BREWING _ BEVERAGES

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BREWING & BEVERAGES
The brewing & beverage industries poses its own set of unique cleaning issues which are formed by the variety of tanks, vessels and pipe work associated with all the different types of production. Perhaps one of the most challenging aspects can be the sheer scale of some of the large storage and fermentation tanks to be cleaned. These need to be cleaned with the minimum amounts of water and chemical leading to minimum effluent production and associated costs, yet still maintaining a hygienic permanently installed CIP system.

Barrel Cleaning & Cask Washing
Barrel cleaning and Cask Washing is traditionally carried out with either automated high pressure systems or with semi automated low pressure systems. In some areas manual high pressure systems are also used. The construction of the barrel or cask and the product it has contained will determine the types of systems that can be used and then the scale of the operation and costs usually define the exact use. In either automated or manual systems, it is important to select the correct cleaning head. Flow rate and drainage of the cask or barrel are very important to get right, as well as impingement requirements for the strength of cleaning required. Ideal tank washers for use in these CIP applications are the CASK WASHER, TURBO DISC & SANITOR.

Bottling/Filling lines
The brewing and beverage industries process systems culminate in the product being packaged into consumer level finished goods or bulk products for onwards shipping to third party bottlers, bulk end users or other such distributors. Therefore there will always be a bottling/filling/packaging or transportation stage to the process. This might involve automatic filling/bottling/canning lines, barrel or tanker filling stations or a manual filling stage. All these stages need to have a cleaning cycle. All too often manufacturers of bottling/canning/filling lines either, don’t install any cleaning system, and rely on the clients manual cleaning or they install simple static spray balls or rotating sprayballs for cost reasons. Sometimes they can use large numbers of fixed nozzles which require high volumes of water. This can lead to lengthy cleaning cycles due to flow rate restrictions and can cause costly shut down periods while the CIP cleaning in place cycle is running. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability. Ideal tank washers for use in these CIP applications are the TURBO DISC, TORUS, CLIP DISC, CHEMI DISC, TURBO SSB & SANITOR

Bright Beer Tanks (BBT’s)
Bright beer tanks or BBT’s are usually horizontal, but in some application they can be vertical. They are usually smaller than the fermenters in the same plant. As the beer contained is not undergoing any significant fermentation, they are usually easier to clean than fermenters. However, the horizontal vessels also pose their own challenge. In older installations, ground movement may have made the position that the tanks sit in change. This might have led to the drainage valve on the tank no longer being the lowest point in the tank and therefore pooling can occur in the bottom of the tank. Additionally the corners of these vessels can be particularly difficult to clean with fixed spray balls or rotating sprayballs. Jetting tank washers such as the Typhoon, Tempest or Fury are particularly good for these CIP cleaning in place applications. Variations on jetting units such as the Zonemiser can also give sweeping actions on the base of these tanks for improved sedimentation/foam cleaning when the tanks are no longer in their correct position. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability.

Ideal tank washers for use in these CIP applications are the TYPHOON, TEMPEST, FURY, JUMBO 6, or TURBO DISC 150 The concept of wash validation is now also very important in the brewing industry, and therefore a range of validation systems are available to suit individual tank washers. See the VERI-CLEAN M & VERI-CLEAN A product details for more information.

Coppers
The high temperatures used inside coppers, lead to baked on residues. These residues require powerful jet cleaning to fully remove the potential contamination. Any tank washer fitted inside a copper must be able to withstand high ambient temperatures, and provide high power jets. Quicker cleaning and the ability to clean at high temperatures ensures the coppers do not have to cool completely down and therefore can lead to quicker turn around times. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability. Ideal tank washers for use in these CIP applications are the TYPHOON, TEMPEST, FURY, and JUMBO 6

Ducting / Pipe Work
Ducting and pipe work can pose very specific problems for the brewing and beverage industry as it comprises a large part of the CIP cleaning in place needs. Often the diameter of the pipes coupled with long and complex pipe runs can generate significant cleaning challenges. Frequently these pipes are flood filled using large amounts of liquid. One solution to reduce the amount of cleaning fluid used is to use retracting devices such as the MR1 or MR2. During the normal process operation they seal flush with the pipe or duct wall. When the CIP system is turned on these units extend into the pipe and clean the pipe. These devices come in a range of sizes, cleaning head configurations and connections to fit many process pipes and ducts. They can also be configured to keep continual over pressure air seals on the units or configured to work in vacuums. Another solution is to use ultra hygienic permanently installed cleaning devices like the TORUS inside the pipe. These units are small and require low volumes and pressures of CIP fluid to operate. However in operation they can generate a very turbulent flow inside a pipe aiding the chemical cleaning effect. Ideal tank washers for use in these CIP applications are the MR1, MR2, TURBO DISC, TORUS and CHEMI DISC. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability.

