{"id":10376,"date":"2022-06-28T09:05:41","date_gmt":"2022-06-28T08:05:41","guid":{"rendered":"https:\/\/fei-online.com\/?p=10376"},"modified":"2022-06-28T09:05:41","modified_gmt":"2022-06-28T08:05:41","slug":"overcoming-clean-in-place-challenges-in-hygienic-applications","status":"publish","type":"post","link":"https:\/\/fei-online.com\/overcoming-clean-in-place-challenges-in-hygienic-applications\/","title":{"rendered":"Overcoming clean-in-place challenges in hygienic applications"},"content":{"rendered":"
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Overcoming clean-in-place challenges in hygienic applications<\/h1>\/ in Featured Articles<\/a> <\/span><\/span><\/header>\n<\/div><\/section>
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Hygienic applications are bound to the most stringent\u00a0compliance regulations, a natural expectation considering\u00a0the importance of maintaining a sanitary\u00a0environment for processes involving food, cosmetics\u00a0and pharmaceuticals. Established by different\u00a0regulatory agencies around the world \u2013 including\u00a0the U.S. Food and Drug Administration (FDA); 3-A\u00a0Sanitary Standards, Inc., (3-A); and the European\u00a0Hygienic Engineering and Design Group (EHEDG) \u2013\u00a0these regulations have proven to help protect the\u00a0public against the distribution of contaminated\u00a0products. In addition, these regulations also serve to\u00a0safeguard manufacturers, providing guideposts that\u00a0mitigate against catastrophic events such as a product\u00a0recall or food-borne illness.<\/strong><\/p>\n

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As a result of these strict regulations, manufacturers must continuously\u00a0work to help ensure the equipment they use do not impart\u00a0any adverse effects at any point in the process. Since pumps are used\u00a0extensively in hygienic applications, they too must be in compliance\u00a0with these regulations at all times. This includes complying with\u00a0cleaning and sanitation procedures that are designed to meet\u00a0hygienic requirements.<\/p>\n

However, properly cleaning these process pumps doesn\u2019t come without\u00a0its share of challenges. Opting for a complete pump disassembly\u00a0is effective, but not efficient and very time-consuming. Another\u00a0option, which many operators prefer, is the clean-in-place (CIP)\u00a0method. Yet, this comes with its own set of challenges.<\/p>\n

Process pumps in hygienic applications endure a lengthy series of\u00a0cleaning phases, including at least four for rinsing alone. The typical\u00a0phases of the CIP process consist of removing gross debris and\/or\u00a0product recovery; pre-rinse; detergent recirculation; intermediate\u00a0rinse; second detergent recirculation; intermediate rinse; disinfection;\u00a0and final rinse. While this thorough process is essential, it also\u00a0creates its share of problems, including inefficient product recovery,\u00a0excessive CIP flow rates, increased water hammer, and performance\u00a0issues caused by temperature variations.<\/p>\n

The problems with CIP<\/strong><\/h4>\n

Product recovery is the first problem to address before the CIP\u00a0process begins. The pump, along with any major part of the process\u00a0installation, is typically full of product. If the pump cannot run dry\u00a0and provide vacuum and compression effects, then product recovery\u00a0can\u2019t occur. In this scenario, alternative methods are used, such as\u00a0a pigging system. While useful at recovering product in specifically\u00a0designed pipe sections, it is ineffective at removing product from\u00a0valves, filters and pumps. Another method is water and air flushing,\u00a0but this is prone to creating product contamination and waste.<\/p>\n

Excessive CIP flow rates present another problem. This rate,\u00a0determined by in-pipe velocity, is based on a minimum value,\u00a0usually 1.5 to 3 m\/s. To provide effective cleaning, the flow must\u00a0be turbulent, resulting in a flow rate almost always higher than\u00a0the process flow rate. Because of this, most process pumps\u00a0require a bypass to avoid an excessive internal pressure drop\u00a0during CIP. However, no one has mastered the ability to split\u00a0the CIP flow rate between the pump and the bypass, meaning\u00a0there is no guarantee the pump will receive a thorough cleaning.<\/p>\n

A third issue comes from water hammer, created when the CIP\u00a0fluid gains speed before reaching the process in the pump. When\u00a0the fluid reaches the process, it creates a shock that can severely\u00a0damage the pump\u2019s mechanical seal and shafts. Ideally, putting\u00a0the CIP system as close to the process as possible can mitigate this\u00a0issue, but most systems are found further away.<\/p>\n

Lastly, temperature variations are also troublesome. CIP fluid\u00a0temperature may vary from 20\u00b0C (70\u00b0F) up to 90\u00b0C (200\u00b0F). If the\u00a0pump technology has thin clearances, they must be enlarged to\u00a0withstand these temperature fluctuations to avoid the pump\u2019s\u00a0rotating parts galling during the CIP\u2019s hot phases. These enlarged\u00a0clearances, however, can affect pump performance during certain\u00a0phases of the process. Additionally, waiting times between the\u00a0hot and cold CIP phases must occur to avoid pump blockage.<\/p>\n

