Innovation provider

MEXEO
ul. Energetykow 9
47-225 Kedzierzyn-Kozle
Poland

Contact

Description

The present project relates to an innovative Cleaning-in-Place (CIP) technology to wash commercial plants in the food processing industry, specifically dairy factories. Compared with the commonly used, conventional 3-step acid-base washing process with disinfection, in the present ECO-CIP process, water consumption and waste water volume are reduced by 55%; chemical load of waste water by 75%, consumed energy by 50%, washing time by 25%, and direct costs of washing by 15% to 20%. Benefits resulting from increasing production efficiency and attained in connection with improving the effective production time are just as important. The above results have been obtained due to the development and implementation of an innovative CIP process to wash commercial plants. Owing to the use of disinfection with chlorine dioxide that is generated „in situ” in the CIP plant combined with the simultaneous so-called acid conditioning rinse, consumption of water and the time dedicated to the subsequent unit operations are much reduced. A patent application was filed for the key element for the preparation and use of the acid disinfecting-and-descaling wash in December 2009. A special software was developed to enable computation and comparison of effectiveness of washing, depending on the process actually used. The software compares economic parameters in various processes, the streams of chemicals used, and media, including water, waste water, and energy.
The new process was commercially implemented in a dairy factory and evaluated after operating it for more than 6 months. Its application may now be extended to more dairy factories and other CIP systems that are commonly used in the food processing and pharmaceutical industries. The innovative CIP washing process has the advantage of low investment costs involved in its application.

Advantages

The new process of technology was implemented in an attempt to obtain reduced costs of process production in dairy factory in connection with industrial waste water discharge fees. It was a primary goal to reduce the chemical load of the waste water (pH, total solids, COD, total phosphorus) as well as the quantity of waste water discharged, and process water consumption. Furthermore, the inventors were searching for opportunities to cut costs by using less energy and shorten the duration of hygienic procedures. The target was to enhance the market competitiveness of the products by improving efficiency indices and reducing the unit costs of manufacturing.

Innovative aspects (ecologic, social and economic)

The innovative aspect that is covered in the invention proposal filed is the method to prepare and use the acid disinfecting-and-descaling wash, including an “in situ” method to generate chlorine dioxide in the acid wash which follows the essential alkaline washing step. Any solutions and/or procedures used in the portion that is not covered by patent laws are part of „know-how” in the form of appropriate choice of components and concentrations of specially developed preparations, which enable elimination of the disinfection step as a separate hygienic procedure, and the final rinse step after the so called acid conditioning rinse may be reduced. The components of the alkaline preparation minimize scaling on the washed surfaces, while the acid conditioning rinse neutralizes any residual alkali, neutralizes process water hardness, and disinfects the washed surfaces due to its content of chlorine dioxide. Chlorine dioxide is a water-soluble gas, approved for use in disinfection of potable water. Therefore, its trace amounts (<0.3 ppm) in the plant do not require final rinsing. A neutral reaction of the residue of the socalled acid conditioning rinse (6<pH<6.5) and the presence of chlorine dioxide at a level that is permissible in disinfected potable water not only enable reduction of the final rinse but also minimize the possibility of so-called secondary infections following hygienic procedures. The entire process of technology is covered by an invention proposal relating to the key elements of the industrial CIP washing process and „know-how” concerning the detailed washing procedure and composition of washing formulations.

Application examples

The innovative commercial ECO-CIP washing process has been implemented for commercial use in the dairy factory in Głubczyce (Okręgowa Spółdzielnia Mleczarska – OSM Głubczyce), where it has been in operation for more than 6 months. At present it is being implemented in other dairy factories. The process is about to be implemented also in other food processing factories.

Cost

Downloads

Current stage of development

Already on the market

Intellectual Property Rights

Secret know-how

Country of origin

Poland

Country of application

Year

2007

National Contact Point

dr Włodzimierz A. Sokół
National Contact Point for Eco-efficient Technologies and Management Systems
Central Mining Institute (GIG)

Plac Gwarkow 1
40-166 Katowice
Poland

Tel: +48 32 259 22 11
Fax: +48 259 22 11

w.sokol@gig.eu
www.actclean.gig.eu