Semi-Automated / Automated COP Cleaning Process. August 1st, 2017

Transcription

1 Semi-Automated / Automated COP Cleaning Process August 1st, 2017

2 CIP vs. COP Clean-In-Place (CIP) An automated system for cleaning processing equipment in place without disassembly. o Spray clean vessels and pressure/flow clean piping o Remove residue with chemical o Little manual intervention Clean-Out-of-Place (COP) COP is required to clean process items that are unable to be cleaned in place and must be disassembled to achieve a complete clean.

3 Critical Cleaning Parameters (TACT) Effective cleaning is a combination of both Physical and Chemical processes. When one parameter is decreased the other parameters must compensate. Time Action Chemical/Concentration Temperature Temperature Chemistry Time Action

4 Does This Look Familiar? Manual Methods Pose Food Safety Challenges Inconsistent cleaning. Results are not repeatable. Increased cross-contamination hazards Cleaning procedures not documented

5 A Familiar Scene? Homemade/Manual Cleaning Is there a tank for soaking only? Is there steam for agitation? Is there air for agitation? Lack of sanitary design Brings bacteria into a facility Ineffective cleaning, damaged parts, wasted water & chemicals, no control

6 Does This Look Familiar? When Equipment Parts Are Cleaned with this Method Unreliable results. No adherence to Time, Action, Chemical Temperature (TACT) Increased damage to parts & lost components Labor-intensive cleaning method

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8 COP Jet Manifold Capabilities/Options Dual Side Jet Recirculation Wash Fittings and Components (End View) Creates Rolling, Turbulent Action 85% Tank Turnover Quad Side Jet Recirculation Wash Fittings and Components (Tanks Deeper than 24 )

9 End Jet Manifold Creates longitudinal flows Washes tube, pipe, and hose interiors Flattened Jet

10 Clean-Out-of-Place (COP) Parts Washers COPs clean individual process components that are removed from equipment and placed in the washer for fully automated or semi-automated cleaning. Food Safety Consistent, Repeatable Results Cleaning procedures can be documented Improve Parts Cleaning Faster, cleaner results Decreased handling - fewer damaged and lost components Labor, Chemical & Water Savings Lower Chemical & Water Costs Labor reductions Worker Safety Higher temperatures and stronger concentrations with minimized operator exposure Isolate cleaning process

11 Typical COP Applications Weigh Buckets, Chutes, Hoppers Filler Components Plastic Fabric Belting

12 Wrong Applications Large quantities Buckets Totes Buoyant items

13 Wrong COP Applications Item too large for the tank Buoyant Items

14 Hose Cleaning Manifold Dedicated flow for multiple hoses to accommodate 5 FPS (feet per second) flow rates Dedicated manual isolation valve Removable manifold assembly Ancillary reducers required for alternate connection sizes

15 CIP/COP Portable Washer Portable CIP Functions Manual Operation Typical Applications Vessels Line circuits Periodic cleaning Features In-Line Steam Separate Rinse & Detergent Reservoirs

16 CIP Wash Cycle (Portable CIP/COP System) Detergent Compartment CIP Wash Supply Reservoir Solution gravity drains to pump suction for recirculation CIP discharge valve is opened

17 CIP Rinse Cycle (Portable CIP/COP System) Rinse compartment CIP rinse supply reservoir Rinse water gravity drains Drain valve is opened Return valve is closed CIP discharge valve is opened

18 Optional Instrumentation Wash Cycle Recording Wash time and temperature Circular Chart recorder provides hard copy for record on timebased paper chart Conductivity Sensor/Controller Monitor and/or control chemical concentration Electrodes conductivity sensor installed in tank or supply line for chemical control

19 Fully Automated COP Features PLC Automated w/panel View Insulated Sidewalls Shell and Tube Heat Exchanger Chemical Addition & Conductivity Controls Temperature & Level Controls Cover & Additional Safety measures Process Recording Fully Automated COP for Pharmaceutical

20 Features Batch Washing Cyclical Operation Automatic Monitored and Controlled Parameters Chemical Addition & Conductivity Controls Temperature & Level Controls Process Recording

