Cleaning Cleaning and and

SanitationSanitation

Define Cleaning, Sanitizing and Food Define Cleaning, Sanitizing and Food contact surfacescontact surfaces

Steps adopted in proper cleaning Steps adopted in proper cleaning processprocess

Cleaning chemicals and different Cleaning chemicals and different cleanerscleaners

The GMP requires that you keep your The GMP requires that you keep your facility and all equipment, utensils facility and all equipment, utensils and food contact surfaces clean and and food contact surfaces clean and sanitary.sanitary.

It is important to understand the It is important to understand the definitionsdefinitions

of of cleaningcleaning, , sanitizingsanitizing, and , and food food contact surfacescontact surfaces..

CleaningCleaning

Cleaning Cleaning means the removal of dirt, means the removal of dirt, food residue, and any other materials food residue, and any other materials from a surface, utensil, or equipment from a surface, utensil, or equipment using detergents or other cleaning using detergents or other cleaning aids and either mechanical or aids and either mechanical or detergent scrubbing actions, followed detergent scrubbing actions, followed by rinsing.by rinsing.

SanitizingSanitizing SanitizeSanitize means to adequately treat means to adequately treat

food-contact surfaces by a process that food-contact surfaces by a process that is effective in destroying is effective in destroying vegetative cells vegetative cells of microorganismsof microorganisms of public health of public health significance, and in substantially significance, and in substantially reducing numbers of other undesirable reducing numbers of other undesirable microorganisms, but without adversely microorganisms, but without adversely affecting the product or its safety for the affecting the product or its safety for the consumer.consumer.

Food contact surfacesFood contact surfaces

Food contact surfaces Food contact surfaces are defined in are defined in the GMP as the GMP as those surfaces those surfaces

that contact human food and those that contact human food and those surfaces from which drainage onto the surfaces from which drainage onto the food or onto surfaces that contact the food or onto surfaces that contact the food ordinarily occurs during the normal food ordinarily occurs during the normal course of operations. course of operations.

Food-contact surfaces include utensils Food-contact surfaces include utensils and food-contact surfaces of equipmentand food-contact surfaces of equipment..

What is the Purpose of Cleaning?:What is the Purpose of Cleaning?: The purpose of cleaning is to remove The purpose of cleaning is to remove solids, juice, and any other debris (soil) solids, juice, and any other debris (soil) from equipment ,utensils and environment. from equipment ,utensils and environment.

The soil is a source of nutrients for bacteria The soil is a source of nutrients for bacteria (fats, carbohydrates, proteins, and (fats, carbohydrates, proteins, and minerals that can build-up on food-contact minerals that can build-up on food-contact surfaces )surfaces )

This debris can be a source of This debris can be a source of microorganisms that may contaminate microorganisms that may contaminate subsequent batches. subsequent batches.

Contaminating microbes may decrease Contaminating microbes may decrease shelf-life and spoil the product and, if shelf-life and spoil the product and, if pathogenic microbes are present, may pathogenic microbes are present, may cause illness. cause illness.

Even the best cleaned surfaces will Even the best cleaned surfaces will probably still have a few microorganisms probably still have a few microorganisms present. present.

If the cleaned surface is a wall, floor, or If the cleaned surface is a wall, floor, or door, this is OK. door, this is OK.

However, this is not acceptable for food However, this is not acceptable for food contact surfaces such as bins, the grater, contact surfaces such as bins, the grater, beverage container ,meat slicer or Ice beverage container ,meat slicer or Ice cream holding container.cream holding container.

Sanitation Standard Operating Procedures (SSOP's):Sanitation Standard Operating Procedures (SSOP's): Good cleaning requires discipline. Good cleaning requires discipline. Employees should be trained thoroughly. Employees should be trained thoroughly. Emphasize on why cleaning is necessary, the Emphasize on why cleaning is necessary, the

procedures involved, and how to monitor their procedures involved, and how to monitor their work.work.

Having written Sanitation Standard Operating Having written Sanitation Standard Operating Procedures (SSOP's) will make training more Procedures (SSOP's) will make training more consistent and is especially important for new consistent and is especially important for new entrants. entrants.

