Optimization Of CIP Process For Ozone Sanitization Retrofit

Paper Title: Optimization Of CIP Process For Ozone Sanitization Retrofit

Source: International Ozone Association-Pan American Group 2008 Annual Conference August 24-27, 2008 Orlando, FL 2008 International Ozone Association




Optimization Of CIP Process For Ozone Sanitization Retrofit
The inclusion of ozone sanitization in Clean-In-Place (CIP) processes promises multiple benefits to the food processing and beverage industries. Chief among these is the reduction in plant down time during the CIP procedure, a benefit which goes directly to the bottom line as increased plant production. Over the years, numerous white papers have lauded the inclusion of ozone sanitization in the CIP process. These case histories credit ozone sanitization with a rapid reduction in bio-film and demonstrate a significant return on the investment made in the ozone system; yet today only a handful of plants include ozone a part of their CIP procedure. The lack of growth in ozone CIP sanitization suggests that integrating ozone into a CIP process requires a level of knowledge and commitment beyond that required for other ozone applications. This paper examines the intricacies of optimizing a beverage CIP system in preparation for retrofit with an ozone sanitization system; illustrating how the benefits of ozone sanitization are highly dependent on the skill at which the ozone system is integrated into the existing CIP process.

Problem / Background

The rapid growth of the bottled water industry has led to the need for non-chemical water sanitization in the Clean-In-Place (CIP) process. Ozone unlike chemicals does not leave a chemical aftertaste after sanitation. In November 1982 the FDA approved the use of Ozone for the sanitization of bottled water. Despite the growth of ozone for achieving Clean-In-Place (CIP) process, chemical sanitization still is more commonly used in Industries requiring CIP.

Diagram: Optimization Of CIP Process For Ozone Sanitization Retrofit

Testing / Method

A pilot study was performed by Laboratories Sanox SA de CV, a chemical company specializing in CIP systems. A bottling plant in Merida, Mexico using hot caustic (sodium hydroxide) as a CIP detergent tested ozone as an alternative sanitizer. A ozone generator distributing 30 grams per hour, Air Sep oxygen concentrator, Process ozone transfer skid were the equipment used. A Carbo Cooler at the bottling plant set the rinse water at 14 degree Celsius to reduce the ozone decay rate.

Optimization Of CIP Process For Ozone Sanitization Retrofit

Conclusion / Results

The plants microbiological target levels for bacteria, fungi, and yeast were met in the study, most samples showing 0 microbes after the ozonated wash for up to 120 hours. In addition to being an effective sanitizer, ozone proved to improve the efficiency and reduced the operating costs of the bottling plant. The use of hot detergent or hot water CIP process requires the plant to wait 36 minutes after cleaning to allow the hot water tanks to reach an acceptable temperature, while ozonated water is distributed at room temperature. At an average of 5 CIP cycles are performed each day, the ozone CIP process saves over 180 minutes of bottling production time a day. There were significant cost savings in reduced fuel costs due to the plant not having to heat more than 7,500 gallons per day.