KEG INTERNAL CLEANING, STERILIZING, FILLING AND CIP
Peter [email protected]
Denis BlaisTechnical support coordinatorFood & Beverage Canada [email protected]
mailto:[email protected]:[email protected]Agenda Internal cleaning process Chemistry of internal keg cleaning Hydraulic of CIP overview Question
InternalCleaning Process
4
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
drain
mixed water reflux
caustic reflux
acid reflux
step 1: pressure check and purging of ullages by sterilized air
234
1
GmbH & Co. KG
5
step 2: mixed water rinse of the KEG-side
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 3: mixed water rinse through the spear
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
7
step 4: mixed water rinse by counter-flow procedure
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 5: purging by sterilized air
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
9
step 6: caustic rinse of the KEG-side
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
10
step 7: caustic rinse through the spear
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
11
step 8: caustic rinse by counter-flow procedure
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 9: purging by sterilized air
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
13
step 10: hot water rinse of the KEG-side
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
14
step 11: hot water rinse throughthe spear
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
15
step 12: hot water rinseby counter-flow procedure
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
16
step 13: purging by sterilized air
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
17
step 14: acid rinse of the KEG-side
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 15: acid rinse through the spear
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 16: acid rinse by counter-flow procedure
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 17: purging by sterilized air
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
21
step 18: hot water rinse of the KEG-side
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
22
step 19: hot water rinse throughthe spear
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
23
step 20: hot water rinseby counter-flow procedure
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 21: purging of KEG by steam
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 22: steam rinse
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
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step 23: pressurization by steam and steaming
234
1
drain
mixed water reflux
caustic reflux
acid reflux
sterilized air
steam
hot water
mixed water
caustic
acid
1 washing head2 pressure switch3 temperature detector 4 liquid detector
internal cleaning process
GmbH & Co. KG
27
1 filling head2 pressure switch (product)3 pressure switch (KEG)4 temperature detector 5 level limit switch6 liquid detector
steam
hot water
drain
step 24: temperature control and purging of condensate by CO2
4
1
filling process
53
V4
V3
V5
2V2
V1
CO2
V6 V7
V8
6V9
V10 V11 V12
V1 sampling valve V7 CIP-valveV2 reflux valve V8 return valveV3 product valve V9 outlet valveV4 CO2 valve V10 relief valveV5 inlet valve V11 rest product valveV6 by-pass valve V12 sampling cock
CIP-infeed and filling product
CIP-reflux/rest product
sampling cock
GmbH & Co. KG
V1 sampling valve
V7 CIP-valve
V2 reflux valve
V8 return valve
V3 product valve
V9 outlet valve
V4 CO2 valve
V10 relief valve
V5 inlet valve
V11 rest product valve
V6 by-pass valve
V12 sampling cock
28
step 25: counter-pressurization by CO2
4
1 53
V4
V3
V5
2V2
V1
CO2
V6 V7
V8
6V9
V10 V11 V12
filling process
drain
steam
hot water
1 filling head2 pressure switch (product)3 pressure switch (KEG)4 temperature detector 5 level limit switch6 liquid detector
sampling cock
CIP-reflux / rest product
CIP-infeed and filling product
V1 sampling valve V7 CIP-valveV2 reflux valve V8 return valveV3 product valve V9 outlet valveV4 CO2 valve V10 relief valveV5 inlet valve V11 rest product valveV6 by-pass valve V12 sampling cock
GmbH & Co. KG
V1 sampling valve
V7 CIP-valve
V2 reflux valve
V8 return valve
V3 product valve
V9 outlet valve
V4 CO2 valve
V10 relief valve
V5 inlet valve
V11 rest product valve
V6 by-pass valve
V12 sampling cock
29
step 26: filling process
4
1 53
V4
V3
V5
2V2
V1
CO2
V6 V7
V8