The SSOP for cleaning a particular piece of The SSOP for cleaning a particular piece of equipment can be laminated and posted near equipment can be laminated and posted near the equipment so that employees can check on the equipment so that employees can check on the correct procedure. the correct procedure.

SSOP cont.SSOP cont. The SSOP should also tell employees how to The SSOP should also tell employees how to

monitor the job they do, what corrective actions monitor the job they do, what corrective actions to take if monitoring indicates a problem, and to take if monitoring indicates a problem, and what records to keep. what records to keep.

Employees do a better job when given specific Employees do a better job when given specific responsibilities. responsibilities.

This responsibility may be cleaning a particular This responsibility may be cleaning a particular piece of equipment or inspecting another piece of equipment or inspecting another employee's work. employee's work.

Employees should be encouraged to speak up if Employees should be encouraged to speak up if they notice problems with current procedures they notice problems with current procedures or pieces of equipment.. or pieces of equipment..

General Cleaning SequenceGeneral Cleaning Sequence

Preparing the Area, Equipment and Preparing the Area, Equipment and Personnel for CleaningPersonnel for Cleaning

Proper preparation is necessary to ensure Proper preparation is necessary to ensure the safety of your employees and the the safety of your employees and the effectiveness of the cleaning. effectiveness of the cleaning.

To ensure safety, all electric equipment To ensure safety, all electric equipment to be manually cleaned should be to be manually cleaned should be disconnected from the power source. disconnected from the power source.

In many food processing plants / In many food processing plants / kitchens, circuit breakers can be tripped kitchens, circuit breakers can be tripped and the power supply effectively "locked and the power supply effectively "locked out." out."

Some equipment may be rinsed and Some equipment may be rinsed and spray-cleaned when it is running. In this spray-cleaned when it is running. In this case, workers should be trained to keep case, workers should be trained to keep their hands away from moving parts that their hands away from moving parts that may cause injury.may cause injury.

Motors, switches, and other electrical Motors, switches, and other electrical components may require covering; components may require covering; consult the equipment manual or consult the equipment manual or manufacturer if unsure. manufacturer if unsure.

A piece of equipment may require A piece of equipment may require disassembly for safety reasons before disassembly for safety reasons before cleaning. cleaning.

Disassembly also enables cleaning to be Disassembly also enables cleaning to be more effective by improving accessibility more effective by improving accessibility and the employee's ability to see the and the employee's ability to see the surface to be cleaned. It is a common surface to be cleaned. It is a common practice to put disassembled equipment practice to put disassembled equipment parts on a table or rack, or in a tub, for parts on a table or rack, or in a tub, for cleaning.cleaning.

The plant environment during The plant environment during cleaning can be hazardous to cleaning can be hazardous to employees unless proper precautions employees unless proper precautions are taken. are taken.

Slippery floors, high pressure hot Slippery floors, high pressure hot water hoses, and cleaning chemicals water hoses, and cleaning chemicals can all be dangerous. Workers should can all be dangerous. Workers should dress appropriately for the task of dress appropriately for the task of cleaning. cleaning.

Boots with non-skid soles, waterproof Boots with non-skid soles, waterproof aprons and gloves are commonly aprons and gloves are commonly worn. worn.

Ideally, pants should not be tucked Ideally, pants should not be tucked into boots because doing so makes it into boots because doing so makes it much easier to accidentally pour hot much easier to accidentally pour hot water or a chemical solution into the water or a chemical solution into the boot. boot.

The label on each container of The label on each container of cleaning chemical should list any cleaning chemical should list any special precautions that should be special precautions that should be taken when using that chemical. taken when using that chemical.

Material Safety Data SheetMaterial Safety Data Sheet

In addition, there should be a In addition, there should be a Material Safety Data Sheet (MSDS) Material Safety Data Sheet (MSDS) available for each chemical in use. available for each chemical in use.

