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SEMINAR OF DE-692

(Minor Field)

Recent Advancement of Cleaning and


Sanitizing Agents Application in Dairy Industry

Presented By:-
Subhash Prasad
Ph.D. (In-Service)
Dairy Engineering
Reg. No. 2018010080011006

POSTGRADUATE INSTITUTE OF DAIRY EDUCATION AND RESEARCH, AMRELI


KAMDHENU UNIVERSITY

SUBHASH PRASAD, CDS, AMRELI 1


Presentation outline
Introduction
Cleaning and cleaning objectives
Basic of cleaning
Cleaning agents
Types of cleaning agent
Blended detergent mechanism
Sanitizers
Types of sanitizers
Factors affecting the sanitizing efficiency
 Progress of cleaning and sanitizing agents
in dairy industry
New trends and recent advancement
Conclusions
SUBHASH PRASAD, CDS, AMRELI 2
Milk is a highly perishable food item.

Contamination starts from its production, collection, conveying, processing and


storage from plant personnel, packaging material and environmental factors.

In dairy operations main processing treatment given to milk is heating which
causes the scaling on the surfaces of heat exchangers and pipes.

Therefore, the cleaning and sanitation of the dairy equipment is of utmost


importance to meet the sanitary and phyto-sanitary (SPS) requirements of the
industry.

The potential effects of poor cleaning, poor standards and poor quality.

SUBHASH PRASAD, CDS, AMRELI 3


Cleaning objectives

 Physical cleanliness –removal of all visible dirt from cleaned surface


 Chemical cleanliness – removal of both visible and microscopic residues
not detected by naked eye but by taste or smell only.

 Bacteriological cleanliness – attained by disinfection


 Sterile cleanliness – destruction of all micro organisms.

SUBHASH PRASAD, CDS, AMRELI 4


Cleaning of dairy industry
Definition: Cleaning is the complete removal of soil using appropriate detergent
chemicals under recommended conditions from the internal and external surface
of the equipment.
Why proper cleaning of dairy equipment/ utensil:
Reduces the chance of product contamination at each step by reducing the
high initial load of micro-organism through removal of their available
nutrients.

Promotes clean and tidy environment that improves operator’s


moral/confidence and helps to maintain safe work place, creates cleaner
production area, prevent/avoid accidents.
Increases the life of equipment.

 Improve plant efficiency


 Improves economy thus profit of the organization.
SUBHASH PRASAD, CDS, AMRELI 5
Soil identification

SUBHASH PRASAD, CDS, AMRELI 6


Properties of various components of milk soil
Surface Deposit Solubility Ease of Removal Heat induced
reaction

Sugar/lactose Water soluble Easy Carmelization

Fat Alkali soluble difficult Polymerization

Protein Very difficult Denaturation


Alkali soluble

Monovalent Salts Water soluble; Acid Easy to difficult -


soluble

Polyvalent Salts Acid soluble difficult Interaction with


other constituents

(Schmidt, 2012)

SUBHASH PRASAD, CDS, AMRELI


7
Basics of cleaning

 Cleaning is reversal of soiling and that requires


supply of energy usually in the form of
mechanical and chemical energy.

 To overcome the forces binding the soil to the


surface both mechanical and chemical effect
must be provided by cleaning system.

SUBHASH PRASAD, CDS, AMRELI 8


Factors affecting of cleaning performance
 Time of contact (a)

 Action (Mechanical Force)(b)

 Detergent Concentration (d)

 Temperature (c)

 Water quality

 Individual performance

 Nature of soil

 Surface is being cleaned

SUBHASH PRASAD, CDS, AMRELI 9


Cleaning cycle
Steps Purpose
1. Recovery of product residue • Minimizes product loss
(flushing, scraping, blowing etc) • Reduces load on sewage system
• Saving in sewage treatment cost
2. Pre-rinse (warm • Removes visible soil, Melt fats
water) • Prevent protein adherence
• Prevent thermal shock
3. Wash (detergent) • Removes remaining soil
•Chemicals lift biofilms that
bind to equipment surfaces
4. Post-rinse • Removes suspended soils and
chemical residues
• Prepares surface for sanitization
5. Sanitization • Kills bacteria that remain on
equipment surface
SUBHASH PRASAD, CDS, AMRELI 10
Cleaning agents
Cleaning agents are mixture of several chemical compounds employed for a
particular function to perform (like washing of surface of equipment), used to
reduce surface tension of water that results in dislodging and loosening of soil
followed by flushing away of the suspend soil particles.

