An Introduction to
A&B Process Systems
Providing our clients with Innovative
Process Solutions
More than 40 years of commitment to the following
Industries
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3
Dairy
Food & Nutritional
Beverage
Confectionary
Pharmaceutical
Renewable Energy
Industrial Chemical Sectors
A&B Process Systems is proud to be part of the JBT Team
Our “Technology Campus” Today!
4
A&B Process Systems is proud to be part of the JBT Team
Clean-In-Place Technologies
Clean-In-Place
Technologies
Sanitary Process
Piping Systems
Surface Finish &
Weld Samples
A&B Process Systems is proud to be part of the JBT Team
What is CIP “Clean-In-Place”?
The automated
delivery of
solutions to,
through and from
process equipment
and piping systems
with limited, if any
manual
connections.
A&B Process Systems is proud to be part of the JBT Team
TEN COMMANDMENTS FOR CIP DESIGN
• Always remember that water runs downhill ...
... and that it is easier to pump water into a tank, than to pump it
out.
• Pitch tank CIPR connections continuously to pump inlet.
• Keep tank head nozzles few in number, short in length, and
large in diameter, for they are not easy to clean.
• Avoid 3-port divert valves like the common plague.
• Design to close all valves against flow.
A&B Process Systems is proud to be part of the JBT Team
TEN COMMANDMENTS FOR CIP DESIGN
• Locate CIP systems in (near) and (when possible) beneath the
center of CIP loads
• Eliminate all "Dead Ends" (branches of more than 1-1/2 pipe
diameters) for they will trouble you forever.
• Pitch all lines to easily opened drain points.
• Design and install supports to eliminate "friendly" piping that
waves when starting pumps and opening and closing valves,
for friendly systems are short-lived.
A&B Process Systems is proud to be part of the JBT Team
Why Clean-In-Place
• Improves operational
hygiene due to reproducible
cleaning processes
• Improves product quality
due to enhanced plant
hygiene
• Reduces expenditure of time
and personnel for
performing the cleaning
tasks
• Reduces cleaning costs
• Safe detergent handling
A&B Process Systems is proud to be part of the JBT Team
How? Clean-In-Place
1.
2.
3.
4.
5.
6.
Temperature
Pressure
Flow - Turbulance
Surface coverage
Chemistry
Integrity of complete Process System
1. ASME BPE compliant Process Equipment &
Components
2. Proper pitch with all process & CIP piping
3. Quality welds within process & CIP piping system
A&B Process Systems is proud to be part of the JBT Team
cGMP & Standards
• ASME BPE – Bioprocessing Equipment Standards
» Provides requirements for systems and components that are
subject to cleaning and sanitization in the manufacturing of
biopharmaceuticals.
» Higher acceptance criteria for fittings, components, and
manufacturing
» Strict quality control and traceability throughout.
» Providing start up and sequencing notes
A&B Process Systems is proud to be part of the JBT Team
cGMP & Standards
• EHEDG “European Hygienic Engineering & Design
Group”
» (EHEDG) is a consortium of equipment manufacturers, food
industries, research institutes as well as public health authorities
and was founded in 1989 with the aim to promote hygiene during
the processing and packing of food products.
» The principal goal of EHEDG is the promotion of safe food by
improving hygienic engineering and design in all aspects of food
manufacture.
» The EHEDG mission is defined as: "EHEDG enables safe food
production by providing guidance as an authority on hygienic
engineering and design".
A&B Process Systems is proud to be part of the JBT Team
cGMP & Standards
• 3-A Sanitary Standards & Accepted Practices
» dedicated to advancing hygienic equipment design for
the food, beverage, and at times referenced in the
pharmaceutical industries.
» They represent the interests of three stakeholder
groups with a common commitment to promoting food
safety and the public health — regulatory sanitarians,
equipment fabricators and processors.
» The mission of 3-A is to enhance product safety for
consumers of food, beverages, and dairy products
through the development and use of 3-A Sanitary
Standards and 3-A Accepted Practices.
A&B Process Systems is proud to be part of the JBT Team
CIP (Be Prepared)
•
•
•
•
•
•
•
•
•
Process interfaces
All stake holder (FAT
and SAT protocol)
Down time
Water use
Start up
Chemical delivery
Line and tank circuits
Equipment flushing
Programing updates
A&B Process Systems is proud to be part of the JBT Team
CIP “buzz words”
•
•
•
•
•
•
•
•
•
•
•
C.I.P. Unit
C.I.P. System
C.I.P. Supply Pump
C.I.P. Return Pump
Burst Rinse
Air Blow-Burst Rinse
Pigging
C.I.P. Loop/Circuit
C.I.P. Tank Circuit
Valve Pulsing/cycling
Water Hammer
A&B Process Systems is proud to be part of the JBT Team
Most Common CIP Applications
• Process Piping Systems “Line Circuits” consisting of
interconnecting piping, pumps, valves and other related
process components/instruments.