By law, signs must be posted that By law, signs must be posted that inform employees of the MSDS inform employees of the MSDS locationlocation

The key to good cleaning and sanitation The key to good cleaning and sanitation practices is to provide training to a wide base practices is to provide training to a wide base of plant employees, which may include of plant employees, which may include personnel outside of the sanitation personnel outside of the sanitation department. department.

It is important for supporting functions to It is important for supporting functions to understand how they enable effective understand how they enable effective sanitation for example, timely disassembly of sanitation for example, timely disassembly of equipment by maintenance staff, end of equipment by maintenance staff, end of production housekeeping, and quality production housekeeping, and quality inspections all impact cleaning & sanitation inspections all impact cleaning & sanitation effectiveness effectiveness

Step 1.Step 1.Pre-cleaning or "Physical Cleaning":Pre-cleaning or "Physical Cleaning": The purpose of this step is to remove large The purpose of this step is to remove large

pieces of debris so that later use of water and pieces of debris so that later use of water and chemicals is more efficient. chemicals is more efficient.

Pre-cleaning may involve picking up packaging Pre-cleaning may involve picking up packaging debris, scraping equipment surfaces, and debris, scraping equipment surfaces, and sweeping the floor. sweeping the floor.

The importance of this step is sometimes The importance of this step is sometimes overlooked. overlooked.

If done properly, it will save you money by If done properly, it will save you money by reducing water and chemical costs.reducing water and chemical costs.

Some processors combine pre-cleaning with Some processors combine pre-cleaning with the next step, pre- rinsing the next step, pre- rinsing

Step 2.Pre-rinsing:Step 2.Pre-rinsing: In this step, the surfaces to be cleaned are In this step, the surfaces to be cleaned are

rinsed with water. rinsed with water. Just as in physical cleaning, pre-rinsing Just as in physical cleaning, pre-rinsing

removes some debris and reduces the need removes some debris and reduces the need for chemicals. for chemicals.

Generally speaking, the pre-rinse will be more Generally speaking, the pre-rinse will be more effective if warm or hot water is used effective if warm or hot water is used because the solubility of many components of because the solubility of many components of the debris is greater at higher temperatures. the debris is greater at higher temperatures.

If excessively hot water is used, there is a risk If excessively hot water is used, there is a risk of "cooking on" the small amounts of protein of "cooking on" the small amounts of protein present in residue. present in residue.

Experience and monitoring will guide your Experience and monitoring will guide your choice of water temperature. choice of water temperature.

Once the best temperature is determined, Once the best temperature is determined, monitoring should be done to ensure that this monitoring should be done to ensure that this temperature is actually used. temperature is actually used.

Pre-rinse may remove virtually all debris. Pre-rinse may remove virtually all debris. However, microbial biofilms and/or mineral However, microbial biofilms and/or mineral

deposits may remain on equipment. deposits may remain on equipment. The later step of chemical cleaning should not The later step of chemical cleaning should not

be skipped without conclusive supporting be skipped without conclusive supporting evidence that it is unnecessary. evidence that it is unnecessary.

Pre-rinsing should be done from the top to the Pre-rinsing should be done from the top to the bottom of a piece of equipment. bottom of a piece of equipment.

Step 3.Chemical Cleaning:Step 3.Chemical Cleaning: Cleaning chemicals are intended to lift Cleaning chemicals are intended to lift

debris from the equipment surface and debris from the equipment surface and keep it suspended in water so that it can keep it suspended in water so that it can be rinsed away. be rinsed away.

No single cleaning chemical does this No single cleaning chemical does this effectively under all conditions. effectively under all conditions.

Instead, we use mixtures that may Instead, we use mixtures that may contain several different chemicals to contain several different chemicals to ensure that the job is done well under ensure that the job is done well under normal conditions normal conditions

Step 4. Post-RinseStep 4. Post-Rinse

Again, it is recommended that only the lowest Again, it is recommended that only the lowest effective pressure and volume of water is used effective pressure and volume of water is used during the post-rinse step to avoid risks during the post-rinse step to avoid risks associated with aerosols and overspray.associated with aerosols and overspray.

