Alfa Laval AB · OMXSTO:ALFA
Alfa Laval AB — Technical Presentation (April 2020)
43 slides from Alfa Laval AB's technical presentation, Apr 29, 2020
Slide 1: Principles of cleaning and CIP
Alyce Hartvigsen Principles of cleaning and CIP − CIP in the brewery (and food and beverage applications) 29/04/2020 | © Alfa Laval 1 | www.alfalaval.com
Slide 2: What we'll talk about today
What we’ll talk about today − Agenda • Principles of cleaning and CIP • CIP in the brewery (and food and beverage applications) • Technologies for tank cleaning • Optimization of CIP process • Automated CIP solutions from Alfa Laval Brewery Systems 29/04/2020 | © Alfa Laval 2 | www.alfalaval.com
Slide 3: Purpose of cleaning and CIP
Purpose of cleaning and CIP − Why do we clean? • Maintenance of product purity, quality and safety • Prevention of product contamination (e.g., spoilage) • Prevention of cross-contamination (e.g., ingress of one product into another) • Maximization of equipment uptime and production capacity (fastes
Slide 4: Principles of cleaning
Principles of cleaning TACT – Sinners Circle Time Temperature • Sinners Circle represents the scope of a given cleaning task • The combined elements of the circle (temperature, action, chemicals, time) accomplish the task • Larger share of one or more elements allow smaller shares of the others (e.g
Slide 5: Mechanical cleaning (action)
Mechanical cleaning (action) − Requirements for mechanical cleaning in the brewery • For pipes: minimum fluid velocity >1.5 m/sec to generate sufficient turbulence to achieve the desired cleaning effect • For tanks: cleaning machines generating geometric reach of all interior surfaces (coverage) and
Slide 6: Mechanical cleaning
Mechanical cleaning − Minimum flow rates in pipes Pipe size Minimum flow rate Velocity DN 25 30 hl/h 1.7 m/s DN 40 80 hl/h 1.8 m/s DN 50 120 hl/h 1.7 m/s DN 65 200 hl/h 1.7 m/s DN 80 300 hl/h 1.6 m/s DN 100 400 hl/h 1.4 m/s © Alfa Laval Slide 6 29/04/2020 | © Alfa Laval 6 | www.alfalaval.com
Slide 7: Chemicals used in CIP
Chemicals used in CIP − Main types of cleaning chemicals and their purpose Chemical Cleaning media Function compounds Water H2 O Pre-rinses, intermediate rinses and final rinses remove solid residues and flush away chemical residues. Caustic (~2%) at NaOH, KOH Dissolves and removes organic residues
Slide 8: Automated Cleaning-in-Place (CIP)
Automated Cleaning-in-Place (CIP) − What is it? • Enables cleaning of tanks, piping and other process equipment without dismantling or manual cleaning processes • Typically consists of tank cleaning machines installed inside the tanks • Involves cleaning stages using water and chemicals that circula
Slide 9: Tank cleaning technology
Tank cleaning technology − Characteristics of tank cleaning machines Static spray ball Rotary spray head Rotary jet head Easy-to-clean tasks Moderate cleaning tasks Difficult cleaning tasks Max. diameter: 3 m Max. diameter: 5 m Max. diameter:15+ m Pressure: 1–2 bar Pressure: 2–3 bar Pressure: 5–7 ba
Slide 10: Principles of cleaning – tank cleaning machines
Principles of cleaning – tank cleaning machines − Effect of cleaning machine type on required cleaning parameters according to the Sinners Circle Temperature Action Chemicals Time Static spray ball Rotary spray head Rotary jet head 29/04/2020 | © Alfa Laval 10 | www.alfalaval.com
Slide 11: Alfa Laval TJ40G
Alfa Laval TJ40G − Best-in-class for rotary jet head tank cleaning with hygienic design and self-cleaning Enhanced self-cleaning features of TJ40G 1 1 Self-cleaning of body 2 2 Self-cleaning of nozzles 3 Self-cleaning of cone 3 29/04/2020 | © Alfa Laval 11 | www.alfalaval.com
Slide 12: Alfa Laval TJ40G
Alfa Laval TJ40G − Self-cleaning demonstration using yogurt as the test media 29/04/2020 | © Alfa Laval 12 | www.alfalaval.com
Slide 13: Challenging cleaning task
Challenging cleaning task − Fermenter yeast ring 29/04/2020 | © Alfa Laval 13 | www.alfalaval.com
Slide 14: Static spray ball for fermenter yeast ring
Static spray ball for fermenter yeast ring − Fast wetting but low action: inefficient and expensive cleaning • Low cleaning action • Long cleaning time • High operating cost 29/04/2020 | © Alfa Laval 14 | www.alfalaval.com