Best “rule of thumb” to consider when selecting a cleaning compound/agent is


that “like cleans like.”

Classified as strong, heavy duty and mild alkaline and acids, employed
for a particular use

Most cleaning agent that are used in dairy industry are classified as blending
products .

SUBHASH PRASAD, CDS, AMRELI 11


Cleaning compounds and their major functions:

Basic Alkalis - Soften the water and saponify fats.

Complex Phosphates - Emulsify fats and oils, disperse and suspend oils, peptize
proteins, soften water by sequestering, and provide rinsability characteristics without
being corrosive.

Surfactant - (Wetting Agents) Emulsify fats, disperse fats, provide wetting


properties.

Chelating agent - (Organic compounds) Soften the water by sequestering, prevent


mineral deposits, and peptize proteins without being corrosive.

Acid - Good at mineral deposit control; and soften the water.

SUBHASH PRASAD, CDS, AMRELI 12


Physically Active Ingredients
 Alter physical characteristics such as solubility or colloidal
stability

 The primary physically active ingredients are the surface active


compounds termed as surfactants.

 Also called wetting agent.

Surfactants- Modify the properties of an interface by lowering the


surface tension, allowing water to contact all surfaces.

 Surfactants are known to “make the water wetter”.

 major functions of surfactants are wetting and penetrating in


soil.

SUBHASH PRASAD, CDS, AMRELI 13


Types of surfactants
a) Ionic surfactants
1.Anionic surfactants:
Release Negatively charged ions in aqueous solutions, Good wetting property and
Weakly bactericidal.
e.g. Primary Sodium alkyl sulphates , Secondary Sodium alkyl sulphates , alkyl
sulphonates and sodium alkyl sulphonates.
2.Cationic surfactants:
Release positively charged ions, Strong bactericidal and Weak detergent property.
e.g. Single quaternary ammonium compounds
3.Amphoteric surfactants:
Charge in aqueous solutions is pH depended, Cationic surfactants under acid
conditions and Anionic surfactants under alkaline condition
e.g. Cocoamidopropyl Betaine, Laurylamidopropyl Betaine

b) Nonionic surfactants:
Do not dissociate when dissolved in water. Properties depending upon the ratio of
hydrophilic/ hydrophobic balance.
e.g. Alkyl phenols and amides
SUBHASH PRASAD, CDS, AMRELI 14
Chemically Active Ingredients
 Modify soil components to make them more soluble and thus easier to remove
1. Alkaline Builders
Usually fats, oils, greases, and proteins can be remove with alkaline cleaning
agent at pH ≥11.

 Strong Alkaline Detergents


Property-
1) Protein dissolving agents
2) Emulsifiers
3) Bactericidal agents

e.g.:
Caustic soda (NaOH)
Caustic potash (KOH)

SUBHASH PRASAD, CDS, AMRELI 15


Heavy duty Alkaline Detergents:
Property-
Protection against corrosion
Prevent scale formation
Emulsifying and wetting properties
Water softening properties
Examples:-
 sodium metasilicate, sodium carbonate (both good buffering agents),
 sodium hexametaphosphate, sodium pyrophosphate and trisodium phosphaste
(has good soil emulsification activity).

Mild cleaners: manual cleaning of lightly soiled surfaces.


 Examples are sodium bicarbonate, sodium sesquicarbonate and tetrasodium
pyrophosphate.
SUBHASH PRASAD, CDS, AMRELI 16
Contd…

2.Acid Builders
 Acid detergents are used for the prevention or removal of stone films
(mineral stone or milk stone)
 Inorganic acids :
 Phosphoric acid (H3PO4)
• Nitric acid (HNO3) (0.5 to 1.5 %)
• Amidosulfonic acid
• Sodium hydrogen sulphate (NaHSO4)

 Organic acids : hydroxyacetic, citric and gluconic acid

SUBHASH PRASAD, CDS, AMRELI 17


Contd…

3. Water Conditioners:-
a. Sequestering agents –
 By inactivating the ion to other detergent ingredients are better able to clean.
e.g. sodium tripolyphosphate, tetra-potassium pyrophosphate, organo-
phosphates and polyelectrolytes.