6V9
V10 V11 V12
filling process
drain
steam
hot water
1 filling head2 pressure switch (product)3 pressure switch (KEG)4 temperature detector 5 level limit switch6 liquid detector
CIP-infeed and filling product
CIP-reflux / rest product
sampling cock
V1 sampling valve V7 CIP-valveV2 reflux valve V8 return valveV3 product valve V9 outlet valveV4 CO2 valve V10 relief valveV5 inlet valve V11 rest product valveV6 by-pass valve V12 sampling cock
GmbH & Co. KG
V1 sampling valve
V7 CIP-valve
V2 reflux valve
V8 return valve
V3 product valve
V9 outlet valve
V4 CO2 valve
V10 relief valve
V5 inlet valve
V11 rest product valve
V6 by-pass valve
V12 sampling cock
30
step 27: filling process
4
1 53
V4
V3
V5
2V2
V1
CO2
V6 V7
V8
6V9
V10 V11 V12
filling process
drain
steam
hot water
1 filling head2 pressure switch (product)3 pressure switch (KEG)4 temperature detector 5 level limit switch6 liquid detector
CIP-infeed and filling product
CIP-reflux / rest product
sampling cock
V1 sampling valve V7 CIP-valveV2 reflux valve V8 return valveV3 product valve V9 outlet valveV4 CO2 valve V10 relief valveV5 inlet valve V11 rest product valveV6 by-pass valve V12 sampling cock
GmbH & Co. KG
V1 sampling valve
V7 CIP-valve
V2 reflux valve
V8 return valve
V3 product valve
V9 outlet valve
V4 CO2 valve
V10 relief valve
V5 inlet valve
V11 rest product valve
V6 by-pass valve
V12 sampling cock
31
4
1 53
V4
V3
V5
2V2
V1
CO2
V6 V7
V8
6V9
V10 V11 V12
step 28: filling process
filling process
drain
steam
hot water
1 filling head2 pressure switch (product)3 pressure switch (KEG)4 temperature detector 5 level limit switch6 liquid detector
CIP-infeed and filling product
CIP-reflux / rest product
sampling cock
V1 sampling valve V7 CIP-valveV2 reflux valve V8 return valveV3 product valve V9 outlet valveV4 CO2 valve V10 relief valveV5 inlet valve V11 rest product valveV6 by-pass valve V12 sampling cock
GmbH & Co. KG
V1 sampling valve
V7 CIP-valve
V2 reflux valve
V8 return valve
V3 product valve
V9 outlet valve
V4 CO2 valve
V10 relief valve
V5 inlet valve
V11 rest product valve
V6 by-pass valve
V12 sampling cock
32
4
1 53
V4
V3
V5
2V2
V1
CO2
V6 V7
V8
6V9
V10 V11 V12
step 29: rinsing of filling head by hot water
filling process
drain
steam
hot water
1 filling head2 pressure switch (product)3 pressure switch (KEG)4 temperature detector 5 level limit switch6 liquid detector
CIP-infeed and filling product
CIP-reflux / rest product
sampling cock
V1 sampling valve V7 CIP-valveV2 reflux valve V8 return valveV3 product valve V9 outlet valveV4 CO2 valve V10 relief valveV5 inlet valve V11 rest product valveV6 by-pass valve V12 sampling cock
GmbH & Co. KG
V1 sampling valve
V7 CIP-valve
V2 reflux valve
V8 return valve
V3 product valve
V9 outlet valve
V4 CO2 valve
V10 relief valve
V5 inlet valve
V11 rest product valve
V6 by-pass valve
V12 sampling cock
33
4
1 53
V4
V3
V5
2V2
V1
CO2
V6 V7
V8
6V9
V10 V11 V12
step 30: purging of filling head andsteaming
filling process
drain
steam
hot water
1 filling head2 pressure switch (product)3 pressure switch (KEG)4 temperature detector 5 level limit switch6 liquid detector
CIP-infeed and filling product
CIP-reflux / rest product
sampling cock
V1 sampling valve V7 CIP-valveV2 reflux valve V8 return valveV3 product valve V9 outlet valveV4 CO2 valve V10 relief valveV5 inlet valve V11 rest product valveV6 by-pass valve V12 sampling cock
GmbH & Co. KG
V1 sampling valve
V7 CIP-valve
V2 reflux valve
V8 return valve
V3 product valve
V9 outlet valve
V4 CO2 valve
V10 relief valve
V5 inlet valve
V11 rest product valve
V6 by-pass valve
V12 sampling cock
Chemistry of internal keg cleaning
DELIVERINGWORLD CLASSSERVICE
VorfhrenderPrsentationsnotizenDave G:The training builds on the counselor salesperson model we teach in Foundations II. We invite you to provide additional questions or request support that will help you we are here to learn and get your input as much as we are here to educate you about this exciting market.Internal Keg Washing
1. Clean kegs are critical to the quality of draft beer.
2. CIP processes similar to that used in cellar tank cleaning are normally used, but
at elevated temperature.
3. If not cleaned properly, beerstone/tannin deposits can develop inside kegs.
This is especially true for kegs holding unfiltered beer, where yeast deposits
can add to these issues. Beer-spoilers can hide underneath these layers.