• Processing Vessels and Storage Tanks “Tank Circuits”
• Process Equipment that is designed for CIP “Mechanical
Cleaning Regimen” via applicable cleaning solution
velocities and or spray devices I.e. Evaporators, Dryer,
Ducting, Cyclones, Heat Exchangers, Centrifuges,
Membrane Systems, etc.
A&B Process Systems is proud to be part of the JBT Team
CIP System Cleaning Parameters
•
•
•
•
 Fluid Mechanics (Flow, Turbulence
and/or Surface
Coverage)
Fluid Mechanics
(Flow, Turbulence
and Surface
Coverage)
 Temperature
Temperature
 Chemical Concentration
Chemical Concentration (Detergency)
(Detergency)
Cleaning Time
 Cleaning Time
A&B Process Systems is proud to be part of the JBT Team
Flow, Turbulence and/or Surface
Coverage
• Requirements - Line Circuits
• Line (pipeline) Circuits typically warrant CIP solution
velocities at 5-7 feet/second
• Select applications within the pharmaceutical &
biotech industries have been designed with velocities
exceeding 10 feet/second
• A recent trend with several large food companies is to
increase CIP velocities to 7 feet/second for 4” process
lines which moves the flow rate from 180 gpm > 252
gpm. This usually requires upgrades to existing CIP
Systems i.e. CIP Header Sizing, pump sizing, HX, etc.
A&B Process Systems is proud to be part of the JBT Team
Guidelines for the Food &
Pharmaceutical Industries
TUBING TUBING WALL
O.D.
THICKNESS
(IN.)
(IN.)
T
U
B
E
S
I
Z
E
GPM @
5.0
FT/SEC.
LPM @
5.0
GAL./
LITRES/
GAL./
LITRES/
FT/SEC. 1.0 FT TUBE 1.0 FT TUBE 100 FT TUBE 100 FT TUBE
0.50
0.049
1.98
7.49
0.01
0.02
0.66
2.50
0.75
0.049
5.20
19.69
0.02
0.07
1.73
6.56
1.00
0.065
9.26
35.07
0.03
0.12
3.09
11.69
1.50
0.065
22.97
86.95
0.08
0.29
7.66
28.98
2.00
0.065
42.80
162.01
0.14
0.54
14.27
54.00
2.50
0.065
68.75
260.22
0.23
0.87
22.92
86.74
3.00
0.065
100.82
381.60
0.34
1.27
33.61
127.20
4.00
0.083
179.92
681.01
0.60
2.27
59.97
227.00
6.00
0.134
402.15
1522.15
1.34
5.07
134.05
507.38
A&B Process Systems is proud to be part of the JBT Team
Flow, Turbulence and/or Surface
Coverage
• Flow Requirements - Line Circuits
» Cleaning of line circuits typically includes various process components
such as valves, pumps, metering devices and or control
instrumentation/sensors.
» Of particular concern is the sequential operation of the process valves
that when sequenced properly, result in minimal hydraulic shock within
the piping system.
» Optimum designs have valves closing against product and C.I.P. Flow.
A&B Process Systems is proud to be part of the JBT Team
Flow Control via orifice plates
Horizontal pipeline orifice
Vertical pipeline orifice
A&B Process Systems is proud to be part of the JBT Team
Flow Control via Flow Meters
•
•
•
•
Turbine Flow Meter
Vortex Flow Meter
Magnetic Flow Meter
Mass Flow Meter
Integrate any of the above meters with frequency invertors on
CIP Supply Pumps and or Modulating Flow Control Valves to
provide maximum flexibility for flow control.
The Magnetic Flow Meter is the most common
choice for CIP Flow Control!
A&B Process Systems is proud to be part of the JBT Team
Line Circuits
• Minimize “Deadleg” with
close-coupled equipment,
component and or instrument
connections.
PRIMARY PIPING RUN
• The “deadleg” associated with
capped “T’s” and instrument
connections are one of the
more difficult cleaning
objectives relative to line
circuit CIP. The shorter the
deadleg, the more effective
cleaning will result.
