23/12/2009 Matthias Schuetzeberg Slide 1 E+H hygienic technology

Matthias Schuetzeberg

Slide 1

23/12/2009

E+H hygienic technology

Food-BTM_Hygiene


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23/12/2009

Goal of this training s ession

Why is hygienic designed equipment demanded?

What are the basic requirements for a hygienic installation?

How should equipment that is used in food look alike?

How does hygienic design looks at wetted parts and housing?

What to remind due to installation?

Which process connection fits into what kind of application?

Please remind, that hygienic design is just a step to improve the hygienic behaviour of a plant. You will never reach 100%. Target is, to stay on a acceptable level.

Food-BTM_Hygiene


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Agenda of this Training Session

What does “Hygiene” means ?

Clean ability and surface roughness

Hygienic constructions

Regulatory Laws, Agencies & Standards

Hygienic Process connections

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What is the meaning of “Hygiene”

Hygiene refers to the set of practices associated with the preservation of health and healthy living. Hygiene is a concept related to medicine, as well as to personal and professional care practices related to most aspects of living, although it is most often associated with cleanliness and preventative measures.

Washing one's hands, a form of hygiene, is the most effective overall way to prevent the spread of infectious disease.

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Culinary hygiene “Food Safety”

Culinary practices include:

Cleaning and sterilization of food-preparation areas and equipment (for example using designated cutting boards for preparing raw meats and vegetables). Cleaning may involve use of chlorine bleach, ethanol, ultraviolet light, etc. for sterilization.

Careful avoidance of meats contaminated by trichina worms, salmonella, and other pathogens; or thorough cooking of questionable meats.

Washing of hands thoroughly before touching any food.

Not using the same utensils to prepare different foods.

Proper storage of food so as to prevent contamination by vermin.

Refrigeration of foods (and avoidance of specific foods in environments where refrigeration is or was not feasible).

Labeling food to indicate when it was produced (or, as food manufacturers prefer, to indicate its "best before" date).

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What is the reason to use hygienic instrumentation? The product quality!

and money:

Longer production cycles between the CIP cycles. higher yield of the plant.

Easier to clean means less water, less cleaning agents, lower temperature and faster cleaning. saving money

More flexible plants due to easier and faster phase change between two products or flushing water and product.

Certified technology is saving time in certified processes!

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Clean ability - Why do we need a smooth surface?

E-coli Proteine

Bacteria

Finger print

Yeast

Grease particle

Dust particle

Biofilm with grease, dirt and yeast

Human HairCracks and crevices

Micro organism

Surface Roughness

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Surface Finish - Conversion

3-A requires Ra 0,8µm (32µ-Inch) or better.

For purified water systems: Ra of 0,4µm (15µ-Inch) is typically required

Ra is the Roughness Average, after Polishing. Ra is usually expressed in Micro-Inch (u-inch) or Micro-Meters (Microns).

Surface final finish is sometimes measured in Roughness RMS (Root Mean Squared). Micro-inches x 1.11 = roughness RMS.

Grit Ra Ra RMS RMS(Reference Only) Micro-Inch Micro-Meter Micro-Inch Micro-Meter

150 27 - 32 0.68 - 0.80 30 - 35 0.76 - 0.89

180 16 - 23 0.46 - 0.58 20 - 25 0.51 - 0.64

240 14 - 18 0.34 - 0.46 15 - 20 0.38 - 0.51

320 8 - 10 0.21 - 0.25 9 - 11 0.23 - 0.28

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polishing of metal surfaces

Polishing is achieved in different ways: mechanical buffing, electropolishing or forming

Electropolishing removes material from uneven surfaces

Reduces surface areas

Provide a hygienic surface finish

Cleans the surface

Passivates the surface of stainless steel with a chromium layer

Removes impurities trapped below folded layers

Mechanical polishing in combination with electropolishing produces the best results

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Cracks and Crevices

Static seals shall be cleanable and drainable with minimum crevices, gaps, and horizontal surfaces

O-rings shall be flush with pipe wall and be self-aligning and self-positioning

EHEDG study shows that protrusion of less than 2mm (1/12”) is not cleanable

Seals must be resistant to CIP solutions and tolerate SIP temperatures

Gaps and dead ends must be self draining/ cleanable.

Rule of thumb: diameter 2 times larger than depth

Example: Tank fitting

DN50/ 2”

25mm

1”

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Hygienic Construction: seals

Metal to metal sealing is, according to EHEDG, not fully hygienic.

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If the O-Ring is to far from the process, the danger of building up reservoirs for product and micro organisms is high.

heating

cool down

Material stretching

product ormicro organism

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Fixed by hand

Fixed by tools

gap

Weak points for hygienic

Milk pipe connection (DIN 11851)

Hygienic

T-ring screwing(ISO 2853)

centering

stop

no deep gap.

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Spectrum Of user Requirements

Keep in mind to establish what different needs a plant have for different processes and products. Some areas in raw material may have a lower need for hygienic design. You can often estimate the hygienic requirements simply by understanding how fast or easy a product will spoil.

