CIP in Food Manufacturing: Efficient Cleaning-in-Place for Hygiene & Compliance

www.pmg.engineering Vol .02-Issue .05-February2023 TECH-KNOWLEDGE The Official PMG Engineering Newsletter FOOD & BEVERAGE INDUSTRY ENGINEERING & DESIGN SCIENCE & TECHNOLOGY A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .05-February 2023 CONTENTS YOUR PARAGRAPH TEXT 1. WHITE PAPER A. Concept of Cleaning and Sanitization B. Clean in Place (CIP) 2. INDUSTRY BUZZ Latest Food Industry News Updates 3. WEEKS HIGHLIGHT A Look Into The Main Events Of The Week 2-5 6-8 9 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 10-12 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .05-February 2023 CONCEPT OF CLEANING AND SANITIZATION Introduction Ceilings Cleaning and sanitization is one of the prerequisite and key element for ensuring food safety and quality of product in food processing industry. Cleaning and sanitation are two different terms having different definition all together. Cleaning refers to the removal of visible dirt or any physical contaminant, while sanitization always comes after cleaning process and focuses more on the removal of any type of microbial contamination, if any. Need of cleaning and sanitation is To prevent transfer of ingredients from same line to avoid chances of cross contamination in case of product change in line production line. To Avoid microbial contamination that lead to reduced product quality, harm to health or life threatening circumstances in some cases. To ensure sanitization efficiency as soils impacts the effectiveness of a sanitizer. To improve plant efficiency as dirt and dust affects production process as well. Food soils (dirt): are unwanted matter on food- contact surfaces. Soil can be visible or can’t be seen visible. The primary source of soil is from the food product being handled. However, minerals from water residue and residues from cleaning compounds contribute to films left on surfaces. Microbiological biofilms also contribute to the soil buildup on surfaces. Types of soils can be fats, oils & greases, proteins, carbohydrates and starches, lime scale, rubber marks, corrosion deposits, adhesives, inks & dyes, algae and fungi. Cleaning Areas: Apart from food contact surfaces various other parts of the plant are to be cleaned and sanitized to maintain a sanitary environment for food processing. Food Contact Surfaces (equipment surfaces, tables & preparation areas, conveyors, utensils, bins & totes, packaging materials), outside of equipment (body, pipelines) and environment light fixtures) require separate cleaning procedure. Equipment design and plant layout should be considered from a clean ability perspective. One needs to reach around and under equipment to clean it properly. (floors, drains, walls, PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION READ MORE.... Vol .02-Issue .05-February 2023 PLATE HEAT EXCHANGER Standard Sanitization for abiding Sanitization: Foremost step the cleaning procedures are to make them available to everyone. Operating Procedures (SSOP’s) and instructions should be written step by step on cleaning equipment, process lines, environmental areas & master sanitation schedules. Sanitization can be achieved by various means either by thermal or chemical sanitization. Thermal sanitization involves the use of hot water or steam for a specified temperature and contact time whereas, chemical sanitization involves the use of an approved chemical sanitizer at a specified concentration and contact time. cleaning. Mechanical Cleaning Procedure: Equipment classification can be done with regard to cleaning method as CIP (Clean in Place), COP (Clean Out of Place) and manual cleaning often referred to as clean-in-place (CIP) requires no disassembly or partial disassembly. Clean-out-of- Place (COP) involves partial disassembling and cleaning in specialized COP pressure tanks. Manual cleaning requires total disassembly for cleaning and inspection. Light fixtures should be of the type approved for food facilities, and should be equipped with break lenses or shatterproof shielding. The resistant fixtures should be designed to be moisture resistant and cleanable. Electrical boxes and related equipment should be water proof and of acceptable sanitary design Different parts of the plant require different types of cleaners. For E.g. CIP system does not require cleaners that foam as much as manual cleaners. Sanitizers usually have a period of effectiveness that only lasts for several hours, so if you sanitize the equipment after cleaning it the night before, just prior to you may need to sanitize again processing. The selection of cleaning & sanitizing chemicals for use in a food processing facility depends upon soil type, surface type, method of cleaning being considered (CIP/COP/Manual) and water quality. Steps for cleaning and sanitization include 1. Dry Cleaning: simply using a broom or brush to sweep off food particles and soil from surfaces 2. Pre-rinse: using warm water (100-120°F) to remove small particles missed in the dry cleaning step and prepares surfaces for application of detergent. 