A&B Process Systems is proud to be part of the JBT Team
TRI-CLAMP FERRULE
TRI-CLAMP
CAP
1.5X
X
"DEAD LEG"
CLAMP
TYPICAL EXAMPLES
PRIMARY PIPING RUN
TRI-CLAMP FERRULE
INSTRUMENTATION
INSTALLATION
TRI-CLAMP
CAP
INSTALLATION OF
CIP VALVES ON
DISTRIBUTION PIPING
1.5X
X
INTRODUCTION OF WATER
FLUSH OR NITROGEN
PURGE PIPING
"DEAD LEG"
CLAMP
SAMPLE OR TEST PORTS
A&B Process Systems is proud to be part of the JBT Team
Tuchenhagen “Varinline” Units
• In-Line control & measurement sensor housing that
provides for more effective cleaning results than
traditional “dead-leg” tee assemblies
A&B Process Systems is proud to be part of the JBT Team
Zero Deadleg “T” Diaphragm Valve
• This valve offers the advantage of total flexibility of
size ranges regarding branch versus spool piece and
still offers a total zero deadleg solution with full
drainabilty. Much more prevalent in the
Pharmaceutical industry than Food.
A&B Process Systems is proud to be part of the JBT Team
Temperature
• Temperature control is critical within the scheme of the
CIP cycles. Available selections for Heat Transfer
include:
»
»
»
»
»
Shell & Tube Heat Exchangers (recommended)
Plate & Frame Heat Exchangers
Direct Steam Injection
Electric Heaters
Direct Contact Water Heater (Gas Fired)
A&B Process Systems is proud to be part of the JBT Team
Shell & Tube
• Shell & Tube Heat
exchangers are the most
common selection for CIP
Solution Heat Exchangers
offering low maintenance,
thermal efficiency and ability
to handle occasional
particulate flow with limited
fouling
A&B Process Systems is proud to be part of the JBT Team
Plate Heat Exchanger
• Plate Heat Exchangers are
functional at a somewhat
reduced cost, however
maintenance costs and the
inability to handle passing
of particulates make plate
heat exchangers a less
common choice.
A&B Process Systems is proud to be part of the JBT Team
Direct Steam Injection
• Advantages
» Reduces energy/steam
consumption over 20%
» Lowers capital cost & investment
• Disadvantages
» Culinary “Clean” and or “pyrogen”
free Steam Supply required
» Inherent dangers related to
pressurized steam within process
piping
A&B Process Systems is proud to be part of the JBT Team
Electric Water Heaters
• Primary
choice when
steam source
is not
available.
Limited
capabilities
dependent on
size of heater
selection.
http://www.hubbellheaters.com/model/shh/
A&B Process Systems is proud to be part of the JBT Team
Gas Fired Water Heaters
• Alternative choice when
steam source is not
available.
» QuikWater
» Heatec
A&B Process Systems is proud to be part of the JBT Team
CIP Tank Sizing
• Single-use tanks – typically sized to minimize retention
volume and simultaneously provide adequate NPSH to CIP
Supply Pump inlet
• Re-use tanks – based upon the highest volume circuit
being cleaned (sum total of retention volume within supply
and return piping, product piping and/or nominal amount
in tank being cleaned)
A&B Process Systems is proud to be part of the JBT Team
Cycle Sequencing
1.
2.
3.
4.
5.
Rinse “Pre-rinse”
Wash
Post-rinse
Sanitizing
Drain
A&B Process Systems is proud to be part of the JBT Team
Pre-Rinse Cycle
• “Pre-rinse” is typically the utilization of the final rinse
from the previous CIP circuit. The recovered solution
(containing residual heat and cleaning chemicals) is
directed through the new circuit to flush out primary
soil load. Most often, this cycle is sent directly to the
drain.
A&B Process Systems is proud to be part of the JBT Team
Wash Cycle
• Wash cycle can utilize one or more cleaning chemicals
depending on type of soils
• For single-use systems, detergent is re-circulated for a
given cycle time and then routed to the drain or solution
recovery tank.
• For re-use systems the detergent is re-circulated and
then recovered.
• Chemical concentration can be re-established and
available for use on the next circuit.