As indicated, sanitation personnel should work As indicated, sanitation personnel should work from walls and floor to equipment, in sequence, from walls and floor to equipment, in sequence, to avoid the potential risk of overspray or to avoid the potential risk of overspray or splashing on equipment that no longer has splashing on equipment that no longer has detergent on it and is considered clean. detergent on it and is considered clean.

Similarly, personnel should minimize spraying Similarly, personnel should minimize spraying the floor once rinsing of the equipment begins.the floor once rinsing of the equipment begins.

RINSINGRINSING : :An important part of the cleaning An important part of the cleaning

process is the water rinse. process is the water rinse. As the substrate leaves the cleaner As the substrate leaves the cleaner

stage it carries spent cleaner, emulsified stage it carries spent cleaner, emulsified soils and other contaminants. soils and other contaminants.

The rinse must remove these unwanted The rinse must remove these unwanted materials and not interfere with materials and not interfere with the subsequent operations. the subsequent operations.

Therefore, the choice of cleaner is also Therefore, the choice of cleaner is also governed by its rinsability. governed by its rinsability.

Caustic and silicate, two major ingredients of Caustic and silicate, two major ingredients of cleaners, are poor rinsers. cleaners, are poor rinsers.

Phosphate, on the other hand, is relatively Phosphate, on the other hand, is relatively easy to rinse. easy to rinse.

Hot water can assist in rinsing. Hot water can assist in rinsing. Care must be exercised so that drying does Care must be exercised so that drying does

not occur just before the rinse tank. not occur just before the rinse tank. Also, blends of caustic, silicate and Also, blends of caustic, silicate and

phosphates rinse more freely.phosphates rinse more freely.Double rinsing is utilized quite often. Double rinsing is utilized quite often. With the final rinse being deionized water With the final rinse being deionized water

for spot free parts or with a corrosion for spot free parts or with a corrosion inhibitor if rusting is a problem.inhibitor if rusting is a problem.

Step 5: Remove and AssembleStep 5: Remove and Assemble

At this point, the equipment is clean and GMPs At this point, the equipment is clean and GMPs are employed as required. are employed as required.

Sanitation personnel will ensure that condensate Sanitation personnel will ensure that condensate and standing moisture are removed, as well as and standing moisture are removed, as well as any tools utilized during the cleaning process.any tools utilized during the cleaning process.

The crew will conduct pre-operational The crew will conduct pre-operational procedures and sanitize any equipment procedures and sanitize any equipment components that are not accessible once components that are not accessible once reassembled.reassembled.

Step 6: InspectStep 6: Inspect

Pre-operational inspection provides Pre-operational inspection provides added assurance that sanitation goals added assurance that sanitation goals have been achieved in Steps 1 through 5have been achieved in Steps 1 through 5

If deficiencies are found at this point, If deficiencies are found at this point, they can be corrected; they can be corrected;

i.e., recleaned by a detergent, rinsed and i.e., recleaned by a detergent, rinsed and reinspected. reinspected.

Cleaning chemicalsCleaning chemicals

i) Wateri) Water The cornerstone of chemical cleaning is The cornerstone of chemical cleaning is

water.water. Water used in cleaning should be potable, and Water used in cleaning should be potable, and

low in suspended matter and impurities that low in suspended matter and impurities that might affect odor and taste. might affect odor and taste.

Ideally, the water should be low in hardness Ideally, the water should be low in hardness minerals. minerals.

Hard water inhibits the ability of some Hard water inhibits the ability of some cleaning compounds to suspend debris and cleaning compounds to suspend debris and can result in mineral deposits on equipment can result in mineral deposits on equipment surfaces. surfaces.

ii) ii) Surface Active Agent (Surfactant)Surface Active Agent (Surfactant)

The major ingredient in most mixtures is a The major ingredient in most mixtures is a surfactant. surfactant.

Its’ function is to suspend debris Its’ function is to suspend debris components that normally do not stay components that normally do not stay suspended in water.suspended in water.