b. Chelating agents-
 Water softening, Mineral deposit control, Soil displacement by peptizing
and Prevention of re-deposition
 Used to prevent the build-up of various mineral deposits
e.g. Sodium salts of ethylene diamine tetraacetic acid (EDTA)

SUBHASH PRASAD, CDS, AMRELI 18


Contd…

4. Fillers:
 Add bulk to dilute dangerous detergent formulations which are difficult to
handle.

 Strong alkalis are often diluted with fillers for ease and safety of handling
e.g. Water in liquid form,
Sodium chloride and sodium sulfate in solid form

5. Additional ingredients :
 Corrosion inhibitors : reduce chemical action between two material
e.g.: sodium metasilicate for aluminium and sodium sulphite for tin

ButylcellosolveTM (improve oil, grease, and carbon removal)


SUBHASH PRASAD, CDS, AMRELI 19
Action mechanism of blended detergents

3. Alkaline detergent
1. Rinsing with water 2. wetting agent added added

4. Chelating agent 5. Soil off 6. Clean surface


added
SUBHASH PRASAD, CDS, AMRELI
20
Sanitization

 Definition (Association of Official Analytical Chemists) of sanitizing for food


product contact surfaces is a process which reduces the contamination level by
99.999% (5 logs) in 30sec. In non-product contact surfaces requires a
contamination reduction of 99.9% (3 logs).
The standard test organisms used are: Staphylococcus aureus and Escherichia
coli

SUBHASH PRASAD, CDS, AMRELI 21


Why Sanitization?

• Product can get contaminated in new plants.

• Reduces potential for cross contamination.

• Prevent the major food based safety incidents to happen in future.

• Creation of hygienic practices intended to continue a clean and healthy


environment from milk and milk products processing to storage

SUBHASH PRASAD, CDS, AMRELI 22


Types of Sanitizers used in Dairy Industries
Thermal Sanitization:
 Involves the use of hot water or steam for a specified temperature and contact
time.
 Effectiveness of thermal sanitizing is dependent upon a number of factors
including: initial contamination load, humidity, pH, temperature and time.
1. Steam-
 Limited application
 Expensive compared to alternatives
 Difficult to regulate and monitor contact temperature and time.
Uses: metal Can and can lids
Temperature:-120-130ºC
2. Hot air- require sterile and dry surfaces, 160 ºC
SUBHASH PRASAD, CDS, AMRELI 23
Contd…

3.Hot Water
 The International Dairy Federation (IDF) recommends circulation of hot
water 85°C for 15 minutes for milk pasteurizer sanitization.
 Food and Drug Administration (FDA) recommended circulation of water in
enclosed system for minimum (77°C) for 15 minutes or >5 minutes at 94°C .

Used- small components (i.e., knives, small parts, eating utensils, and small
containers) into water heated to 80°C or higher temperature.
Advantages:
Easy to apply and readily available
Relatively non-corrosive
Penetrates into cracks and crevices
Disadvantages
 Slow process which requires come-up and cool-down time
 Forming or contributing to film formations
 Shortening of gaskets
SUBHASH PRASAD, CDS, AMRELI 24
Radiation based Sanitizers

1. Ultraviolet (UV) Irradiation


The optimum wavelength for UV radiation to be effective is 254 nm.
The effectiveness falls rapidly away at shorter or longer wavelengths than
the above.
The effect seems to arise from direct absorption of the radiation by DNA of
the bacterial cell.
Uses: Packaging of milk and milk products

SUBHASH PRASAD, CDS, AMRELI 25


Contd…

2. Ozone (O3):

Ozone has been found to be equivalent in antimicrobial kill rates to 200 times
the concentration of chlorine.
Ozone is most effective at a pH range of 6.0 to 8.5. As water temperature
increases, the solubility of ozone decreases. It dissipates almost immediately
at 40°C.
Uses:-
Cheese ripening rooms possess an environment that encourages mold growth.
Ozone is effective in the inactivation of airborne molds in this environment
(Serra et al.,2003).
Two companies DEL and Novazone are promoting the use of ozone as a
sanitizer for food contact surfaces.