• Chemical concentration can be monitored and maintained
on a continual basis until turbidity reaches set point at
which time it is neutralized and sent to drain or recovery
tank
A&B Process Systems is proud to be part of the JBT Team
Post or Final Rinse Cycle
• Post-rinse cycle delivers a final flushing or rinse step
with approved process water and can be followed up with
a sanitizing cycle
» For single-use systems, the post-rinse water is then discharged to drain
and or solution recovery tank
» For re-use systems, the water is routed to the pre-rinse tank for use on
the next circuit as a pre-rinse step
A&B Process Systems is proud to be part of the JBT Team
Sanitize Cycle (When Required)
•
Sanitize cycle is applied to reduce bacterial contaminant
levels. This step is often repeated both at the end of the
cleaning cycle as well as just prior to utilization of the
same process equipment that further insures against any
bacterial growth.
•
Apply caution when utilizing chlorinated sanitizers within
your CIP System. If appropriate draining and or rinsing is
not accomplished, “pitting” of stainless tubing and
process vessels/equipment/components can occur.
A&B Process Systems is proud to be part of the JBT Team
Drain Cycle
The Drain cycle can present problems of it’s own!
Common oversights surrounding CIP drain cycles is that
the hub drains are undersized and result in . . . . . . . . . . . .
The Great Flood!
A&B Process Systems is proud to be part of the JBT Team
Drain Cycle
• Hub Drain sizing recommendations for a variety
of Flows:
» 25 GPM Minimum Drain Size . . . 2.0”
» 50 GPM Minimum Drain Size . . . 2.5”
» 70 GPM Minimum Drain Size . . . 3.0”
» 100 GPM Minimum Drain Size . . . 4.0”
» 120 GPM Minimum Drain Size . . . 4.0”
» 180 GPM Minimum Drain Size . . . 6.0”
A&B Process Systems is proud to be part of the JBT Team
Chemical Monitoring & Dispensing
A&B Process Systems is proud to be part of the JBT Team
Chemical Monitoring Methods
• Temperature compensated pH controller
» Provides acid or caustic indication only. Concentration levels are best
addressed via Conductivity measurement
• Temperature compensated conductivity controller
(recommended)
» A Linear relationship exists between concentration and conductivity
» This is a quantitative measurement of chemical concentration
A&B Process Systems is proud to be part of the JBT Team
Chemical Dispensing
• Peristaltic Pump
• Pneumatic Diaphragm Pump
• Gravity feed from “Day Tanks”
A&B Process Systems is proud to be part of the JBT Team
Chemical Dispensing
A&B Process Systems is proud to be part of the JBT Team
Chemical Dispensing
A&B Process Systems is proud to be part of the JBT Team
C.I.P. Controls
A&B Process Systems is proud to be part of the JBT Team
Monitoring of CIP Variables
A&B Process Systems is proud to be part of the JBT Team
Variables Controlled and/or Recorded
•
•
•
•
•
•
Flow/Pressure
Solution Volumes/levels
Solution Temperatures
Solution Conductivity & pH
Cycle Timing
Alarm Functions/Logs
A&B Process Systems is proud to be part of the JBT Team
CIP Supply Pumps
• High Speed, High Efficiency
Centrifugal Pumps are the
preferred choice for CIP
Supply Applications
A&B Process Systems is proud to be part of the JBT Team
Return Pumps and Motive Systems
•
•
•
•
Traditional centrifugal return pump
Self priming return pump
Eductor vacuum return systems (rarely applied anymore)
Utilization of the new “Twin Screw” positive displacement
pumps that can run at speeds that will handle both
viscous product transfer at high discharge pressures as
well as the CIP return function.
» Increased H.P. Requirements
A&B Process Systems is proud to be part of the JBT Team
Traditional Centrifugal Return
Pumps
•
•
•
•
Low speed – 1750 RPM
Best in “tank farm” applications
Need adequate net positive suction head
Air eliminators are typically applied for food industry
applications.
• Ideally the tank being cleaned should be free of any
building cleaning solution level
A&B Process Systems is proud to be part of the JBT Team
Air Eliminator Valve
• Air eliminator valves (when
implemented on top of suction
header as close to pump inlet as
is feasible) allows for evacuation
of entrained air in the suction
line of CIP Return Pumps and
help prevent or minimize pump
cavitation.
A&B Process Systems is proud to be part of the JBT Team
Standard Centrifugal Pumps
• Feature a vaned, double-curved open impeller that allows
for gentle product handling.
• Its practical design and flexibility provide for an
economical choice for a wide range of applications.
• Flow Rates up to 1000 GPM with discharge pressures up
to 300 feet (130 PSI/9 bar)
A&B Process Systems is proud to be part of the JBT Team
High Performance Centrifugal Pumps
• The enlarged inlets combined
with an advanced impeller
design result in unobstructed
product flow and very low NPSH
requirements.