Milk and dairy products have among the shortest shelf life vs. for example the very long shelf life for dry grain products.

All processes can be improved by using hygienic design.

Users oftens don’t recognize the possibilities to improve the safety of their process. If you talk to the engineers they often satisfied to stick with what they have. If you have the opportunity to point out to a quality manager the benefits of for example using a fully drainable straight flow tube vs. a U-tube your opportunity is much greater.

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Promag H – gasket design

GasketPFA liner PFA liner

Mechanical fixationof the liner

Process connection

Measuring tube,steel

Measuring tube inside

Mechanical fixationof the liner

Measuring tube,steel

Measuring tube inside

Gasket

Process connection

gasket dismounted gasket mounted

Example of good gasket design, compression and extrusion of gasket is controlled. No cracks or crevices are created.

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Hygienic Process connections

Dairy Connection acc. to DIN 11851 Aseptic connection acc. to DIN 11864 SMS - connection DRD Welding adapter Varivent connections APV connections Welding adapter for Deltapilot S Tri-Clampacc. to DIN 32676/ISO 2852NEUMO BioConnect & Aseptic Welding adapter „F“ for Liquiphant Process connection DN 25 Ingold I - Line Clamp - Fitting ; Cherry BurellRosemount/Foxboro tank spudKingGage / Anderson Tank Spud

+++

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Tri-Clamp (DIN 32676/ISO 2852)

The Tri-clamp connection is common in the food industry and was originated and designed by the company Tri-clover.The sensors can either be placed at tanks or in pipes. The advantage of that system is the easy installation of the sensors. The parts of the clamp system are put together via clamps. Pressure rated to 600psi with standard clamp (1000psi with high pressure clamp) up to 2“ only

Sizes from ½“ to 6“½“ + ¾“ – same clamp1“ + 1-1/2“ – same clamp

Parts of the Tri-clamp connection:2 x Clamp parts, Clamp, seal

Tri-clamp process connection

Pay attention when selecting clamp option; there are ISO , DIN std and Tri-Clamp. Style is not critical for “dead end” connections such as for pressure, temperature but is critical for “flow-through”. The ID is slightly different that can cause cleaning problems

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Cherry-Burrell I-Line

Similar to Tri-clamp but have male and female connectors, making alignment easier.

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DIN 11851, DIN 11864 and SMS

DIN 11851 (Milk Coupling)Older European std. Being slowly phased out by 11864

DIN 11864 Aseptic CouplingVery good hygienic seal design

SMS couplingCommon in Scandinavia and France

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Tuchenhagen Varivent

The Varivent - Inline housing must be used together with a Varivent flange. With the inline housing a hygienic flush mounting is reached. The Varivent parts are held together with a clamp

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Tuchenhagen Varivent options

Tank Adapter Form - T -

Tankmount or pipe mount.

4 sizes

17mm

50mm

68mm

114mm

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APV connections

Similar concept as the Tuchenhagen Varivent , Mounts with screws.

More commonly seen on brewing skids from Europe

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DRD – Flush weld fitting

DRD flange – common in Europe for brewing, wine and juice

Large diameter + bolts make it less practical

CO2 - head pressure measurement at the fermentation tank in the brewery with Deltapilot S DRD-flange

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Ingold 25mm

The Ingold process connection 25 mm is most common in the pharmaceutical industry for the implementation of pressure transmitters, analytical instrumentation and level switches in fermenter.

Available from E+H for:pH-assembly CPA 442, 465, CleanfitCerabar M PMP 45Liquiphant M

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NEUMO Aseptic and Bio Connect

The aseptic connection NEUMO was especially designed by the company NEUMO for hygienic applications and is simliar to the DIN 11864.

The aseptic connection BioConnect was designed for hygienic and aseptic processes in the pharmaceutical industry and is similar to the DIN 11864 and the aseptic connection from NEUMO.

NEUMO Aseptic

NEUMO Aseptic BioConnect

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23/12/2009

Anderson, KingGage, Continental and TankmateCommonly seen in dairy and beverage industry

•KingGage Long 8”, medium 6”,short 2.5” - 1.26” diameter•Anderson Long 6.5” and short 2.2” – 2.2” diameter

E+H Deltapiot S DB50S or FMB70 with Anderson fitting

Food-BTM_Hygiene


Slide 32

23/12/2009

Rosemount tank spud

Referred to as 2” or 6” version large diameter of 3.63” use a 4”clamp for mounting.

Primarily used hydrostatic pressure tank level applications

Available on FMD 78, PMP46 and with adapter for FMB70 (Cerabar M PMC 45 is available as TSP)

Seen here in reference to 2” tri-clamp

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23/12/2009

Endress+Hauser Weld fittings

Endress+Hauser offers weld fittings to provide hygienic flush connections of several products

Weld spud for:

Deltapilot S FMB 70

Cerabar M PMC 45

Liquicap FMI 51

Levelflex FMP41C

NA Connect – Tri-Clamp compatible weld fitting – Shown here when used with FMR245

Weld spud for Liquiphant M

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23/12/2009 Matthias Schuetzeberg Slide 1 E+H hygienic technology