SUBHASH PRASAD, CDS, AMRELI 26


Chemical Sanitizers
 Chlorine-based Sanitizers
 Iodine
 Quaternary Ammonium Compounds (QACs)
 Acid Sanitizers
 Hydrogen peroxide
 PAA

SUBHASH PRASAD, CDS, AMRELI 27


Chlorine based sanitizers
 Chlorine is the most common chemical sanitizing agent used in the milk industry.
 Liquid chlorine, hypochlorites, inorganic and organic chloramines, and chlorine
dioxide function as sanitizers. Hypochlorous acid, the most active of the chlorine
compounds
 Chlorine dioxide (ClO2) is known to have 2.5 times the oxidizing power of
chlorine.
Uses: cleaning small parts, milk tank and milk tanker
Advantages
 Economical
Effective against most bacteria, spores and phages

SUBHASH PRASAD, CDS, AMRELI 28


Contd…

Disadvantages:-
Corrosive and Strength
dissipates under storage, heat or
light, Skin irritant, objectionable
odor , Hard on rubber gasket

SUBHASH PRASAD, CDS, AMRELI 29


Iodine
 Free elemental iodine and hypoiodous acid (HIO) are the active agents in
microbial destruction.
 The major iodine compounds (I2) used for sanitizing are iodophors, alcohol-
iodine solutions, and aqueous iodine solutions.
 Generally recommended use of idophors is 12.5-25 ppm .

Uses:
Iodine sanitizers are used extensively in filling/packaging machines and areas,
culture processing equipment, drop hoses and hand dipping stations.

Advantages
 Not a skin irritant, Stable, long shelf life and Non-corrosive

Disadvantages
Discolor equipment
Less effective against spores
May cause product off flavors

SUBHASH PRASAD, CDS, AMRELI 30


Quaternary Ammonium Compounds (QACs)
 The most common agents are the cationic detergents, which are poor
detergents but excellent germicides.

 Quaternary ammonium compounds are very effective sanitizers for the


destruction of L. monocytogenes and effective in reducing mold growth.

 Used in case washing areas and other environmental surfaces

 Advantages:
 Active against gram positive slime-formers, thermodurics
 Low toxicity, odorless, colorless and Non-corrosive
 Less affected by pH

 Disadvantages:
 Undesirable in cultured dairy product applications
 Low activity against gram negative and coliform organisms
 Loses effectiveness with anionic detergent contamination

SUBHASH PRASAD, CDS, AMRELI 31


Acid sanitizers
 The active acid ingredient may be sulfonic, phosphoric, de-cationic,
cyanuric or a blend of and to provide not more than 100ppm of available
halogen.
 Uses: large (silo) milk storage tanks, milk tankers and other large milk
storage vessels within the plant.
 Advantages
 Rapid activity
 Controls milk-stone
 Disadvantages
 Increase in pH level decreases effectiveness
 Relatively expensive
 Cannot be used with alkaline detergents
SUBHASH PRASAD, CDS, AMRELI 32
Characteristics of commonly used sanitizers and application of chemical
sanitizers
Characteristics Steam Iodophors Chlorine Acid Quats

Germicidal Good Vegetative cells Good Good Somewhat


efficiency selective
Yeast destruction Good Good Good Good Good
Mold destruction Good Good Good Good Good
Shelf strength — Yes Yes Yes Yes
Stability stock — Varies with Low Excellent Excellent
temperature
Use — Varies with Varies with Excellent Excellent
temperature temperature
Speed Fast Fast Fast Fast Fast
Penetration Poor Good Poor Good Excellent
Film forming No None to slight None None Yes
Affected by organic None Moderate High Low Low
matters
Affected by other No High pH Low pH and High pH Yes
water constituents iron
SUBHASH PRASAD, CDS, AMRELI 33
Contd…

Characteristics Steam Iodophors Chlorine Acid Quats

Ease of Poor Excellent Excellent Excelle Excellent


measurement nt

Ease of use Poor Excellent Excellent High High foam


foam
Odor None Iodine Chlorine Some None
Taste None Iodine Chlorine None None
Effect on skin Burns None Some None None
Corrosive No Not to SS Extensive Bad on None
on mild mild
steel steel

Cost High Moderate Low Modera Moderate


te

(Marriott and Gravani, 2006)