• Designed for either CIP or
manual cleaning, these quiet
pumps are available with
capacities up to 1300 gal/min
and pressures up to 227 psi (525
head in feet of water).
A&B Process Systems is proud to be part of the JBT Team
High Purity Centrifugal Pumps
• High-purity-water pumps meet
specifications for water-forinjection (WFI) and other
demanding applications
• The pump can be cleaned in
place, sterilized in place, or
cleaned manually and is
authorized to carry the 3A
symbol
A&B Process Systems is proud to be part of the JBT Team
Self-Priming Centrifugal Pumps
• Liquid ring models are widely
used to pump liquids
containing air or gases. The
liquid ring is self-priming when
at least half filled with liquid,
so it's capable of pumping
from a suction line partly filled
with air.
A&B Process Systems is proud to be part of the JBT Team
Twin Screw Pump Technology
Excellent application for handling of viscous product
transfer as well as CIP return applications
A&B Process Systems is proud to be part of the JBT Team
CIP Solution Filtering
A&B Process Systems is proud to be part of the JBT Team
Strainers
A&B Process Systems is proud to be part of the JBT Team
Mechanical – Self Cleaning Filters
A&B Process Systems is proud to be part of the JBT Team
Multiple Designs Available
1. Single Pass
2. Single Use
3. Multi-Tank Reuse Systems
4. Eductor Assisted CIP Return Designs
5. Dual + Simultaneous Solution Supply
A&B Process Systems is proud to be part of the JBT Team
Single Pass System Advantages
• Minimal capital equipment
investment
• Easily adjusts to wide ranging
cleaning applications
• Virtually no chance for crossover
contamination
• Small “foot print” in process area
A&B Process Systems is proud to be part of the JBT Team
Single Pass System Disadvantages
Higher costs associated with
chemical, water, steam, and
wastewater
A&B Process Systems is proud to be part of the JBT Team
Single-Use Designs (Recirculating)
A&B Process Systems is proud to be part of the JBT Team
RO SUPPLY
TRC TE POF
RO SUPPLY
CIP RETURN
CT
CE
CIP SUPPLY
WASH TANK
LT
LE
STEAM SUPPLY
SHELL AND
TUBE
TE TT
VFD
CONDENSATE
RETURN
FLOW
CIP SUPPLY
METER
PUMP
SINGLE USE CIP SYSTEM
A&B Process Systems is proud to be part of the JBT Team
CHEMICAL SUPPLY
Re-Use Designs
• The most common choice in
the Dairy, Foods, cosmetic,
and Nutriceutical sector.
• Re-use designs typically
recover re-circulated post
rinse and wash solutions for
use within the next cleaning
application.
A&B Process Systems is proud to be part of the JBT Team
Re-Use System Advantages
• Chemicals, water, and
energy retained with
cleaning solution and
normally “re-used” as
the title indicates.
A&B Process Systems is proud to be part of the JBT Team
Re-Use System Disadvantages
• Limited to similar soil loads
• Potential for cross-contamination
• Larger “foot print” in process area
A&B Process Systems is proud to be part of the JBT Team
CHEMICAL SUPPLY
TRC TE POF
RO SUPPLY
WFI SUPPLY
CIP RETURN
CT
CE
CIP SUPPLY
RINSE TANK
WASH TANK
STEAM SUPPLY
SHELL AND
TUBE
LT
LT
LE
LE
TE TT
VFD
CONDENSATE
RETURN
FLOW
METER
CIP SUPPLY
PUMP
TWO TANK CIP SYSTEM
Re-circulation Method
A&B Process Systems is proud to be part of the JBT Team
CHEMICAL SUPPLY
WATER SUPPLY
TRC TE POF
CIP RETURN
AIR BLOW
VALVE
CT
AB
CIP SUPPLY
RINSE
RECOVERY
TANK
STEAM SUPPLY
SHELL AND
TUBE
CE
DETERGENT
TANK
LT
LT
LT
LE
LE
LE
TE TT
CONDENSATE
RETURN
ANGLE LINE
STRAINER
FLOW
METER
VFD
RINSE
TANK
CIP SUPPLY
PUMP
THREE TANK CIP SYSTEM
A&B Process Systems is proud to be part of the JBT Team
WATER SUPPLY
TRC TE POF
CIP RETURN
AIR BLOW
VALVE
CT
AB
CIP SUPPLY
RINSE
RECOVERY
TANK
STEAM SUPPLY
SHELL AND
TUBE
CE
CAUSTIC TANK
ACID
TANK
