Monitoring & Plant Optimisation Service:a thorough investigation of your systems/operations

Once the system commences monitoring, In-Site personnel can analyse data and compile a detailed report identifying

Which cleans do not comply with the site’s quality spec

we detail non-compliance per item cleaned

Current cost to clean each separate item

detailing average, minimum and maximum costs incurred

Current CO2 emissions of each separate item cleaned

detailing average, minimum and maximum emissions

Effectiveness (or otherwise) of interface detection

during pre-rinse/detergent & detergent/post rinse cycles.

Is circuit properly rinsed prior to addition of biocide?

analyse temperature, conductivity, pH values

What was CIP temperature on completion of program?

does temperature confirm/signify adequate rinsing

Non-operation or poor sequencing of plant items

typically, does sanitiser dosing pump/dosing valve operate in unison, is the circuit being 'dead-ended'.

Amount of time/frequency CIP HOLD/ALARM is triggered

per separate item cleaned, i.e. is an ALARM predictable

and summarise corrective actions needed to optimise plant performance/operations as identified above

Investigation of each clean to ensure that all stages/steps required, actually occur. Establish minimum values achieved, particularly solution flow rate, temperature and conductivity (as detergent concentration), and also report on exceptional values that could impact on effectiveness of subsequent rinse cycles.

Investigation of each clean to establish if costs are consistent or if they can vary significantly, i.e. does a clean to a vessel cost £20 on one day but can cost £40 on another day.

Investigation of each clean to establish if carbon emissions are relatively consistent, clean on clean.

Investigation of the interface between initial pre-rinse and any product residues to establish whether residues are routed to product recovery, waste product tank or drain/effluent system.

Investigation to ensure 'purity' of biocidal solution to ensure chemical wash cycle residues to not neutralise or impact on the sterilant agent.

Is vessel interior/circuit sufficiently cooled to permit release of tank back for product storage.

Analyse sequencing of all plant items. Check that during sanitising stage that the circuit re-circulation valve was energised.

Following a CIP 'service' routine, is the immediate circuit rinsed of all detergent residues before onset of subsequent cleaning programs.

Is production time being lost due to extended/delayed cleaning due to alarms occurring and also delay in 'accepting' alarms.

Analysis of each step/stage duration and if significant variances occur in the completion of each program, why such delays are occurring.

If a clean terminates in a much shorter time than usual, if not due to clean being aborted, is it due to interference, i.e. rinse times shortened to 'speed-up' CIP system.

Does the In-Site 'log' evidence that objects or circuits which have been cleaned and have not been classified as PASS or CAUTION are subsequently re-cleaned; (or a notation has been entered into the relevant Verification Report).

Analysis of all circuits to ensure that having achieved the required detergent concentration, say 1.0% NaOH, the tank/pipe line is then washed at this detergent strength for the minimum period stipulated by the site's quality standards.

This analysis also encompasses achievement of temperature and solution flow rate (litres/minute).

Investigation to ensure that spent rinse water is routed to drain (or rinse recovery tank); detergent solutions are correctly routed back into reservoir tanks and not diverted into recovered rinse tank or routed to drain/effluent.

Is the process operating system continually 'alarming', delaying completion of the program and preventing tanks/pipe lines being returned to production.

Is the hot detergent wash solution achieving too high a temperature. Could the energy supply valve be turned off sooner; typically this applies to hot wash circuits that are rinsed with cold water, In-Site details the time it takes for the latent heat in the circuit to be dissipated by subsequent cold rinsing.

Having a background of food hygiene, In-Site will only make recommendations to reduce the usage of utilities provided such reductions pose no threat to the 'quality of the clean'.

Quality comes first.

Any changes to the program software to deliver projected savings will immediately be evidenced by In-Site in subsequent cost reports.