Thermal treatment
+ : No add-ons or chemicals required, Sterile water after cycle , no impact on material
- : Energy usage, Pre-filtration for particles necessary
3) Chemical treatment (Chlorine, Bromine, Hydrogen peroxide)
+ : Strong disinfection agent, easy to operate
19
+ : Strong disinfection agent, easy to operate
-: Possible creation of by products, risks on material / product if not correctly handled
For these reasons we had to design a fit-for-purpose specific water treatment system
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3333---- PrinciplePrinciplePrinciplePrinciple
• Coarse filter to remove solids, avoid debris build up & reduce COD level
• Online checking station for incoming water, with rejection inappropriate of water
Here is the principle :
20
• Online checking station for incoming water, with rejection inappropriate of water
• Raw-water buffer tank and pumps to “transform” a batch process to a continuous process
• Self cleaning filter (size 20-30µm) to prevent that any debris or build-up of substances in the system becomes nutrients for bacterial growth.
• UV light for water disinfection, as it will not impact the water chemistry nor require special safety protections/training of operators deal with hazardous substances.
• Ozone police disinfection via ozone injection to keep the system clean after the UV treatment and provide verification of chemical sanitation
• Clean water buffer tank and pumps
• Automatic CiP system to provide weekly cleaning and sanitation of the whole recycling system
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3333---- Deep dive : Checking stationDeep dive : Checking stationDeep dive : Checking stationDeep dive : Checking station
1) Theory : role of the checking station
Photo Cell
LampLens
Aperture
90°scattered Light
Glas Cuvette
21
-> Temperature control : filters out water >45°C (damage to turbidity/UV light devices)
-> Conductivity control : water quality (condensate vs softened)
-> Turbidity control : filters out polluted water
2) Lessons learned on turbidity
-> VDN : On line measurement -> Not working because of air bubbles from emptying pumps
-> ERN/GAR : Measurement in bypass and bubble removal with ultrasonic bath -> Working better, but too long time between measurement & rejection (too late), bacteria buid-up in bath
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3 3 3 3 ----Deep dive : Checking stationDeep dive : Checking stationDeep dive : Checking stationDeep dive : Checking station
3) Recommendation for future project
• By pass solution
• Need to reduce the time between taking the water and measuring as much as possible
• Turbidity meter to be placed far enough from tank1 to allow possibility to reject batches
22
• Commissioning with involvement of manufacturer
• Rejection limit =4 NTU
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3333---- Deep dive : FiltersDeep dive : FiltersDeep dive : FiltersDeep dive : Filters
1) Theory : role of the filter
Basics of Filtration Molecular weight 200 20.000 100.000
0,1 1 10 100 1000 10.000
Particle Colloids Macro-
molecules Pharma-ceuticals pesticides
Ions Microfiltration (MF)
Ultrafiltration (UF)
Nanofiltration (MF)
Reverse Osmose (RO)
0,1B – 2 bar
0,1 – 5 bar
3 – 10 bar
5 – 100 bar
B
P
V
B P
V
23
Here the goal is not to filter out all particles/bacts, but just to remove “big” particles (>10-30 microns) which could prevent the UV light to work properly (shadow effect) or create a nest for bact growth.
To fulfil its role the filter must be as well :
- Automatic self washable (backwash) and able to remove bacts/ biofilm
- Withstand CIP conditions
- Several units in parallel to allow continuous operation
0,1 1 10 100 1000 10.000
Particle size (nm)
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3333---- Deep dive : FiltersDeep dive : FiltersDeep dive : FiltersDeep dive : Filters
2) Results from VDN pilot
Techno : Disk filter 20 µm Beckerfeld
24
WorkingWorks fine for ½ week (biofilm)Low water usage
ChallengesSuitable only up to 50°C (plastic)Not able to work continuously 1 week
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3333---- Deep dive : FiltersDeep dive : FiltersDeep dive : FiltersDeep dive : Filters
3) Implementation ERN/GAR
-> Stainless filter 30 micron (hot CIP 85°C) from Wolftechnik
-> Problems we faced :
•Mesh destruction : solved after changing design to 3 layer & setting proper operational conditions
•Blockages by biofilm : solved by manual cleaning 3/week and local CIP by mid-week
25
Working Filters water @ 30 microns
ChallengesLong time to find the solutionManual cleaning 3/week and mici CIP mid weekStill blockages in GARgzdai
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3333---- Deep dive : FiltersDeep dive : FiltersDeep dive : FiltersDeep dive : Filters
4) Recommendation for future projects
• Ability to clean automatically the pollution including bio film for 1 full week
• Withstand CIP conditions 85°C with caustic
• Hygienic design
• Mesh size as small as possible (20 µm max)
• Water usage limited as much as possible
26
• Water usage limited as much as possible
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3333---- Deep dive : UV lightDeep dive : UV lightDeep dive : UV lightDeep dive : UV light
1) Theory : role of the UV light
Ultraviolet radiation causes damage to organic cells by modifying their vital enzymes and the DNS. Because of that, the metabolic process and cell replication will be stopped. The microorganisms will then die shortly
27
- The disinfection effect of the light is in a range of 240 to 290 nm wave length with a maximum at 254 nm. - Water has to be clear water with low absorption within the UV range-2 types of lamps : low pressure and the medium pressure lamps