3. Wash: removes all soils by following all SSOP’s for cleaning procedures and chemical selection. Factors that are to be considered are time, action, concentration and temperature. 4. Post-rinse: removes detergent and Chlorine. There can be acid rinse if required by using acidified water. Acid removes mineral and prevent mineral deposition as well. 5.Sanitize: reduces the number of microorganisms on the surface. Before use the surface needs to be sanitized and pre requirement before sanitization is that surface should be clean and free of any form of dirt. Facilities not cleaned regularly have potential safety risks due to constant spills & falls. It has positive finance response, by reducing waste from spoilage can significantly extend life of equipment and machinery. The psychological benefits & confidence of clean, hygienic equipment & tidy surroundings have significant impact on both worker satisfaction and customer confidence. Although it may not be common knowledge, there are often legal requirements for food facilities to clean surfaces and equipment to a specific standard the PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .05-February 2023 CLEAN IN PLACE (CIP) Introduction Clean in Place is a method of cleaning the interior fittings, surfaces of process equipment and without disassembling them.Industries that rely heavily on CIP are those requiring high levels of hygiene, i.e. dairy, beverage, brewing, processed foods, pharmaceutical, and cosmetics and CIP is an integral part of automated industry. CIP method highly depends on type of soil or food residue to be cleaned. It is recommended to have CIP Process to be designed accordingly. Selection of chemicals and their strength, chemistry of product and its interaction with different solutions, time of interaction of chemicals with process line etc. are to be considered while designing the CIP line. Soil also differ in nature; it can either be simple water soluble or can be water insoluble. Water soluble one’s are easy to clean as simple flush of water can dissolve them. Water insoluble soils are hard to tackle as they are again divided into organic and inorganic soils. Organic ones include fats, oils, grease, proteins, starch, and carbohydrates. Inorganic soils include minerals, salt deposits, millstones etc. CIP performs in two ways: - Single use cleaning CIP and recovery CIP. Single use cleaning is for that industries where the line gets way too dirty and chemicals once used can’t be further used due to high soil contamination. In Recovery CIP the process line is not so filthy and hence the chemicals can be collected and reused, though the equipment for recovering cleaning solution is more expensive. Design Principle Depending on soil load and process geometry, the CIP design principle is one of the following: 1.Deliver highly turbulent, high flow-rate solution to effect good cleaning (applies to pipe circuits and some filled equipment). 2.Deliver solution as a low-energy spray to fully wet the surface (applies to lightly soiled vessels where a static spray ball may be used). 3.Deliver a high energy impinging spray (applies to highly soiled or large diameter vessels where a dynamic spray device may be used). CIP systems is more consistent results due to accurate and rapid monitoring, due to less down time and fully automated process.Due to no need for dismantling of equipment and lesser manual work it lessens the burden on workers and human error. The Most important point is that it doesn’t compromise with quality as it provides consistency in the cleaning process. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .05-February 2023 Parameters to be considered CIPeffectiveness depends totally on the correct functioning of the 5 T’s. Titration (1.5%): It is always important to select cchemical concentration in the supply tanks and in the circuits is in accordance to our need. It should be able to remove any deposits and residue of soil in the process equipment’s. It generally lies in the range of 0.5-2% and the optimal one being 1.5%. Turbulence (1.5m/s): Flow velocity in all parts of the system should be sufficient to cause turbulent flow. This should be around 1.5-2 meters per second, below this laminar flow will occur which will not yield effective cleaning. of circuit (~70°C): Temperature Temperature the cleaning solution and water at the beginning & end of consider. the Temperature impacts on the rate of chemical reaction. Typical temperatures can be around 85 Deg. C for cleaning solution but for water it should not exceed 70 Deg. C important to is Time (15 min): Duration of each step of the CIP procedure and time shall be determining the cleaning is achieved or not. The standard time span should be 15 minutes. total CIP the Technology (Design): Total design of the complete line including all circuits to and from the chemical and water tanks should be proper. Even fault in the equipment design can result in cleaning of the line. Procedure The standard procedure for CIP which needs to be followed after or between product run include 5 major steps. 