Of the three types of surfactants, anionic, Of the three types of surfactants, anionic, nonionic, and cationic, the anionic nonionic, and cationic, the anionic surfactants are most commonly used. surfactants are most commonly used.

iii) Acid or Alkaliiii) Acid or Alkali - -

One or more compounds will be included to One or more compounds will be included to adjust the pH (degree of acidity or alkalinity) adjust the pH (degree of acidity or alkalinity) of the cleaning solution. of the cleaning solution.

Alkaline cleaners are recommended for high- Alkaline cleaners are recommended for high- fat debris, particularly when this debris has fat debris, particularly when this debris has been heated. been heated.

Chlorinated alkaline cleaners are used for Chlorinated alkaline cleaners are used for removing many different types of debris and removing many different types of debris and work especially well against high- protein work especially well against high- protein debris. debris.

A chlorinated alkaline cleaner is commonly A chlorinated alkaline cleaner is commonly used in most kitchens / processing plants. used in most kitchens / processing plants.

Acidic cleaners are very useful for Acidic cleaners are very useful for removing mineral deposits. Debris removing mineral deposits. Debris from the food and soil can support from the food and soil can support microbial growth over time,microbial growth over time,

An acidic cleaner may be periodically An acidic cleaner may be periodically useful if mineral deposits develop. useful if mineral deposits develop. Phosphoric acid and gluconic acid are Phosphoric acid and gluconic acid are two acids commonly used for this two acids commonly used for this purpose.purpose.

iv) Chlorine Compoundsiv) Chlorine Compounds - - Chlorine-containing compounds are Chlorine-containing compounds are

sometimes included in an alkaline sometimes included in an alkaline cleaning mixture. cleaning mixture.

In this application, the chlorine is In this application, the chlorine is intended to react with protein in the intended to react with protein in the residue, with little chlorine remaining to residue, with little chlorine remaining to kill microorganisms. kill microorganisms.

v) Water Softenersv) Water Softeners

Some cleaning mixtures will contain Some cleaning mixtures will contain components, called either water components, called either water softeners or chelators, that chemically softeners or chelators, that chemically bind water hardness minerals. bind water hardness minerals.

Examples of chelators include certain Examples of chelators include certain polyphosphates, gluconates, and EDTA polyphosphates, gluconates, and EDTA (ethylenediamine tetra- acetic acid).(ethylenediamine tetra- acetic acid).

Sequestering or Chelating materials have two Sequestering or Chelating materials have two (02) functions(02) functions..

1)1) To condition water, which permits To condition water, which permits better rinsing and cleaning. better rinsing and cleaning.

2)2) To hold iron or other metals in solution to To hold iron or other metals in solution to prevent this keeps them from prevent this keeps them from redeposition on the part. Some chelators redeposition on the part. Some chelators such as EDTA hold heavy metals very such as EDTA hold heavy metals very tightly, hence could be a problem in waste tightly, hence could be a problem in waste treatment. treatment.

Gluconates are more desirable in these Gluconates are more desirable in these cases.cases.

Alkaline CleanersAlkaline Cleaners : :

Alkaline salts, usually caustic, silicates Alkaline salts, usually caustic, silicates and phosphates, together with a and phosphates, together with a balanced amount of surface active balanced amount of surface active agents, constitute a very effective agents, constitute a very effective blend for metal cleaning. blend for metal cleaning.

For dissolving in hot water and For dissolving in hot water and spraying on the dirty ware, this spraying on the dirty ware, this kind of cleaner generally removes kind of cleaner generally removes most soils. most soils.

This is the cheapest and best method This is the cheapest and best method of automated cleaning.of automated cleaning.

Acid Cleaners :Acid Cleaners :Materials used here are usually mineral acids, Materials used here are usually mineral acids,

although organic acids can be used. although organic acids can be used.

By the addition of wetting agents to the acid-water By the addition of wetting agents to the acid-water solution, cleaning as well as metal rust and solution, cleaning as well as metal rust and scale removal can be accomplished. scale removal can be accomplished.

Since soils and oils are best removed on the Since soils and oils are best removed on the alkaline side, the use of acid materials is alkaline side, the use of acid materials is somewhat limited.somewhat limited.