Medium pressure discharge lamps have a higher specific electric power in W/cm, produce a lower percentage of UV at 254 nm , but emit a wider spectral range of microbial effective radiation
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3333---- Deep dive : UV lightDeep dive : UV lightDeep dive : UV lightDeep dive : UV light
2) Results from VDN pilot
1 medium pressure lamp from Prominent
-> 2kW power
-> over designed power (3000J/m2 whereas 450J/m2 are enough in theory)
28
WorkingKilling bacteria0 bacts after UV and ozone
ChallengesStill some bacts after UVEnergy usage
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3333---- Deep dive : UV lightDeep dive : UV lightDeep dive : UV lightDeep dive : UV light
3) Results from ERN/GAR
On supplier recommendation, we decided to go for low pressure lamps from Wedeco (more homogeneous energy flow due to higher number of lamps, better efficiency at 254 nm, lower consumption…)
-> 10 -16 lamps in 1 housing 3-5 kW
-> Over designed power (3000J/m2 instead 450J/m2 )
29
Working Killing bacteria, efficiently as in VDN (medium pressure)
Challenges
Still some bacts after UVKilling rate around 1:100 to 1000 (vs 1:100.000 promised by supplier)Measured power is only 80W/m2 (Design=220W/m2) due to water qualityIssues on commissioning
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3333---- Deep dive : UV lightDeep dive : UV lightDeep dive : UV lightDeep dive : UV light
4) Recommendation for future projects
• No bacteria after UV
• Overdesigned
• Involve supplier for commissioning
• Automatic emitter tube wiping system (based on time/ actual power)
• Withstand CIP conditions when Off
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• Withstand CIP conditions when Off
• Withstand up to 45°C in normal operations
• Equipped with a intensity sensor (W/m2 or %)
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3333---- Deep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone system
1) Theory : role of the Ozone
Role :
-> Keeps the water sustainably clean (avoid re-infection after UV)
->Traceability (presence of ozone in water = no bacteria)
-> Target 0,3-0,7 ppm in water after tank 2 (clean water)
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It is composed of different equipments :
-> Ozone generator
-> Ozone dosing & mixing devices
-> Online concentration measurement
-> Gas warning system (safety)
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3333---- Deep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone system
2) Results from VDN pilot
• From Prominent
• Designed on 1,5g/m3/hour
• Compressed air inlet -> ozone/air outlet
• Online dosing in main water pipe before tank 2
• Static mixer
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• Static mixer
Working Ozone is injected and measured on line
Challenges -
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3333---- Deep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone system
3) Results from ERN/GAR
On supplier recommendation, we used a different technology :
• From BWT
• Designed 1,5-2 g/m3/h
• Water by pass 6m3/h from the main water flow to tank 2
• Ejector sucking air by venturi effect
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Working Ozone in fresh water concentration after injection at target
ChallengesLong investigations to find out the dilution problem (mixers)Still not enough ozone in water to cope with pollution
• Ejector sucking air by venturi effect
• After analyse of gaps between dosed and measured quantities, we implemented 2 additional static mixers
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3333---- Deep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone systemDeep dive : Ozone system
4) Recommendation for future projects
• Recommendation for the VDN solution with compressed air and no bypass(more simple)
• Cruise dosing 2g/m3/h
• 2 Ozone mixers
• Connexion to both tanks to avoid bacteria growth in tanks
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• Ozone measurement online based on VDN solution but after tank 2
• Involvement of manufacturer for commissioning
• Gas detector as in ERN/GAR
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3333---- Deep dive : CIP systemDeep dive : CIP systemDeep dive : CIP systemDeep dive : CIP system
1) Theory : role of the CIP system
•Bring the overall system 100% clean once a week
• Cleaning via caustic soda solution (0,5-2%)
• Disinfection with Chlorine
• Must include as well the inlets/outlets from/to retorts
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2) Results from VDN pilot
• Only local CIP (Treatment system)
• Cold CIP
Working Core system is clean after CIP
ChallengesDirtiest point of the system (pipe from retorts) not cleanedLimited efficiency (cold)Need manual mechanical / chemical cleaning several times/year
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3333---- Deep dive : CIP systemDeep dive : CIP systemDeep dive : CIP systemDeep dive : CIP system
3) Results from ERN/GAR
• Hot CIP 85°C
• Includes pipes from / to retorts including individual & main pipes
• Reutilisation of the caustic mix (tank)
• Possibility to make local CIP wihin the week, without stopping production
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Working System fully cleaned
Challenges Long commissioning phase
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3333---- Deep dive : CIP systemDeep dive : CIP systemDeep dive : CIP systemDeep dive : CIP system
4) Recommendation for future projects
• Based on ERN/GAR overall –> RWR + retort main + retort pipes
• Hot CIP, but with bypass if disk filters
• For automated factory, based on ERN solution