LT
LT
LT
LT
LE
LE
LE
LE
TE TT
CONDENSATE
RETURN
ANGLE LINE
STRAINER
FLOW
METER
VFD
RINSE
TANK
CIP SUPPLY
PUMP
FOUR TANK CIP SYSTEM
A&B Process Systems is proud to be part of the JBT Team
CHEMICAL SUPPLY
WFI SUPPLY
TRC TE POF
RO SUPPLY
CIP RETURN
TRC TE POF
CIP RETURN
CIP SUPPLY
WASH
TANK
LT
STEAM SUPPLY
SHELL AND
TUBE
RINSE
TANK
LE
TE TT
VFD
CONDENSATE
RETURN
FLOW
METER
CIP SUPPLY
CIP SUPPLY
PUMP
STEAM SUPPLY
SHELL AND
TUBE
TE TT
CONDENSATE
RETURN
VFD
FLOW
METER
CIP SUPPLY
PUMP
A&B Process Systems is proud to be part of the JBT Team
DUAL
RE-USE SYSTEM
LT
LE
Re-Use CIP Unit Configurations
• Two (2) Tank
• Three (3) Tank
• Four (4) Tank
• Dual, Triple, Quad and more CIP Solution Supply Systems
A&B Process Systems is proud to be part of the JBT Team
Water Supply
• Potable, R/O and or WFI Water Supply(s) to the CIP Unit
should be capable of delivering flows which meet or
exceed the flow rate of the most extreme line circuit or
tank cleaning solution flow requirement.
• Potable, R/O and WFI water Storage Tanks can be
integrated into system design and compensate for water
supply limitations
A&B Process Systems is proud to be part of the JBT Team
CIP Supply & Return Routing Methods
• Manual “swing” connections
• Transfer panels with/without proximity switch(s)
• Single-seat valve manifold(s)
• Mix-proof valve manifold(s)
• Check Valve routing for “common” return header only
A&B Process Systems is proud to be part of the JBT Team
Things to Avoid in Line Circuit Cleaning
Not recommended
Recommended
Traditional single seat divert valves when utilized in process lines also require
“pulsing” to insure cleaning of the valve seat, stem & o-ring. During the pulsing
process, water hammer results and reduces valve seat life.
A&B Process Systems is proud to be part of the JBT Team
Sudmo Non-Slamming Diverter Valve
• The non-slamming changeover
valve eliminates hydraulic
shock and water hammer
problems.
• Ideal for multi-circuit product
or CIP distribution systems
with shifting circuits under
pump fluid pressure.
A&B Process Systems is proud to be part of the JBT Team
CIP Mixproof Valve
• Type “K” Valve by
Tuchenhagen is primarily
applied for “Shut-off” within
CIP Supply routing systems
and is an economic
alternative to other types of
mixproof valves for CIP
Routing applications
A&B Process Systems is proud to be part of the JBT Team
Mixproof Valve Technology
A&B Process Systems is proud to be part of the JBT Team
GEA Tuchenhagen VARIVENT Mixproof
Valve System
2:36 Second Video
https://www.youtube.com/watch?feature=player_detailpage
&v=SeAaBVzjnxw
A&B Process Systems is proud to be part of the JBT Team
Spray Devices & Combinations
A&B Process Systems is proud to be part of the JBT Team
Traditional “Static Spray Ball”
• Advantages
»
»
»
»
»
Low cost
Easy to inspect
Can be validated
Drill mapping
Positive placement
• Disadvantages
» Higher flow rates
» Reliance on cascading flow
» Longer cycle times
A&B Process Systems is proud to be part of the JBT Team
Spray Pattern Differentiation
https://www.youtube.com/watch?v=5iDR6cOA3ns&featu
re=player_detailpage 0:55 duration
A&B Process Systems is proud to be part of the JBT Team
A&B Process Systems is proud to be part of the JBT Team
Tank CIP Considerations
A&B Process Systems is proud to be part of the JBT Team
Flooding and draining
A&B Process Systems is proud to be part of the JBT Team
“Static” Bubble Spray Ball
For special applications where minimum
clearance is a factor
BUBBLE SPRAY
DUCT
TUBE SPRAY
BELT CONVEYOR
SPRAYS
A&B Process Systems is proud to be part of the JBT Team
Custom devices
A&B Process Systems is proud to be part of the JBT Team
Retractable Spray Device
.