1.Pre-rinse: Water at temperature of about 40-60 Deg. C is used initially to remove any type of loose soil like melt fat and also for the water soluble materials such as sugar. Note: Temperature shouldn’t exceed 60 deg. C. 2.Alkali/ Caustic Circulation: Alkaline cleaning solutions dissolve proteins and saponify salts. The typical and most frequent alkaline agent used in the composition of the detergents is Sodium Hydroxide (NaOH), otherwise known as caustic soda. 3.Intermediate Rinse: To purge out the alkaline detergent used and to remove the remaining soil, process line is flushed with water. 4.Acid Circulation: Acid solutions are used for removing hard deposits such as milk stone (calcium phosphate) and water scale. The deposits are typically formed on hot surfaces and they cannot dissolve in alkalis. Acid solutions are most effective when used at pH 2.5 or lower & they leave surfaces without film. HNO3, H3PO4 are the most frequent acid agents used. 5.Final Rinse: To remove any trace of acid in the line, water is flushed. Before starting production, the line is sterilized using disinfectants to inhibit any microbial activity to a certain level. It is always recommended to verify and validate all the cleaning procedure. Repeatable, reliable, and effective cleaning in a manufacturing facility are prominent characteristic of the CIP system. Various influencing parameter are to be kept in mind as well as manipulated to achieve in manufacturing unit. The process can be validated hence it proves its authenticity. If proper care is taken in each stage of CIP including flow and temperature, it will provide safe environment for food manufacturing and processing owners. standard required quality the PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ Rise of Food and beverage probiotics as well as dairy probiotics Consumer awareness of conventional foods has shifted to functional foods that are healthier and more nutrient-dense because of the growing scientific and innovative research. The concept of functional food is founded on the inclusion of probiotics, which increase immune function, cognitive function, and overall health. Alternative dietary and nutritional treatments through diet are being researched more than ever before to reduce the infection at a time when there is no proven treatment for the infectious viral disease Covid-19, which is a global pandemic caused by Sars-CoV-2. Nanotechnology applications in food processing, packaging & safety is an emerging, rapidly anotechnology in the developing technology that ensures development of novel materials with potential and applications. industrialist novel nanomaterials with multiple functions that renders great potential for food and food- related industries. researchers on researching Many are The demand for nanoparticle-based materials has been increased in the food industry as many of them contain essential elements and also found to be non-toxic. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Non-alcoholic beer set to continue to grow in 2023 Proseal celebrates 25 years of tray sealing. 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION Long a dormant segment of the larger beer market, non-alcoholic beer has seen its growth soar in recent years due to the introduction of new products by larger beer juggernauts like AB InBev and Heineken as well as the emergence of like Athletic Brewing as independent brewers consumers seek out healthier beverage options. Athletic Brewing CEO Bill Shufelt said “This is the moment we’ve been waiting for in the category,” which is projected to grow to upwards of $40 billion by 2032. This year, the world's leading provider of tray 25th sealing its anniversary. The company was founded in an English village. technology will celebrate in whole packing Since then, the business has expanded into a global leader in tray sealing technology and a pro at designing and putting line solutions. Today, Proseal employs about 600 people worldwide, has manufacturing facilities in the USA and Australia, as well as a global distribution network, in addition to its nearly 250,000 square foot manufacturing headquarters in Adlington, UK. In 2019, the business joined the JBT Corporation. The Coca-Cola Company hopes to achieve 100 percent recycling in India in 2-3 years. As part of its World Without Waste global initiative, the Coca-Cola Company said its India business is optimistic that it will be able to recover and recycle 100 percent of post-consumer packaging, primarily