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• For semi automated based on GAR solution (CIP needs manual validation before starting, problem on retort during CIP handled differently, light management)
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4444---- RecoRecoRecoReco basisbasisbasisbasis
Item Top line Spec Base
Coarse filter 0,2mm ERN/GAR
Check station Turbidity by pass ERN/GAR + relocation
Tanks & pumps Hygienic design, 1h ERN/GAR
As a summary, here is the lessons learned recap from VDN/ERN/GAR installations which could be used to setup a reco. However, future investigations may be needed
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Fine filtration Disks 20µm VDN stainless steel
UV Medium or low Test needed
Ozone 2g/h, compressed air VDN
CIP system Including full piping ERN/GAR
ControlsJust fit for purpose &
interfaceFunctions ERN/GAR
Techno VDN
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5 5 5 5 ---- What have we achieved initiallyWhat have we achieved initiallyWhat have we achieved initiallyWhat have we achieved initially
From the beginning (commissioning summer 2011) we achieved
-> Water savings >90%
-> No impact on the rest of the factory
-> Good hygienic design & very efficiency CIP system
But :
-> Quick build up of biofilm
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-> Quick build up of biofilm
-> generating bacteria over limit after 3 days in ERN and 1 day in GAR (higher pollution)
-> and blockage of the filter generating installation stop.
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5555---- What have we achieved finallyWhat have we achieved finallyWhat have we achieved finallyWhat have we achieved finally
After months of optimisation on :
-> Filters (3 layers design, operating conditions)
-> Ozone dilution (adding mixers)
-> Controls (filter cleaning, rejection dirty batches...)
-> Implementation of mid week local CIP
-> Setting up proper supervision procedures
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-> Setting up proper supervision procedures
We managed to reach the required quality of water and signed the HO2 in July 2012 for ERN and in June 2013 for GAR
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12:00 – 12:30 Welcome on Site and a first introduction Philippe Frickert
12:30 – 13:30 Lunch in the cafeteria All
13:30 - 14:00 Retort Process Steam Air and the special requirements Gebhard Kregel
14:00 – 14:45 Detail technical presentation of the RWR Christophe Crouzet
14:45 – 15:00 Break
15:00 – 16:30 intensive and detailed factory tour All
Quality requirementsQuality requirementsQuality requirementsQuality requirements
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15:00 – 16:30 intensive and detailed factory tour All
16:30 – 17:00 Quality requirements for a successful operation Philippe Bernard
17:00 – 17:30 Question & Answer Session Gebhard, Christophe and Philippe
17;30 Return to the Hotel Petite France in Strasbourg
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ERN Achieved quality todayERN Achieved quality todayERN Achieved quality todayERN Achieved quality today
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Conclusion : ERN meets expectations on KPIs as far as a good maintenance & supervision is carried out
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1) Preventive maintenance
-> Systematic CIP &system emptying at weekend & verification of effectiveness (CIP report)
-> Systematic mini CIP on Wednesdays/Thursdays
-> Filter cleaning systematically 3 times/ week
2) Supervision & corrective actions
-> Control of key parameters daily (Ozone, UV, pollution ultrasonic bath...) by key user
-> Automatic alarm if problem with the system (filter blockages, water rejection too high, UV transmission too
ERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirements
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-> Automatic alarm if problem with the system (filter blockages, water rejection too high, UV transmission too low, stopped ozone generator....)
In case of deviation the key user put the system back in good function. If pollution is suspected, the system will be emptied, a mini CIP will be run and 1 ATP control will occur within 24h. As emergency solution, the system is switched to softened water until the root cause is found. Further punctual treatment with biocide is possible in addition
-> Supervision of production defects (which could pollute the system) by sterilisation operator
In case of production defect, the system will be stopped immediately
-> Systematic water analyse (system outlet) on Friday
In case of deviation, the following procedure will take place :
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3) Escalation procedure in case of excessive bacteria count
From the Friday analyse, the results are available
4.1 If total bacteria count is between 100 and 10000 UFC/ml :
� System is switched off
� Analyse root causes and implement corrective actions
� mini CIP and ATP control every day until the results of bacteria count. Biocide treatment possible
4.2 If total bacteria count is above 10000 UFC/ml or another parameter is above 1 :
ERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirementsERN operational procedure to fit R&D requirements
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4.2 If total bacteria count is above 10000 UFC/ml or another parameter is above 1 :
� System is switched off
� PRIMP process is started
� Analyse root causes and implement corrective actions (System cleaning with biocide is possible/required)
� restart only after a validation with microbiological analysis
� ATP controls every day during 2 weeks