A&B Process Systems is proud to be part of the JBT Team
Retractable CIP Spray Nozzles
.
A&B Process Systems is proud to be part of the JBT Team
Retractable Spring Loaded Spray Disc
• Designed to remain in place
during production in sanitary
applications. The liquidactivated spray head, which
fully retracts after CIP,
provides a wider spray and
larger jets to ensure complete
cleaning of equipment and
components.
A&B Process Systems is proud to be part of the JBT Team
Rotary “Dynamic” Spray Ball
• Allows Solution to flow directly
onto entire tank surface for
reduced cleaning time
• Lower flow rates
A&B Process Systems is proud to be part of the JBT Team
Rotary “Dynamic” Jet Head
• Provides the ultimate in direct
impingement cleaning
• Some Mechanical spray heads are
not suited for sterile applications
https://www.youtube.com/watch?feature=playe
r_detailpage&v=YfOHoTPyV4Y 0:44 duration
A&B Process Systems is proud to be part of the JBT Team
Tank CIP Considerations
A. Low profile man-way
B. Depth of spray ball
C. Minimize nozzle height &
quantity.
D. Tank outlet sizing & elevation.
Recommended minimum tank
outlet elevation is 30”.
E. Small bore nozzles on sides
of insulated tanks are difficult
to clean.
C
SHADOW ZONE
A
E
A&B Process Systems is proud to be part of the JBT Team
B
D
Tank CIP Considerations
• Select appropriate spray
device
• Adequate venting-CIP
Applications often dictate
venting requirements, not
product volume
displacement during fill &
empty cycles
• “Shadow zone” resulting
from agitator shafts is
counteracted with the
application of two or more
spray devices
MANWAY
SPRAY
DEVICE
SHADOW
ZONE
AGITATOR
SHAFT
A&B Process Systems is proud to be part of the JBT Team
Tank CIP Considerations
OFFSET SPRAYS TO OPPOSITE SIDE
AND FORE/AFT OF AGITATOR SHAFT
VENT/SIGHT
GLASS
SLIP COUPLING
1/4"/FT
MANHOLE
POD OUTLET
VENT/SIGHT
GLASS
1/4"/FT
SLIP
COUPLING
MANHOLE
POD OUTLET
CIP VENT
MANHOLE
MANHOLE
BAFFLES
(4)
BAFFLE
POD OUTLET
CENTER OUTLET
A&B Process Systems is proud to be part of the JBT Team
Cleaning of “Silo” Tanks
DISH
DISTRIBUTOR
SIDE-ARM VENT/
OVERFLOW LINE
3-4"
CIP SUPPLY/
RE-VENT LINE
2"
CIP SUPPLY
CIP VENT DOOR
CIP MANIFOLD
MANUALLY CLEAN
AGITATOR
CIP RETURN LINE
A&B Process Systems is proud to be part of the JBT Team
Cleaning “Busy” Agitation Systems
• Often times effective cleaning of agitated vessels is
complicated due to difficulty in cleaning the backside of
a pitched blade or scraper blade agitation system with
traditional spray device positioning above the agitator.
Various methods and spray devices have been applied
without any one method working for all applications.
• This is more often than not associated with more
viscous and sticky products that warrant the more
extensive agitation designs
A&B Process Systems is proud to be part of the JBT Team
Cleaning “Busy” Agitation Systems
• Traditional overhead spray device positioning and
resulting CIP Solution spray coverage. Outlet valve can
be cycled on and off to create reservoir in tank that results
in more vigorous cleaning of underside of agitation
system(s).
• Manually inserted Spray Devices - (static spray ball or
bubble spray device) in select tank locations (sidewall and
or bottom head) that are typically removed during process
operations.
• Agitated immersion
A&B Process Systems is proud to be part of the JBT Team
Anchor “Swept” Surface Agitation
A&B Process Systems is proud to be part of the JBT Team
Anchor Scrape Surface Agitation
A&B Process Systems is proud to be part of the JBT Team
Anchor Scrape & Axial Turbine Agitation
A&B Process Systems is proud to be part of the JBT Team
Helical without Scrape Surface
A&B Process Systems is proud to be part of the JBT Team
Helical with Scrape Surface
A&B Process Systems is proud to be part of the JBT Team
Retractable spay device for tank cleaning
• New valve offering from
Tuchenhagen which
provides for automated
deployment of spray
devices into a product
zone. When not required,
the spray device retracts
and seals against product
zones in process vessels
and or ductwork etc.