bottles and cans, in the next two to three years. The company's goal is to collect and recycle every bottle and can it sells globally by 2030. Recycling post-consumer packaging is one of the three focus areas of Coca-Cola Company's ESG (Environment, Sustainability and Governance) priorities. The other two are related to water and sustainable agriculture. The company through its focus on three fundamental goals -- design, collect and partner -- is laying emphasis on entire packaging lifecycle -- from how bottles and cans are designed and produced to how they are recycled and repurposed. source: https://economictimes.indiatimes.com/ PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Foundation Earth strike and DSM partner to promote food eco- labelling. As part of their agreement to work together on eco-labelling of foods and beverages, Royal DSM, and "empower consumers to make more sustainable food choices based on transparent and reliable information." Earth hope Foundation to Both the independent, non-profit organisation that assigns front-of-pack Eco Impact scores to food products and the multinational purpose-driven science company said that as part of the new partnership, DSM will carry out comprehensive Life Cycle Assessments (LCAs) for taking part brands using the Foundation Earth methodology. Food Processing Equipment Market will value USD 98.7 billion by 2030 India's food processing equipment market size was valued at USD 0.60 billion in 2022 and is expected to reach USD 0.96 billion by 2030, at a CAGR of 6.1% from 2023 to 2030. To achieve a substantial market share in the worldwide food processing equipment market and strengthen their position, manufacturers are pursuing expansion methods such as current developments, mergers and acquisitions, product innovations, collaborations, and partnerships, joint ventures. it is anticipated that the market would grow increased automated technology adoption and research & development processing equipment. in the next years because to spending food on PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION N O N - T E C H N I C A L C O N T E N T WEEKS HIGHLIGHT 30 JANUARY WORLD LEPROSY DAY We Should Believe that we will achieve a world without leprosy one day. But along the way, we need to realize an inclusive society in which everyone has access to quality treatment and services, and a diagnosis of leprosy no longer comes with a possibility of devastating physical, social, economic or psychological consequence. 1 FEBRUARY INDIAN COAST GUARD DAY The Indian Coast Guard is a maritime law enforcement and search and rescue agency of India with jurisdiction over its territorial water including its contiguous zone and exclusive economic zone. The Indian Coast Guard was established on this date, i.e. February 1, 1977 by the Coast Guard Act, 1978 of the parliament of India. 2 FEBRUARY WORLD WETLAND DAY Every year 2nd February is observed as World Wetlands Day. This day is celebrated in order to make everyone importance of wetlands and aims at aware of the motivating people to work towards saving it. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Y R A U R B E F PMG T E C H N I C A L C O N T E N T DID YOU KNOW? Fact 1 A mango tree can grow quickly and large, reaching heights of 100 feet or more and a canopy of 35 feet or more. Of course, the rate of mango tree growth, the stages of mango tree growth, and the height of mango trees all vary depending on soil and weather conditions. Fact 2 storage, transportation, foods varies during The temperature of most and processing, the consumption. Temperature food components, physiochemical properties of final influencing the overall properties of the product. Thermal analysis of food provides a better understanding of how temperature affects food properties, allowing food manufacturers to optimize processing conditions and improve product quality. changes alter Y R A U R B E F PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Fact 3 It is common to enjoy salty chips along with a sandwich, but these chips are high in carbohydrates that feed on cavity-causing bacteria. T E C H N I C A L C O N T E N T Fact 2 Flavonoids, a group of natural substances with variable phenolic structures, are found in fruits, vegetables, grains etc. Y R A U R B E F PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/6 2/6 3/6 4/6 Y R A U R B E F PMG 5/6 6/6 Fact 3 The temperature of most foods varies during processing, transportation, storage, and consumption. Temperature changes alter the physiochemical properties of food components, influencing the overall properties of the final product. Thermal analysis of food provides a better understanding of how temperature affects food properties, allowing food manufacturers to optimize processing conditions and improve product quality. DESIGN+BUILD FOOD FACTORIES. 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