Synthetic detergentsSynthetic detergents Possess the desirable properties of Possess the desirable properties of

ordinary soaps and can be used with hard ordinary soaps and can be used with hard water and in acidic solutions as well.water and in acidic solutions as well.

These are sodium salts of a long chain These are sodium salts of a long chain benzene sulphonic acids or sodium salts benzene sulphonic acids or sodium salts of long chain alkyl hydrogen sulphates.of long chain alkyl hydrogen sulphates.

CHCH33(CH(CH22))1010CHCH22OSOOSO33--NaNa++ Sod.lauryl sulph Sod.lauryl sulph

Alkyl Benzene sulphonateAlkyl Benzene sulphonate

Their calcium or magnesium salts are Their calcium or magnesium salts are soluble in water.soluble in water.

The hydrophobic part is the hydrocarbon chainThe hydrophobic part is the hydrocarbon chain and the water soluble part can beand the water soluble part can be

*An anionic group like sulphate or sulphonate*An anionic group like sulphate or sulphonate

*A cationic group like amine salt or QAC*A cationic group like amine salt or QAC

*A non-ionic group like alcohol or ether*A non-ionic group like alcohol or ether

Some of these have very low biodegradability.Some of these have very low biodegradability.

Therefore they cause water pollution when they Therefore they cause water pollution when they are discharged to surface waters. are discharged to surface waters.

SoapsSoaps Anionic surfactant used in conjunction with Anionic surfactant used in conjunction with

water for washing and cleaning.water for washing and cleaning. Can be solid or viscous liquid.Can be solid or viscous liquid. They consists of sodium or potassium salts They consists of sodium or potassium salts

of fatty acids.of fatty acids.

Applied to a soiled surface, soapy water Applied to a soiled surface, soapy water effectively holds particles in colloidal effectively holds particles in colloidal suspension so it can be easily rinsed with suspension so it can be easily rinsed with clean water. clean water.

Solvent cleanersSolvent cleaners Petroleum or Chlorinated solvent applied by Petroleum or Chlorinated solvent applied by

some absorbent material usually a rag.some absorbent material usually a rag. Oil is removed by the action of the solvent Oil is removed by the action of the solvent

while the soils are removed / reduced by the while the soils are removed / reduced by the rubbing action.rubbing action.

The rag and solvent quickly become dirty and The rag and solvent quickly become dirty and must be replaced frequently. must be replaced frequently.

DisadvantagesDisadvantages Expensive.Expensive. Cannot be automatedCannot be automated Hazardous -Fire, health and environmental Hazardous -Fire, health and environmental

Mechanical Cleaning :Mechanical Cleaning :The materials used here include some type of The materials used here include some type of

an abrasive-steel brush, sandpaper, or an abrasive-steel brush, sandpaper, or nylon rolls impregnated with abrasive. The nylon rolls impregnated with abrasive. The cleaning is accomplished by metal removal cleaning is accomplished by metal removal from the surface. from the surface.

Selecting a cleanerSelecting a cleaner : :

• Determine the types of metal surface to be Determine the types of metal surface to be cleaned. cleaned.

• Ensure the alkaline cleaner will not attack the Ensure the alkaline cleaner will not attack the metal (important with aluminium, zinc and some metal (important with aluminium, zinc and some exotic metals) exotic metals)

• Be sure the cleaner is formulated to effectively Be sure the cleaner is formulated to effectively remove the soils you encounter. remove the soils you encounter.

• Some compounds require heat and in many Some compounds require heat and in many cases higher alkalinity to saponify cases higher alkalinity to saponify

animal fats if present.animal fats if present.

• Choose a cleaner suitable for the Choose a cleaner suitable for the mechanics of your system. mechanics of your system.

• Immersion cleaners normally require Immersion cleaners normally require different surfactant systems than spray different surfactant systems than spray cleaners.cleaners.

• Remember conditioners in the cleaning Remember conditioners in the cleaning product are critical to counteract the product are critical to counteract the undesirable effects of hard water salts undesirable effects of hard water salts on cleaning solutions.on cleaning solutions.

• Consider whether a liquid or powdered Consider whether a liquid or powdered product would favor your operation.product would favor your operation.