Brewery Soil Characteristics
Typical cleaning procedures
Insufflation(deflation of CO2)
Transport
Water filling (deflation of CO2)
Caustic cleaning (replenish)(deflation of CO2)
Draining
Hot caustic cleaning
Rinsing
Steaming
Water flushing Acid pre-cleaning
Transport
Draining
Hot acid cleaning
Rinsing
Draining
Filling
1
2
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Pre Rinsing&
CO2 Exhaust
Cleaning
Rinsing
Sanitizing
Pre Rinsing & CO2 Exhaust
Most critical step why?
Option Expected goal Comment
Water flush Removing gross soil Good and consider using reclaimed water to reduce water cost.
Air blowing Blow out the CO2 This step is critical and need to be optimized as much as possible
Sacrificial Caustic Pre-clean the keg and removing CO2 Very little benefit observed for CO2 reduction.
Acid Rinsing Removing gross soil Very good practice especially if followed by a caustic wash without rinsing (over ride)
Water filling Removing CO2 Very effective for CO2 removal but very high usage of water and time
Pre Rinsing & CO2 ExhaustResidual CO2 inside the keg will influence the cleaning performance
Caustic/Carbon Dioxide Reactions Na2CO3
Sodium+ H2O
Water+ CO2Carbon Dioxide Carbonate
1) 2NaOHSodium Hydroxide(Caustic)
2) Na2CO3 + CO2 + H2O 2NaHCO3SodiumBicarbonate
Why Sodium Carbonate and Sodium Bicarbonate can influence Cleaning Performance?
Active Caustic vs. Carbonate BaselineCaustic / Carbonate Titration in Main Wash Tank
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 100 200 300 400 500 600 700
Kegs Cleaned
Conc
entra
tion
(%)
0
20
40
60
80
100
120
140
160
Cond
uctiv
ity (m
S)
% Caustic% CarbonateConductivity
Conductivity does not indicate a problem
Titration shows rapid loss of active alkalinity, and a rapid buildup of carbonate alkalinity
Sodium Bicarbonate (not showed in graphic) will foamed and will make the cleaning solution hard to rinse
Optimizing the CO2 blowout step will help to achieved sustainability of the cleaning performance and lowered your chemical cost.
VorfhrenderPrsentationsnotizenIf you expand this view to a full day of cleaning and filling returned barrel kegs, we see the same trend in the morning of rapid hydroxide alkalinity degradation paired with an equally rapid accumulation of carbonate alkalinity. We also see that throughout the day, active alkalinity never recovers and by the end of the day we had no active hydroxide alkalinity in the wash solution.Now let me point out something very interesting here. This green line that hovers around 77 80 mS, as shown on the secondary y-axis on the right, represents the conductivity reading of the caustic wash solution throughout the day. You can see that it starts off high in the morning, and as active alkalinity is consumed, conductivity drops. At the point where carbonate alkalinity becomes the dominate species in the wash solution, the conductivity has reached the set point, and continues to maintain its set-point throughout the day by cyclically re-dosing every 7 10 kegs. Whats happening here is that the carbonate ion is also a very conductive ion. As hydroxide alkalinity is consumed, the conductivity lost is being replaced by the conductive carbonate ion. The conductivity meter can not differentiate between the two species, and only reads the conductivity of the entire wash solution.So, the key learning here is that conductivity does not tell the whole story. According to conductivity, weve maintained the set-point all day long and everything should be fine, but the titration results show a loss of active alkalinity, replaced with carbonate alkalinity! The next question is, why is this happening? Could it be reaction with excess CO2 coming in with the returned kegs?Cleaning
Most critical step why?
Option Advantage Desavantage
Caustic Best in class cleaning agent for beer soils residue
CO2 residual in the kegs will reduce the effectiveness of the cleaning.
If the additive in the blend do not controlled the mineral precipitation, scale and beer stone or foam will appear.
Acid
CO2 will not reduce the product performance.
Prevent scaling and controlling beer stone.
Good to moderate cleaning agent for organic soils. On a long time usage a combination of organic soils an
Calcium Oxalate can appear.
Caustic and Acid
Providing all the advantage from both products and usually controlling soiled buildup.
Need a more intensive equipment investement to performed both wash.
Combine Premium Caustic
Providing the same advantage of a Caustic / Acid cleaning in a single step wash.
Can be used on a one step wash machine.
Higher cost of Caustic product.
