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Combined Use CIP System from Campbell Cleantec

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article image Combined Use CIP System

The Food Hygiene Systems Division of Campbell Cleantec has won three individual State Innovation Awards in 2007.

The Productivity Press Development Team has now won the DIAA Queensland State Innovation Award for 2008 with its Combined Use CIP System.

Technology employed

As the name suggests, this recent development in CIP technology takes the features of both Recovery (Reclaim) and the Single Use CIP systems and combines them to deliver a new option to all CIP applications.

Economic benefits

  • Reduction in water usage (water conservation)
  • Reduction in chemical usage (less chemical required for Single Use CIP)
  • Reduced impact on the effluent system (reduction in water and chemical usage)
  • Reduction in energy (reduction in heating required)
  • All equates to a lower cost of clean

Impact on the environment

  • Reduction in water usage (water conservation)
  • Reduction in chemical usage (less chemical required for Single Use CIP)
  • Reduced impact on the effluent system (reduction in water and chemical usage)
  • Reduction in energy (reduction in heating required)

Benefit to the customer

  • Minimisation of the risk associated with cross contamination, particularly with regard to the various food allergens
  • Reduction in water usage (water conservation)
  • Reduction in chemical usage (less chemical required for Single Use CIP)
  • Reduced impact on the effluent system (reduction in water and chemical usage)
  • Reduction in energy (reduction in heating required)
  • Lower cost of clean
  • Protection of brand integrity

Benefit to the Food and Beverage industries

  • Minimisation of the risk associated with cross contamination, particularly with regard to the various food allergens
  • Reduction in water usage (water conservation)
  • Reduction in chemical usage (less chemical required for Single Use CIP)
  • Reduced impact on the effluent system (reduction in water and chemical usage)
  • Reduction in energy (reduction in heating required)
  • Lower cost of clean
  • Protection of brand integrity

Chemical Systems Engineering was recently invited to review the CIP operations within the Ice Cream production facilities at a large Dairy Processing site in Australia.

Further to this review, they were asked to investigate the various options available for upgrades to the CIP plant to support current and future operations. A requirement was to minimise the risk associated with cross contamination, particularly with regard to the various food allergens.

More specifically, the customer’s concern was associated with managing and reducing the risks associated with the cross contamination of allergens via the cleaning solutions in the CIP recovery tankage.

The previous CIP plant was installed over 18 years ago and was running at or beyond capacity resulting in some compromises to the plant production schedules and the quality of cleans.

Its configuration did not support the required flexibility now and into the future as the pressures of more flexible production activities demand immediate, flexible and effective CIP programmes that can be customised to suit those changing needs of the plant and production activities.

A previous report also identified many of the shortfalls associated with the old system. While some of the issues had been resolved there continued to be a number of issues that were yet to be rectified.
 
However the age, location and system design precluded this old system from satisfying the modern production demands and flexibility required.

A number of re-development options were considered including the use of single use CIP systems.

The final option offered by the Chemical Systems Engineering Division of Campbell Cleantec for the CIP redevelopment at the processing site was that of Combined CIP Technology.

They are particularly effective where there is a need for the efficiencies of a recovery system. However, periodically there is a requirement for remedial cleans to be performed using a different chemical regime to those within the recovery tanks or as in this case the risk of cross contamination of allergens through the use of common CIP recovery tankage must be effectively managed.

The single use feature of this system is then used in isolation to the recovery system. Cleaning solutions are confined to the Combined Use balance tank and to the equipment item to be cleaned. This minimises the risk of cross contamination when the feature is selected for a particular equipment item.

As with the single use systems, a circuit is established to the equipment item to be cleaned and to the Combined Use balance tank. The circuit volume is then dosed to concentration and heated to the required temperature.

They are recirculated for the required wash time and then dumped to drain, either in the area where the equipment item is located or perhaps via the existing return circuits to the location of the CIP systems. Again as with the single use systems this Combined Use balance tank also acts as a water break tank.

Where this feature is used to help mitigate the risks of cross contamination a short CIP of the common balance tank and pipe work is performed.

The unique design and configuration of the system also dramatically reduces the utilities and services demand when the system is using the recovery tankage.

The recovered CIP solutions are drawn down from the relevant recovery tank and only the volumes required to satisfy the requirements of the clean are used. To achieve this and, as with the single use systems, a circuit is established to the equipment item to be cleaned and to the Combined Use balance tank.

These CIP solutions are delivered at the background recovery tank concentration and temperature to the equipment item being cleaned. If further dosing or heating is required then only the current circuit volumes are treated.

Advantages

  • The Ice Cream production plant could be separated for the purposes of CIP into two distinct areas - Pre Pasteurised and Post Pasteurised
  • The new system would be more flexible and efficient in its ability to service the various areas, A, B or C as required
  • The issues and risks associated with cross contamination would be significantly addressed with the implantation of this option
  • When required and selected the recovery component of this system would deliver significant savings with regard to the services and utilities required

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