SUBHASH PRASAD, CDS, AMRELI 34
Factors Affecting of Sanitizers Effectiveness

 Physical Factors
 Surface Characteristics
 Exposure Time and Temperature
 Concentration
 Soil

 Chemical Factors
 pH
 Water properties
 Inactivators

 Biological factors
 Type of microorganisms

SUBHASH PRASAD, CDS, AMRELI 35


Progress of cleaning and sanitizing agent uses in dairy
industry

Pure lye and lye soap (early 1900s )were the main alkaline cleaning agent.
 Weak lye solutions were used for hand cleaning operations and strong
solutions were used in mechanical washers.
Lye soap was used extensively as a general cleaner. It was mild and less
corrosive than pure lye.
Soda ash, sodium metasilicate, and sodium bicarbonate were incorporated
with lye to improve it.
 Sodium metasilicate (late 1920s), contributed to the alkalinity and
inhibited the corrosion of white metal.
 Sodium bicarbonate was used as filler and buffer. These compounds
improved the cleaners to some extent, but they lacked wetting ability and
were inefficient water softeners.

SUBHASH PRASAD, CDS, AMRELI 36


Contd…

Trisodium phosphate (early 1920s) was one of the first compounds used to
cleaner formulations to improve the cleansing action. The addition of
polyphosphates to cleaners was another step forward.

EDTA and gluconates (late 1930s; (Cole, 1955)

 Muriatic acid was the first mineral acid used as a cleaner.

Live steam or hot water was frequently used as a bactericide but the
method was costly.

Bleaching powder was commonly used for bottle sanitization.

SUBHASH PRASAD, CDS, AMRELI 37


Contd…

2. After 1940
Numerous chemical combinations are possible, and "tailor-made"
wetting agents of specific anionic configuration are manufactured for
specific problems. These agents have been found to react synergistically
with sodium sulfate and this activity is increased about 33% over the pure
substance.

Organic chelates vary in their ability to sequester calcium, magnesium,


or iron, and specific chelates are required for specific problems.

Anionic and nonionic wetting agents are available and commonly used
in detergent formulations.

Alkaline detergents are complex compounds. They contain basic alkalis,


polyphosphate wetting agents, and chelating agents. They are called
balanced alkaline cleaners and they are tailor-made to meet the
requirements of the water supply.

SUBHASH PRASAD, CDS, AMRELI 38


Contd…

Hydroxyacetic acid and gluconic acid, have replaced muriatic acid as a acid
detergent.

Corrosion inhibitors are added to these acid cleaners to prevent metallic


degradation of the highly polished surface.

Chlorinated alkaline cleaners also possess enhanced cleaning activity, Iodine or


bromine also use in these formulations.

Iodophors uses to enhanced germicidal activity over pure iodine.

Fungicidal paint is used to control mold growth on the walls and ceilings of
butter storage rooms, cheese curing rooms, and walk-in coolers.

Solubilized copper-8-quinolinolate is incorporated in the paint to provide


effective in the cook room of process cheese plants where high temperatures
band high humidities prevail throughout the season.

SUBHASH PRASAD, CDS, AMRELI 39


Contd…

 The introduction of quaternary ammonia compounds as cleaners in


1939 (Hall, 1976) and hexametaphosphate in milking units (Babel, 1955).

Quaternary ammonium compounds are also available in the dairy plant


sanitization.

Reactive sanitizing agents on dairy product quality, such as the residual


effects of quaternary ammonia on lactic acid bacteria growth (Miller and
Elliker, 1951) and halogen residuals on off-flavors (Jensen et al., 1963;
Hekmati and Bradley, 1979) and color (Toba et al., 1980) in milk.

SUBHASH PRASAD, CDS, AMRELI 40


New trends………
The use of specially formulated chemicals ( more chelating agent) for
cleaning and sanitizing in in Indian dairy industry.

 The acidic stage can be replaced with additive package to caustic


which will the eliminate or reduce the need of acidic stage.

Use of foam cleaning machine.

 Foam and gel technique.

Dry ice blasting process use of solid CO2 pellets.

 Ice pigging method of removing fouling in duct, pipes and heat


exchangers.

SUBHASH PRASAD, CDS, AMRELI 41


Contd…

A balanced alkaline cleaner with an acid cleaner prevents proteinaceous films


and milkstone deposits from building up. This is known as the alternate
cleaning technique.