A&B Process Systems is proud to be part of the JBT Team
Retractable spray device for tank cleaning
• The horizontal mount into
the sidewall of this
process vessel with
extensive agitation
illustrated. The underside
of the agitator blades and
or baffles are often times
very difficult to clean
when a top down
cascading CIP design is
employed ….. Functional
but very expensive.
A&B Process Systems is proud to be part of the JBT Team
Tank Cleaning considerations…
A&B Process Systems is proud to be part of the JBT Team
Tank cleaning considerations…
< 5 Bar, 1 Meter
5 Bar, 2 Meter >
A&B Process Systems is proud to be part of the JBT Team
Tank cleaning considerations…
A&B Process Systems is proud to be part of the JBT Team
Things to Avoid in Tank Cleaning
• Attempting to clean tank and line circuits together
• Application of “high speed – 3600 rpm” centrifugal CIP
Return Pump
•
Fouling of spray devices (filter C.I.P. Supply Solution
prior to spray devices)
• Exceeding flow ranges of spray devices (will cause
atomization of fluid and adversely affect performance)
A&B Process Systems is proud to be part of the JBT Team
Validation of Surface Coverage
• Spray coverage testing is performed on equipment that is
cleaned using a spray device or devices (e.g., balls,
nozzles, etc.).
• Spray coverage testing provides assurance that spray
devices used during cleaning for a particular piece of
equipment are able to reach and rinse all interior process
contacting surfaces.
• Spray coverage testing identifies any potential hard-toclean or inadequately cleaned locations (blind spots) on the
equipment. Riboflavin fluorescence is used to identify blind
spots on tanks. If blind spots are identified during spray
coverage testing, a corrective action should be performed
to ensure that the blind spot is cleaned.
A&B Process Systems is proud to be part of the JBT Team
Validation of Surface Coverage
• “RIBO-FLAVIN” C.I.P. Validation Process is often times
specified to verify C.I.P. Spray Device Surface Coverage. The
procedure can involve a wet or dry riboflavin application that is
followed by ambient water flow to the spray device(s).
• Flow, Pressure and or time are monitored and documented
followed by visual inspection of vessel internals with “UV
Light”.
• Any remaining riboflavin is easily identified. Steps are then
taken to provide solution spray coverage to the area(s) in
question and the test is then repeated until all areas of the tank
are free of residual riboflavin.
• This requirement is almost always applied in the
Pharmaceutical Industry but is becoming a more common
request within the Food Industry.
A&B Process Systems is proud to be part of the JBT Team
Product Recovery Systems
A&B Process Systems is proud to be part of the JBT Team
Product Recovery Systems Video
https://youtu.be/9CNjBKy-caE
3:29 duration
https://www.youtube.com/watch?v=80vqBP
NnuBE&feature=player_detailpag
2:20 duration
A&B Process Systems is proud to be part of the JBT Team
Passivation of Product Contact Surfaces
• A final chemical treatment/cleaning process that removes
exogenous iron or iron compounds from the surface of
stainless steel piping and equipment by the use of a mild
oxidant, such as a nitric or citrus acid solution, or by
electro-polishing. The purpose of passivation is to restore
and/or enhance the spontaneous formation of the
chemically inert surface or protective passive film.
• Proper cleaning/removal of greases and other soils prior
to passivation is critical and when not addressed properly
can result in eventual rouging.
A&B Process Systems is proud to be part of the JBT Team
Passivation of Product Contact Surfaces
Astro Pak Corporation
12201 Pangborn Ave.
Downey, CA 90241
(562)803-3400 Main
http://www.astropak.com
A&B Process Systems is proud to be part of the JBT Team
CIP Summary
The overall effectiveness of Clean-inplace Systems are largely dependent
upon overall surface finish, integrity of
process components and equipment,
process piping system including pipe
supports as well as the quality of the
process & C.I.P. tube welds.
A&B Process Systems is proud to be part of the JBT Team
White Papers & Other Resources
Visit our website to see our white-papers and case studies
and our recently released corporate video
Lunch & Learn offerings covering topics such as:
• Clean-In-Place (CIP)
• Process Piping Design/Layout
• Hygienic Process Components
• Hygienic Welding & Surface Finishes
• Process Vessel Design Considerations
• Material Selection considerations. . . 316L-duplex-AL6XN
A&B Process Systems is proud to be part of the JBT Team
Thank you!
We look forward to the opportunity
to serve as your process partner…..
Challenge us to help solve your next
process objective…..
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A&B Process Systems is proud to be part of the JBT Team