The eccentric disc and ECS solution<\/strong><\/h4>\n

These problems, though, can be overcome by selecting a pump\u00a0technology \u2013 such as eccentric disc \u2013 that not only has a pump\u00a0design that makes it easier to get a thorough clean from the CIP\u00a0process, but can also integrate the CIP system directly into the pump.\u00a0This new integrated CIP system, often referred to as an Easy Clean\u00a0System (ECS), incorporates the bypass into the pump, mitigating\u00a0the need for an additional power source. The compressed air source\u00a0and solenoid valve used for the regular CIP bypass can be used to\u00a0power the ECS.<\/p>\n

When speaking specifically about eccentric disc pumps, Mouvex\u00a0offers two pump series that are equipped with an ECS: SLS and\u00a0H-FLO Series Eccentric Disc Pumps. On these models, the transmission\u00a0includes a pressurized capacity designed to intake 4 bar\u00a0(58 psi) of compressor air. The air supply opens the pump interior,\u00a0allowing the full CIP flow rate to cross through the pump with\u00a0limited pressure drop. This design does not require an external\u00a0bypass valve or linked piping.<\/p>\n

When a pump goes through its usual process, the transmission stays\u00a0at atmospheric pressure, keeping the disc in contact with the cylinder\u00a0to allow the pumping action. During the CIP process, the pump stops\u00a0and compressed air flows through the transmission. The compressed\u00a0air forces the bellows to stretch and push the disc away from the\u00a0cylinder, allowing the full CIP flow rate to pass through the pump\u00a0with limited pressure drop. The compressed air also balances the\u00a0internal and external pressure of the bellows, creating resistance\u00a0to pressure and water hammers.<\/p>\n

The tandem of eccentric pump technology and an ECS provides an\u00a0answer to the common problems associated with the CIP process.\u00a0The eccentric pump design allows it to pump air, which creates\u00a0a vacuum effect on the pump\u2019s suction side and a compressor effect\u00a0on the discharge side. This feature results in a plug effect that pushes\u00a0product out of the pump prior to cleaning and allows some eccentric\u00a0pumps to recover product from transfer lines at rates of up to 95%\u00a0(suction) and 85% (discharge). These pumps also help eliminate the\u00a0risk of additional contamination as the pump uses air already in\u00a0contact with the product. Additionally, with the ability to remove\u00a0most of the product before CIP, the pump\u2019s internals are less soiled\u00a0during the cleaning process and require less detergents and other\u00a0fluids to reach proper cleanliness.<\/p>\n

Because the ECS mitigates the need for the CIP bypass and has the\u00a0full CIP flow pass through the pump, the cleaning process becomes\u00a0more thorough and efficient. With the pump fully open, pressure\u00a0drop decreases dramatically. Additionally, the lack of the CIP bypass\u00a0simplifies installation and makes cleaning easier overall with less\u00a0piping, risk and product retention.<\/p>\n

Regarding water hammer, the ECS pressurizes the bellows, which\u00a0provides higher CIP pressure at the pump inlet (up to 6 bar [90 psi]),\u00a0improving the resistance to this occurrence. On many eccentric disc\u00a0pumps, the suction port is tangential instead of centered. This offers\u00a0better cleaning through centrifuge effect and reduces water hammer\u00a0impact on the bellow.<\/p>\n

Temperature variations also don\u2019t hamper the functionality of an\u00a0eccentric pump or the ECS because they don\u2019t need clearances. On\u00a0many pumping technologies, functional clearances are necessary to\u00a0prevent pumping parts from galling or clogging. But with eccentric\u00a0disc technology, those clearances aren\u2019t required because the parts\u00a0remain in permanent contact. Even with a 90\u00b0C (200\u00b0F) gap, there\u00a0isn\u2019t a waiting period between hot and cold phases.<\/p>\n

Conclusion\u00a0\u00a0<\/strong><\/h4>\n

In the hygiene technology landscape, cleanliness will always be\u00a0a paramount concern and essential to an operation\u2019s success.\u00a0An ECS-equipped eccentric disc pump can help manufacturers\u00a0ensure cleanliness while also keeping costs in check and\u00a0efficiency and functionality high.<\/p>\n<\/div><\/section>
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About the author<\/em><\/strong>
\nPaul Cardon is Business Development Manager PSG Auxerre, France. He can be reached at paul.cardon@psgdover.com Mouvex is a product brand of PSG, a Dover company, Oakbrook Terrace, IL, USA. PSG is comprised of leading pump brands, including Abaque, All-Flo, Almatec, Blackmer, Ebsray, em-tec, EnviroGear, Griswold, Hydro Systems, Mouvex, Neptune, Quantex, Quattroflow, RedScrew and Wilden. You can find more information on PSG at www.psgdover.com<\/a> Headquartered in Auxerre, France, Mouvex is a leading manufacturer of positive displacement pumps and compressors for the transfer of liquids in hygienic-manufacturing applications worldwide. For more information on Mouvex, visit www.mouvex.com<\/a><\/p>\n<\/div><\/section>
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