Hydraulic of CIP Overview
DELIVERINGWORLD CLASSSERVICE
VorfhrenderPrsentationsnotizenDave G:The training builds on the counselor salesperson model we teach in Foundations II. We invite you to provide additional questions or request support that will help you we are here to learn and get your input as much as we are here to educate you about this exciting market.What is CIP Clean-in-Place
The cleaning of a beer pipeline. filling machine or vessel with minimal disassembling of equipment components (hence the name Cleaning in Place)
The process involves the jetting or spraying of solution through spray devices on a tank or vessel surface or by the controlled flow velocity through pipelines
43
CIPClean-In-Place
Not justcirculate in place
RESULTSClean tanks and lines = Good Beer
CIP 4 X 4 Process
44
Preparation - Critical Disassemble, clean all surfaces NOT cleaned by CIP Brush wash dead areas
Mechanical Force is the most common challenge
Remove gross soils from surface
Soil being lifted from surface and held, suspended or dissolved within the detergent solution
Helps assure Food Safety
Removal of detergent residual and cool process surface
Pre-Rinse Cycle Detergent Cycle Post-Rinse Cycle Sanitize Cycle
Mechanical Force
Temperature
Time
Concentration
Mechanical Force - Lines
45
Mechanical Force is the most common CIP challenge for keg filler and beer line circuits Different pipe sizes.
Same flow but different velocity Dead legs
Difficult or impossible to clean by CIP(micro harborage) Manual cleaning
Split flows The flow will be split by pressure and not by pipe size or velocity (difficult to
impossible to control) Equipment (Cooler, Flash pasteurizer, Holding tank)
Equipment is engineered with a recommended flow / pressure. Verify the head loss pressure
Long circuits Increases the head loss pressure and makes the CIP pump ineffective (pump
curve)
46
Common Mistakes: Dead legs In Pipes
Preassigned hygiene problems
L
L > 1.5 D
Direction of flow D
L > 1.5 D
Not ideal, but a little better!
L
DDirection of flow
Mechanical Force - Tanks
49
NO SPRAY DEVICE IS BAD. ITS ONLY INADEQUATE FOR THE JOB Spray Ball
Properly sized spray ball will achieving tank cleaning in the shortness time and energy with a lower maintenance cost
Operate to a lower pressure (25 PSI) 1 axle Rotary Spray
Will required less water but will need longer step time With the exception of a visual inspection its impossible to
validate to rotation. Multi axal Rotary Spray
Usually required a higher pressure at the pump to operate Rotation can be monitor Longer time due to pattern. High maintenance
Hygiene ManagementWhy Clean and Sanitise at all?
Beer-Contamination Risk Management Microbial Chemical Physical
Maximising Equipment Efficiencies Brand Protection Consumer Safety and Loyalty Stay in Business and Grow
Thank You!
Denis BlaisCoordonnateur technique brasserie & breuvageTechnical support coordinator brewery & beverageFood & Beverage Canada
Ecolab Co.2222 Boul. Dagenais OuestLaval, Quebec, H7L 5Y2
Tel: 450 978 6415Cel: 514.998.8997
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Questions?
Peter MackenrodtCEOm+f KEG-Technik GmbH & Co. KGWeusterstr. 2746240 Bottrop, GermanyTel.: +49 2041 743-125Fax: +49 2041 743-190e-mail: [email protected]
mailto:[email protected]://urldefense.proofpoint.com/v2/url?u=http-3A__www.mfKEGtechnik.com&d=DwMFAw&c=clRTYxLjfWTYQkksq4Trqw&r=dSK0xKqlwhV5HfBo_Jk0HoOmPG_8qnLyd0jNkDRBKck&m=qCksgYw1OoqNkYy637_oK5_fPgqUg94qWlZC-5sA0ZY&s=0ZpCLnwkZE80U2zyliz8ija0J0IhetjeB1zm0d1Kck8&e=Foliennummer 1AgendaInternal Cleaning ProcessFoliennummer 4Foliennummer 5Foliennummer 6Foliennummer 7Foliennummer 8Foliennummer 9Foliennummer 10Foliennummer 11Foliennummer 12Foliennummer 13Foliennummer 14Foliennummer 15Foliennummer 16Foliennummer 17Foliennummer 18Foliennummer 19Foliennummer 20Foliennummer 21Foliennummer 22Foliennummer 23Foliennummer 24Foliennummer 25Foliennummer 26Foliennummer 27Foliennummer 28Foliennummer 29Foliennummer 30Foliennummer 31Foliennummer 32Foliennummer 33Foliennummer 34Foliennummer 35Foliennummer 36Typical cleaning proceduresFoliennummer 38Foliennummer 39Active Caustic vs. Carbonate BaselineFoliennummer 41Foliennummer 42What is CIP Clean-in-PlaceCIP 4 X 4 ProcessMechanical Force - LinesCommon Mistakes: Dead legs In PipesFoliennummer 47Foliennummer 48Mechanical Force - TanksHygiene ManagementWhy Clean and Sanitise at all?Foliennummer 51