21 SaniCab Rack-on-Cart System Standard 3-tiered rack and standard cart 3-D custom-designed Rack-on-Cart System

22 Rack Loading/Unloading Rack-On-Cart Design Eliminates Lost & Damaged Parts, Ramps & Pits Cart engages and latches to SaniCab frame. Cart runner mates with cabinet runner, and rack rolls into cabinet. Trip dogs prevent rack from rolling back out without cart. Hand release on cart disengages cart from cabinet frame. Operator training tool. If the part isn t on the rack it is missing or still on the equipment. Cart runner mates with cabinet runner Easy release handle

23 High-impact Rotary Sprays Two (2) sprays spaced evenly on each sidewall One (1) overhead One (1) lower spray Includes port for optional lower spray assembly Hydraulically driven rotary union Quick spray device disconnect for easy inspection and cleaning

24 SaniCab: Multi-Purpose Cabinet Washer Food Safety Consistent, Repeatable Cleaning Results Eliminate cross contamination Cleaning procedures can be documented Improve Parts Cleaning Cleaner, faster results Less damage & loss Less labor More uptime Reduce Chemical & Water Usage Re-circulated Solutions Allows Higher Flow Rates Lower Chemical & Water Costs Worker Safety Ergonomic rack on cart, reduces handling Eliminates need for recessed pit (dirty, hard to access) or inclined ramp (dangerous, especially when wet) Isolate cleaning within cabinet

25 Applications Scale Systems Weigh Scale Systems MULTIPOND Ishida Yamato Heat & Control Markets Protein (Meat/Poultry) Bakery Snack Cheese Confectionary Vegetables Full Scale System SaniCab Weigh Scale Rack Yamato Weigh Scale MULTIPOND Weigh Scale

26 Applications Rotary Filler Systems Rotary Fillers for Viscous & Whole Products Parts. Pistons typically removed from equipment (cleaning around o-rings difficult) Products. Jelly, Salsa, Tomato Paste, Soups Rotary Fillers Elmar Filler Specialists FMC / JBT Rotary Filler Systems SaniCab Piston Rack Rotary Filler Pistons

27 Applications - Slicers Slicers All parts can be removed to be washed Formax Weiler CFS Markets Cheese Protein (Meat/Poultry) Confectionary Vegetables Formax Slicer Rack with Slicer Components Blades Grippers

28 Applications - Dicers Dicers Formax Weiler CFS Urschel Markets Snack Bakery Cheese Protein (Meat/Poultry) Confectionary Vegetables Dicer Cheese Shredder Parts to Remove for Cleaning Dicer Guards

29 Portable Rack-on-Cart Assembly Intralox Belting Bucket Rack Tote Rack

30 Portable Rack-on-Cart Active Assembly Active Racks Sprays integrated/manifolded on rack Components with difficult areas to clean Buckets Canisters IBC/Tote Two methods of connecting rack Manual w/hose each wash Automated quick coupling Manifold

31 Wrong Applications Hoses/Piping/Tubing Pump impellers/components Small intricate components with creviced areas Heavy and baked-on soils Solution for Hoses & Pipes? Sani-Matic Clean-Out-of- Place (COP) Washer

32 Typical Operation / Cycles Recirculated Pre-Rinse 3 Mins Nominal Soils Minutes 3 Mins F Recirculated Detergent Wash Moderate Soils Minute Cycles 3 Mins 3 Mins Recirculated Post Rinse 3 Mins F Recirculated Final Rinse Heavy Soils Minute Cycles 3 Mins 3 Mins 3 Mins F Cleaning Cycle dependent upon type, amount, and adhesion of soils The Final Rinse is reused for next cycle s pre-rinse If sanitizer is utilized, the saved final rinse is not reused.

33 Dryer Module Increased Productivity. Turnaround times up to 75% faster Available in electric or steam Capable of temperatures up to 200 F Available for existing systems, which can be retrofitted Not filtered Compact, easy to install Vertical Manifolds Provide Even Flow Internally Heater Cabinet / Remote Mounted

34 PharmiCab Wash Chamber CIP System Dryer

35 PharmiCab PharmiCab Cabinet Washers capable of washing an entire suite of process parts. Pit Mounted Floor Mounted

36 PharmiCab Pit-Mounted Custom Racks

37 Sani-Matic TactiWash Small Parts Washer

38 Questions??????