Slide 15: Rotary jet head
Rotary jet head − High-impact cleaning • Fast effective wetting • High cleaning action • Fast cleaning time • Low operating cost 29/04/2020 | © Alfa Laval 15 | www.alfalaval.com
Slide 16: Development of TJ40G cleaning pattern
Development of TJ40G cleaning pattern − TRAX simulation of time, wetting intensity and cleaning fluid consumption • TRAX program illustrates wetting intensity in all areas of tank during the cleaning cycle • Examples show wetting and water consumption after 2 minutes (1 cycle) and 16 minutes (8 cycl
Slide 17: Alfa Laval TJ40G Burst
Alfa Laval TJ40G Burst − Fast-wetting AND high-impact cleaning Cut 29/04/2020 | © Alfa Laval 17 | www.alfalaval.com
Slide 18: Standard TJ40G versus TJ40G Burst
Standard TJ40G versus TJ40G Burst Standard TJ40G TJ40G Burst Less caustic is necessary to wet the tank surface using TJ40G Burst as there is no need to build up a dense cleaning pattern 29/04/2020 | © Alfa Laval 18 | www.alfalaval.com
Slide 19: Savings
Savings − Standard spray ball CIP with caustic recovery Steps CIP program Re-use factor % Minutes EUR 1 Water rinse 0 10 26.25 2 Caustic re-circulation 85 60 26.25 3 1 x water rinse (1 cycle) 50 5 6.56 4 8 x sterilant continues re-circulation 90 20 9.33 5 1 x final rinse (2 cycles) 100 6 0.00 Total
Slide 20: Savings
Savings − Burst spray ball CIP without caustic recovery Steps CIP program Re-use factor % Minutes EUR 1 1 x ambient caustic burst 0 1.5 4.38 2 Wait time 5 3 1 x ambient caustic burst 0 1.5 4.38 4 Wait time 5 5 1 x ambient caustic burst 0 1.5 4.38 6 Wait time 5 7 1 x ambient caustic burst 0 1.5 6.13
Slide 21: Savings
Savings − TJ40G Burst CIP without caustic recovery Steps CIP program Re-use factor % Minutes EUR 1 1 x ambient caustic burst 0 1 2.22 2 Wait time 5 3 1 x ambient caustic burst 0 1 2.22 4 Wait time 5 5 1 x ambient caustic burst 0 1 2.22 6 Wait time 5 9 1 x water rinse 50 2 1.43 10 8 x sterilant conti
Slide 22: Comparison
Comparison − Summary of savings Spray ball with Spray ball without TJ40G Burst without caustic recovery caustic recovery caustic recovery Water 73 hl 15 hl 3 hl Caustic 52 hl 35 hl 9 hl Sterilant 12 hl 12 hl 6 hl 2,530 EUR 2,100 EUR 789 EUR Yearly operation cost 29/04/2020 | © Alfa Laval 22 | www.al
Slide 23: Optimizing burst cleaning
Optimizing burst cleaning − Trials to find appropriate number of repetitions 1st burst of 60 seconds 2nd burst of 60 seconds 3rd burst of 60 seconds 29/04/2020 | © Alfa Laval 23 | www.alfalaval.com
Slide 24: Optimizing burst cleaning
Optimizing burst cleaning Evaluate and Before After analyze the cleaning results! 29/04/2020 | © Alfa Laval 24 | www.alfalaval.com
Slide 25: Considerations for retrofit to TJ40G Rotary Jet Head
Considerations for retrofit to TJ40G Rotary Jet Head − Insertion of machine into tank • Most static spray balls are <100 mm in diameter • Insertion flanges for these on tank tops are therefore typically 100 mm or smaller • TJ40G Rotary Jet Head requires an opening of 180–200 mm to insert the machine
Slide 26: SCANDI BREW top plate with TJ40G and Rotacheck
SCANDI BREW top plate with TJ40G and Rotacheck − Insertion flange for TJ40G with optimal placement of Rotacheck validation instrument already mounted 29/04/2020 | © Alfa Laval 26 | www.alfalaval.com
Slide 27: Considerations for retrofitting with a rotary jet head
Considerations for retrofitting with a rotary jet head − Required capacity for CIP-Forward pump • Static spray balls typically require high flow rates but low inlet pressure (~2 bar at inlet) • Rotary jet heads have lower flow requirements, but higher inlet pressure (5 bar at inlet) • CIP-F pump cap
Slide 28: Process considerations for use of rotary jet head
Process considerations for use of rotary jet head − Risk: Gas flow through rotary jet head during pressurization and emptying • Typical fermenter design: Cleaning-in-Place/CO2 line with non-return valve (NRV) • NRV should allow gas to flow out of tank during filling and fermentation – and into tank