Electrolyzed water is a good sanitization method because it has antimicrobial


properties, is not corrosive to skin, mucous membranes or organic material, is
safe to handle and has little adverse effect on the environment.

Electrolyzed water (EW) has been used as sanitizer (EW containing HOCl)
and cleaner (EW containing NaOH) in recent years.
(Kim and others 2000a)
Spray cleaning and insulated jet used for vacuum pans, evaporators, storage
tanks, hot wells and other enclosed equipment.

SUBHASH PRASAD, CDS, AMRELI 42


Hydrogen Peroxide(HP)
FDA approval has been granted for HP use for sterilizing equipment and
packages in aseptic operations

Majority of the systems apply the peroxide solution (usually at 30-35%


concentration) to the surface of the container material by dipping or by a finely
dispersed spray.

A Hydrogen peroxide-based powder in 3% and 6% solutions has been found


to be effective against biofilms (Felix, 1991).

Uses:- flexible packaging surface for aseptic operations.


Recent development is use of vapour phase Hydrogen peroxide(VPHP)
The most widely used system is the VHP-1000 Biodecotamination series.

SUBHASH PRASAD, CDS, AMRELI 43


Peroxyacetic Acid (PAA)
PAA is relatively stable at use strengths of 100 to 200ppm.

 PAA is highly active against both gram-positive and gram-negative


microorganisms.

 PAA has a pungent odor and the concentrated product (40%) is a highly toxic,
potent irritant, and powerful oxidizer.
It is being promoted as a potent chlorine replacement as food industry is as a
sanitizer.

It is probably more effective as a disinfectant in aqueous solutions than on


biofilms (Ntsama et al., 1997) or in organic waste slurries.

Uses:-
All types of Process Equipment in dairy including farm equipment.

SUBHASH PRASAD, CDS, AMRELI 44


Bio-detergents

 Bio-detergents or biocleaners, which offer a better option to the synthetic


detergents with respect to their biodegradability.

 Also known as green chemicals.

Advantages:

 Fast emerging,

 Low toxicity,

 Non-corrosive,

 Environmental friendly and

 Enhanced cleaning properties

SUBHASH PRASAD, CDS, AMRELI 45


Enzyme based biodetergents
 Uses of most enzyme cleaners are limited to unheated surfaces ( e.g.,
cold-milk surfaces)

Advantages- 1) More environmentally friendly 2) Require less energy


3) Less hot water in cleaning

Type Substrate Brand name


Protease Protein / Alcalase, Durazyme,
polypeptide Esperase, Maxatase,
Optimase

Lipase Mono /di /tri Lipolase, Lipomax, Lumafest


glycerides
Amylase Amylose / Maxamyl, Optiamyl
amylopectin
 Firms – Gist-Brocade, Nova-Nordisk,Genecor, Solvay enzymes

SUBHASH PRASAD, CDS, AMRELI 46


Centralized CIP System
Cleaning unit
(with in
broken lines)
1. Tank of alkaline
detergent
2. Tank of
acid
detergent

Objects to be cleaned
A. Milk pasteurizer
B. Tanks
C. Silo tanks
D. Filling Machines

SUBHASH PRASAD, CDS, AMRELI 47


De-Centralized CIP System

SUBHASH PRASAD, CDS, AMRELI 48


Conclusions
Selection of clean water, cleaning and sanitizing agents, cleaning and
sanitizing equipment, and sanitizers for each cleaning application.

Every processing facility should verify the effectiveness of its cleaning and
sanitation program .

In recent advancement of cleaning and sanitizing in dairy industries are


The use of specially formulated chemicals or tailor-made and designer
cleaning and sanitizing agents used in in dairy industry.
Use of foam and gel technique, ice blasting process and ice pigging method
of removing fouling in duct, pipes and heat exchangers.
Electrolyzed water (EW) has been used as sanitizer.
Spray cleaning and insulated jet used for vacuum pans, evaporators, storage
tanks, hot wells and other enclosed equipment.
A current trend has been toward modification of CIP systems using PLC and
SCADA.
SUBHASH PRASAD, CDS, AMRELI 49
SUBHASH PRASAD, CDS, AMRELI 50

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