-- Liquid are easily automated andLiquid are easily automated and

-- Available in bulk or bins hence Available in bulk or bins hence

eliminating drums.eliminating drums.

-- Powders are normally manually added Powders are normally manually added

but more economical in smaller but more economical in smaller

operations.operations.

MORNING CLEAN UP :MORNING CLEAN UP :

Before processing starts for the day all Before processing starts for the day all work surface should be cleaned with work surface should be cleaned with water containing 5 - 10 ppm residual free water containing 5 - 10 ppm residual free chlorine.chlorine.

Freezer storage should be free from odours & Freezer storage should be free from odours & should be cleaned to ensure good hygienic should be cleaned to ensure good hygienic environment. environment.

Effective measures should be taken to Effective measures should be taken to protect against entrance of insects, protect against entrance of insects, rodents, birds or other vermin.rodents, birds or other vermin.

DURING WORKING HOURS :DURING WORKING HOURS :

The surface which come into contact The surface which come into contact with food should be wiped / hosed with food should be wiped / hosed down with clean water as down with clean water as frequently as necessary to ensure frequently as necessary to ensure cleanliness. cleanliness.

Clean In PlaceClean In PlaceCIPCIP

Multi – use CIP Systems :Multi – use CIP Systems :Multi – use CIP systems offer a Multi – use CIP systems offer a

remarkable range of remarkable range of programmable thermal and programmable thermal and sequencing combinations and sequencing combinations and the overall dexterity of these the overall dexterity of these systems can be shown in the systems can be shown in the following examples ;following examples ;

CIP cleaningCIP cleaning Utilized to clean the interior surfaces of Utilized to clean the interior surfaces of

pipelines and tanks of liquid and semi-pipelines and tanks of liquid and semi-liquid food and beverage processing liquid food and beverage processing equipment. equipment.

This type of cleaning is generally done This type of cleaning is generally done with large tanks, kettles or piping with large tanks, kettles or piping systems where there are smooth systems where there are smooth surfaces. surfaces.

CIP involves circulation of detergent CIP involves circulation of detergent through equipment by use of a spray ball through equipment by use of a spray ball or spray to create turbulence and thus or spray to create turbulence and thus remove soil remove soil

Pre-Rinse Operation :Pre-Rinse Operation :

a)a) Either from water recovery (usual) or Either from water recovery (usual) or mains supply.mains supply.

b)b) Variable periods available at various Variable periods available at various temperatures.temperatures.

c)c) Pre-rinse can be either directed to Pre-rinse can be either directed to drain or diverted via re-circulatory loop drain or diverted via re-circulatory loop for a timed period and then sent to for a timed period and then sent to drain. In some cases product recovery drain. In some cases product recovery is feasible.is feasible.

d)d) If required, chemical injection can be If required, chemical injection can be initiated to aid pre-rinsing efficiency.initiated to aid pre-rinsing efficiency.

Detergent Recirculation :Detergent Recirculation :

a)a) Recirculation can be established either via the Recirculation can be established either via the detergent vessel or the recirculatory loop.detergent vessel or the recirculatory loop.

b)b) Recirculation times are variable and chemical Recirculation times are variable and chemical injection can either boost the strength or utilize injection can either boost the strength or utilize any combination of chemicals as required.any combination of chemicals as required.

c)c) Recirculation can either be via the plate heat Recirculation can either be via the plate heat exchanger or the plate heat exchanger by-pass exchanger or the plate heat exchanger by-pass loop. Variable temperature programming allows for loop. Variable temperature programming allows for total detergent tank heating or this can be limited total detergent tank heating or this can be limited to the recirculatory loop and the main detergent to the recirculatory loop and the main detergent vessel maintained at ambient or differing vessel maintained at ambient or differing temperature.temperature.

d)d) Chemicals can be either recovered or sent to Chemicals can be either recovered or sent to drain.drain.

Intermediate Rinse :Intermediate Rinse : This is variable but similar in principle This is variable but similar in principle

to the pre-rinse except that chemicals to the pre-rinse except that chemicals would not normally be required at would not normally be required at this stage.this stage.