Slide 29: Process considerations for rotary jet head
Process considerations for rotary jet head − Improved design of fermenter CIP-CO2 system for rotary jet head (RJH) applications • Non-return valve is replaced with two automated butterfly valves • During filling, emptying, pressurization and fermentation: valve to RJH closed, valve on CIP/CO2 line o
Slide 30: Process piping design for cleanability
Process piping design for cleanability − Avoiding dead legs in piping branches Butterfly valve Butterfly valve with drain Single seat valve Unique Mixproof valve More dead leg No dead leg Poor cleanability Optimal cleanability 29/04/2020 | © Alfa Laval 30 | www.alfalaval.com
Slide 31: Optimizing CIP of valves and piping
Optimizing CIP of valves and piping − Water and chemical savings with Alfa Laval Unique Mixproof valves • Optimizing valve configuration and operation results in savings of water and chemicals • Valve configuration determines the method of cleaning the valve (e.g. external valve CIP or seat lift Pas
Slide 32: Seat lift CIP versus external valve CIP
Seat lift CIP versus external valve CIP Seat lift cleaning External cleaning • More hygienic solution • Standard offering • 70% savings of water and (e.g., SPX and GEA) chemicals • Cheaper solution from • Same investment cost SPX and GEA • Fewer pipe installations • Clean without CIP in pipe install
Slide 33: Case story: Unique Mixproof seat lift cleaning
Case story: Unique Mixproof seat lift cleaning − Influence of CIP supply pressure on wall shear stress and cleaning efficiency Flow through Unique Mixproof valve (seat lift) Pressure (bar) 0.5 4.0 Higher CIP supply pressure gives stronger Wall shear stress opening (Pa) 8.23 50.8 pulsations, which cl
Slide 34: Case story: Unique Mixproof seat lift cleaning
Case story: Unique Mixproof seat lift cleaning − Water and chemicals savings using pressurized CIP supply and short seat lifts Product Periods Possible water savings during CIP (Unique Mixproof 3" valve) Yearly water savings (30 Unique Mixproof valves) Milk 1–2 Conditions during lift of seat ½ bar,
Slide 35: Automated CIP modules from Brewery Systems
Automated CIP modules from Brewery Systems • Standard CIP modules of up to four tanks • Tank supply can be included or optional • Central or local CIP plants with communication by Ethernet/Profibus • Automatic and safe operation • Optimal consumption of cleaning fluids • CIP recovery to save cleanin
Slide 36: CIP plant locations in a brewery
CIP plant locations in a brewery − Examples of individual CIP plant applications CIP for: • Brewhouse • Wort line • Fermentation and lagering cellars • Filtration and beer conditioning • Bright beer tanks, filling lines and fillers • Yeast plants, propagation and storage • Pasteurizers, beer sterile
Slide 37: Brewery Systems construction set for CIP plant
Brewery Systems construction set for CIP plant − Each individual CIP plant can be tailored to fit your process requirements 29/04/2020 | © Alfa Laval 37 | www.alfalaval.com
Slide 38: Sample P&ID of a CIP plant from Brewery Systems
Sample P&ID of a CIP plant from Brewery Systems − Piping and instrumentation diagram 29/04/2020 | © Alfa Laval 38 | www.alfalaval.com
Slide 39: Sample layout of CIP plant from Brewery Systems
Sample layout of CIP plant from Brewery Systems 29/04/2020 | © Alfa Laval 39 | www.alfalaval.com
Slide 40: Webinars for brewers
Webinars for brewers − Upcoming webinar 25 June, 2020 Dry hopping II Learn how you can streamline and optimize your dry-hopping processes Dry hopping II Webinar 25 June, 2020 29/04/2020 | © Alfa Laval 40 | www.alfalaval.com
Slide 41: Webinars for brewers
Webinars for brewers − Past events Our brewery experts share their beer production know-how. Choose from a range of topics – from dry hopping to dealcoholization and more. Beer dealcoholization Separation for your brewery Webinar 21 November, 2019 Webinar 24 September, 2019 Click here to visit our w
Slide 42: Thank you for your attention!
Thank you for your attention! − Any questions? 29/04/2020 | © Alfa Laval 42 | www.alfalaval.com
Slide 43: www.alfalaval.com
www.alfalaval.com