REDUCING SODIUM HYDROXIDE IN PROCESS CLEANINGUMASS LOWELL - TURI

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OUTLINEREDUCING SODIUM HYDROXIDE IN PROCESS CLEANING

B k d• Background• Method• Preliminary results• Preliminary results• Potential recommendations• Next Steps• Next Steps• Acknowledgements

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BACKGROUND

• Sodium hydroxide (NaOH) is widely used in combination with hydrogen peroxide (H2O2) as an effective FCS cleaner.

• NaOH (Caustic Soda) is classified as toxic chemical by• NaOH (Caustic Soda) is classified as toxic chemical by Toxic Use Reduction Act (TURA).

• When used in large quantity it pose significant chemicalWhen used in large quantity it pose significant chemical hazards to the processed food, employees and the environment

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OBJECTIVES

1 E t bli h i i t ti f N OH/ H O• 1. Establish a minimum concentration of NaOH/ H2O2 for cleaning-in-place (CIP) at Kettle Cuisine (KC).

• 2. Identify and test green alternatives of caustic soda for CIP processes. p

• 3. Reduce down-time, energy and labor cost for CIP processes.

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METHOD

Scaling and weight: place stainless steel (SS)316 coupons in Mac & Cheese heat at 180°F for 3 hoursCheese, heat at 180 F for 3 hours.

Cleaning with NaOH/ H2O2 and g / 2 2 weight: different concentration 

and temperature.

Physical scrubbing with diluted phosphoric acid.

QC ‐ ATP measurement

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QC ‐ ATP measurement

MEASUREMENT

• Dry weight changes among different steps• QC ATP test• QC – ATP test

– ATP, the energy molecule found in all living things, making it a perfect indicator to determine if a surface is clean or not.

– To ensure no product contamination or biofilm development presents on SS surface.

– The amount of ATP present in the sample providingThe amount of ATP present in the sample, providing information on the level of contamination.

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PRELIMINARY RESULTS

Table 1. Alternative experiments associated with concentration of NaOH/H2O2 and p / 2 2descaling temperature. 100% = simulated KC’s application (250 gallons of H2O, 8 lbs of HCL‐5000, 2 lbs of H2O2). Size of coupon: 1.5 inch x 1.5 inch. 

TemperatureConc. Of NaOH/H2O2

100% 75% 50%

82°C √ √ √

75°C √

65°C √

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PRELIMINARY RESULTS – DOSE

DE‐SCALE RATIO ATP TEST

101102103

atio

DE SCALE  RATIO

10

12

14

LU)

ATP TEST

‐‐ 82°C  ‐‐ 82°C 

96979899100

idue

 Rem

oval Ra

4

6

8

10

ATP values (R

L

939495

100% 75% 50%

Resi

Concentration of NaOH/H2O2

0

2

100% 75% 50%Concentration of NaOH/H2O2Concentration of NaOH/H2O2 Concentration of NaOH/H2O2

Figure 1. (A) Weight removal test and (B) ATP test of SS316 coupons under 82 °C cleaning temperature RLU: relative light unit 0‐10 RLU: good; 11‐30 RLU: caution; over

(A) (B)

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cleaning temperature. RLU: relative light unit. 0 10 RLU: good; 11 30 RLU: caution; over 30 RLU: failure. 

PRELIMINARY RESULTS - TEMPERATURE

14

ATP TEST ‐‐ 75% NaOH/H2O2

8

10

12

lues (R

LU)

2

4

6

ATP va

082°C 75°C 65°C

Concentration of NaOH/H2O2

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RESULTS

Cl i ff t f 75% N OH/H O ith 82 °C 75 °C• Cleaning effect of 75% NaOH/H2O2 with 82 °C, 75 °C, and 65 °C is able to pass ATP test.

• Cleaning effect of 50% NaOH/H2O2 with 82 °C is able to pass ATP test, but its ATP values are higher than that p gof 75% NaOH/H2O2 .

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POTENTIAL RECOMMENDATIONS

• In 2015 44,662 lbs of sodium hydroxide was used in the l icleaning process.

• It was anticipated that by 2017 taking production growth into account an additional 9 379 pounds per year wouldinto account, an additional 9,379 pounds per year would be used.

• Results show using 75% NaOH, considered as the new dosing concentration, about 15% (3.5 Tons) can be reduce annually while achieving same ATP results as 100%.

• Reduce CIP temperature to 65oC = savings on energy bill!

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NEXT STEPS

• Continuing to evaluate the concentration of NaOH/H2O2(50%) ith t t 82°C d 50°C(50%) with temperature 82°C and 50°C.

• Screening alternatives will investigate the following: Phix XIVPhix XIV Chlorine Materials Hydrogen peroxideHydrogen peroxide Ozone Peracetic acid/peroxyacetic acidPeracetic acid/peroxyacetic acid Phosphoric acidPotassium hydroxide

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Potassium hydroxide

T i U R d i I i• Toxics Use Reduction Institute

• Kettle Cuisine; AlanACKNOWLEDGEMENTS

• Xiaobo Liu, Manyun Yang,

D i K jDuniya Kajang

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