Acid Recirculation if required :Acid Recirculation if required :

a)a) The recirculatory loop is established The recirculatory loop is established on mains water either through the on mains water either through the plate heat exchanger or via the plate plate heat exchanger or via the plate exchanger by-pass loop.exchanger by-pass loop.

b)b) Acid is injected to pre-set strength Acid is injected to pre-set strength based on timing for a specific circuit based on timing for a specific circuit volume.volume.

c)c) Recirculation time and temperature Recirculation time and temperature are both variable.are both variable.

Sterilant Recirculation :Sterilant Recirculation : This is similar to the acid injection This is similar to the acid injection

sequence except that heating would not be sequence except that heating would not be required under normal circumstances. required under normal circumstances.

Hot Water Sterilisation :Hot Water Sterilisation : Recirculation loop established on mains Recirculation loop established on mains

water via the plate heat exchanger.water via the plate heat exchanger. Variable time and temperature available.Variable time and temperature available. Contents can be sent either to drain or Contents can be sent either to drain or

water recovery.water recovery.

Final Water Rinse :Final Water Rinse :

a)a) Mains water can be pumped through the Mains water can be pumped through the CIP route and directed to water CIP route and directed to water recovery.recovery.

b)b) Both times and temperatures are Both times and temperatures are variable.variable.

Programmes of the above type can be Programmes of the above type can be used for either vessels, lines or specific used for either vessels, lines or specific items of process plant. The duration of items of process plant. The duration of each function would be entirely each function would be entirely dependent on the circuit and associated dependent on the circuit and associated soil load.soil load.

CClean lean OOut of ut of PPlace operationlace operation

In food plants, a common use of the In food plants, a common use of the COP cleaning method involves pieces COP cleaning method involves pieces of equipment that are small, complex of equipment that are small, complex and otherwise hard to clean. and otherwise hard to clean.

They are dissembled, rinsed and then They are dissembled, rinsed and then cleaned and sanitized. cleaned and sanitized.

COP may occur in a sink with a worker COP may occur in a sink with a worker scrubbing to clean, or in tanks scrubbing to clean, or in tanks specially designed for COP specially designed for COP

COP tank used for small parts COP tank used for small parts

In these tanks, detergent and In these tanks, detergent and agitation are used to clean the agitation are used to clean the equipment in question. equipment in question.

Sanitizing may be done using hot Sanitizing may be done using hot water or chemical sanitizers. water or chemical sanitizers.

Small items, such as valves, sanitary Small items, such as valves, sanitary fittings and such, can be placed in fittings and such, can be placed in cages and cleaned with larger items. cages and cleaned with larger items.

Options include doing a rinse, hot Options include doing a rinse, hot water wash with detergent, rinse and water wash with detergent, rinse and soak in sanitizer. soak in sanitizer.

Operators can also sanitize COP Operators can also sanitize COP items by raising the second rinse items by raising the second rinse temperature and holding for 15 temperature and holding for 15 minutes at >180F. minutes at >180F.

Steps in a COPSteps in a COP Dry cleaning to remove dust, soil and other Dry cleaning to remove dust, soil and other

debris from the equipment to be cleaned and debris from the equipment to be cleaned and the area in which COP tasks will take place.the area in which COP tasks will take place.

A pre-rinse of the equipment and area on racks A pre-rinse of the equipment and area on racks or in COP tanks.or in COP tanks.

Soap and scrub the equipment and equipment Soap and scrub the equipment and equipment components in COP tanks or vessels.components in COP tanks or vessels.

Post-rinse parts to remove residual detergent or Post-rinse parts to remove residual detergent or cleaning chemicals.cleaning chemicals.

Conduct pre-operational procedures Conduct pre-operational procedures and sanitize any equipment and sanitize any equipment components that are not accessible components that are not accessible once reassembled. once reassembled.

Reassemble the equipment.Reassemble the equipment.

Sanitize the reassembled equipment Sanitize the reassembled equipment with a sanitizing agent or heat with a sanitizing agent or heat treatment. treatment.