Brewery Optimization –
Water Reduction in
Cleaning Operations
Linda A. Rastani
Alfa Laval Inc.
October 18, 2010
How do you conserve resources
while effectively cleaning ?
The tank must be clean=> effective cleaning
meets the following requirements:
•
•
•
•
•
low consumption of fresh water
low consumption of cleaning agents
minimum of energy consumption
Low amount and pollution level of waste water
Reduce cleaning process time
www.alfalaval.com
The Optimal Cleaning Operation.
• turn around as quickly as possible.
• Using a minimum of water,
chemicals, energy
• producing a
minimum of waste water.
• Being able to validate the process.
www.alfalaval.com
TACT Cleaning Parameters
Traditional TACT
- Jet Head Approach
Action
Time
Cleaning Impact
(impingement)
Action
Temperature
Action
Chemical Concentration
Reduce: Time, Chemicals &
Temperature
Improve: Action & Coverage
Surface Coverage
Slide 4
www.alfalaval.com
Comparing Static Spray Ball
with Rotary Jet Head
Cleaning with
Static Spray Ball
Cleaning with
Rotary Jet Head
Concentration
Time
Mechanics
Temperature
www.alfalaval.com
Static Spray Ball
Rotary Spray Head
Rotary Jet Head
Coverage:
Means:
Cascading
Swirling fan
Index Pattern
Effect:
Partial
Partial to full
Full
Action:
Low
Medium
High
% Resources used
100%
70-75%
Slide 6
<50% in most cases
www.alfalaval.com
Energy Labelgy
Label
A
D
G
www.alfalaval.com
<< Back to Total Cost of Ownership start page.
Static Spray Ball
Slide 8
www.alfalaval.com
Cleaning Technology
P≈V
1. Pressure is the driving force
1. The flow is turning the tank cleaning
machine
2.
Pressure is converted to water jet velocity
2. High Wall Shear Stress Zone
3. Machine gearing makes the
indexed criss-cross pattern

Water Jet
t
d
d
Wall Shear Stress under
Turbulent Flow Conditions
Min. 40 Pa at r = 11 cm
Slide 9
www.alfalaval.com
Rotary Jet Head
Cleaning Technology
- Attack of residues
Slide 10
www.alfalaval.com
Mash Tun
Required number of Rotary Jet Heads
Type
number
RJH
2
4 x 5.2mm, 50 USGPM @ 75 PSIG
Slide 11
www.alfalaval.com
Mash Tun
Slide 12
www.alfalaval.com
Mash Tun
RJM
Standard cleaning
water rinse
10
Min
water rinse
caustic recirc.
60
Min
caustic recirc.
5
Min
20
water rinse
acid recirculation
water rinse
Total
9
Min
18
Min
water rinse
9
Min
Min
acid recirculation
9
Min
5
Min
water rinse
9
Min
100
Min
Total
54
Min
100 USGPM = 1,600 USG per Cleaning
to drain.
100 USGPM = 900 USG per Cleaning
to drain.
Net Savings/Cleaning = 700 USG x # Boils (Or Cleaning Cycles)
Example = 1 cleaning/day x 700 USG = 176,400 USG/yr (252 days) saved!
www.alfalaval.com
Mash Tun
Added value by using Rotary Jet Heads
• Cleaning time can be reduced by 46 %
• Shorter down time
• Total costs can be reduced by 60 %
• Higher cleaning standard
Slide 14
www.alfalaval.com
Kettle
Required number of
Rotary Jet Heads
Cylindrical
Type
RJH-BKV
number
3
4 x 7mm, 58 UGPM, 75 PSIG
Slide 15
www.alfalaval.com
Kettle
RJH BKV
•
The heating surfaces are hard
to keep efficiently clean
•
Many have internal heaters
which do have “difficult-to-clean
areas”
•
Many do have Static Spray Balls
which do not clean well and
use large fluid volumes and
strong chemicals
Slide 16
www.alfalaval.com
Kettle
RJH - BKV
Standard cleaning
water rinse
10
Min
water rinse
caustic recirc.
90
Min
water rinse
10
acid recirculation
water rinse
Total
13,5
Min
caustic recirc.
36
Min
Min
water rinse
9
Min
20
Min
acid recirculation
13,5
Min
10
Min
water rinse
9
Min
130
Min
Total
81
Min
170 USGPM = 3,230 USG to drain
175 USGPM = 2,365 USG to drain
Net Savings/Cleaning = 865 USG x # Boils (Or Cleaning Cycles)
Ex: 1 cleaning/day x 865 USG = 217,980 USG/yr (252 days) saved!
Slide 17
www.alfalaval.com
Kettle
Added value by using Rotary Jet Heads
• The cleaning time can be reduced by 37 %
• Shorter down time
• The costs can be reduced by 35 %
• Validation possibility
Slide 18
www.alfalaval.com
Benefits using RSH & Jet Heads
•
Cleaning standard
Less than 1 year pay-back
– Repeatable high cleaning standard
•
Volume of water, waste and detergents
– Up to 50% Flow reduction
– Up to 75% Water Consumption Reduction
– Up to 75% Detergent Consumption reduction
•
Time
– Up to 50% Cleaning time reduction
– allowing more time for production
Cleaning
Cleaning
Production
Production
Slide 19
www.alfalaval.com
Thank You