Fermenters
In the brewing industry, fermenters can range from large 20 meter tall 8 meter wide giants to small micro fermenters in specialist micro breweries. They all have very similar CIP cleaning in place issues. As the brew ferments, the yeast head leaves deposits at the tan line of vessel which can be hard to remove. There can also be significant amounts of sedimentation during the brewing process. Additionally upon emptying the vessel this yeast head can be spread around the tank and coupled with sedimentation in the bottom of the tank and in sample ports, this can lead to potential contamination issues. Various philosophies exist as to which is the best method of cleaning such a tank. Generally this can be split into two main concepts – Jetting tank washers creating high degrees of impingement all over the surface of the tank, or large amounts of cleaning fluid sprayed into the top of the vessel via a fixed spray ball or a rotating spray ball creating a turbulent flow down the walls of the tank. The later solution can also be achieved with a high volume jetting tank washer, combining both high impingement at the tan line with high volume turbulent flow down the walls of the tank. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability.

Ideal tank washers for use in these CIP applications are the TYPHOON, TEMPEST, FURY, and JUMBO 6. The concept of wash validation is now also very important in the brewing industry, and therefore a range of validation systems are available to suit individual tank washers. See the VERI-CLEAN M & VERI-CLEAN A product details for more information.

Maltings
Maltings can be very difficult parts of the process system to clean. Their large scale and complexity at the bottom end of the maltings can lead to significant cleaning installations. In trying to overcome some of the associated costs, the maltings should be considered in two stages. The large grain silo at the upper part should be considered as one stage, and the mesh grid and mechanical equipment at the bottom end as the other stage. With the silo stage, this is reasonably easy to clean with a large jetting tank washer such as a TEMPEST or FURY 600 suspended on a hose which can be lowered down or raised up the length of the silo. The gives a quick, powerful clean and has some secondary effect on cleaning the bottom end stage of the maltings. The bottom end can be cleaned (depending on the setup) with a jetting tank washer on a tripod or trolley which can be moved around to ensure all areas are cleaned. Alternatively if costs allow, various tank washers can be added to moving equipment that rotates under the mesh. No single solution will suit all applications. Ideal tank washers for use in these CIP applications are the TYPHOON, TEMPEST, FURY, JUMBO 6, or TURBO DISC 150

Mash Tuns
Mash Tuns are often cleaned at low temperatures and the residue to be cleaned is often thick and viscous. For efficient and effective CIP cleaning in place, a jetting tank washer is required. Use of spray balls or rotating sprayballs can lead to lengthy cleaning times and large quantities of water being used. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability. Ideal tank washers for use in these CIP applications are the TYPHOON, TEMPEST, FURY, and JUMBO 6

Maturation Vessels
Often large in size these vessels require varying degrees of cleaning depending on the product inside. Often they can be cleaned in place by a large spray ball or equivalent product. However, the use of a jetting tank washer will speed up the cleaning time and aid turn around times. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability. Ideal tank washers for use in these CIP applications are the TYPHOON, TEMPEST, FURY, JUMBO 6 or TURBO DISC 150

Process Vessels
The brewing and beverage industry contains various stages in the brewing process. During these stages a variety of individual tanks, vessels, vats and hoppers are used. These tanks hold various products at all stages of the production process from raw materials to finished product. The product contained can be easily soluble in water or simply a water storage tank, or it can be very viscous or very sticky. Cleaning these will depend very much on the product contained. All too often they are fitted by the manufacturer with a fixed spray ball or a rotating sprayball for cost reasons. For some CIP cleaning in place applications this is satisfactory, but for many applications, they are incorrect and do not achieve a cost effective CIP cleaning in place solution. The correct tank washer and CIP cycle should be chosen by first looking at the product inside the tank and its physical cleaning requirements. The Ideal tank washers for use in these CIP applications will vary depending on the product stored. See the technical resource section of this web site or contact your local distributor for assistance in choosing the

right solution for your tank washer application. For generic spray ball replacement, a good place to start is with the TURBO DISCS. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability.

Yeast Tanks
Yeast tanks are generally not large in size, but they generally require more powerful cleaning as the yeast residue can be particularly sticky. Fixed spray balls or rotating sprayballs are often not powerful enough and can lead to long CIP cleaning in place times or insufficient cleaning. Yeast crossover is very important to prevent from batch to batch, and therefore CIP of yeast vessels can be a particularly critical part of the cleaning process. A small jetting tank washer such as the PRIMA or a tank washer that creates a high degree of droplet impingement such as a TURBO DISC can be an ideal cost effective solution for this CIP application. Optimized CIP cycles and efficient use of water with high tech tank washers can lead to greatly reduced down times, increased plant efficiency and increased profitability.


				
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posted:11/9/2009
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