REDUCING SODIUM HYDROXIDE IN PROCESS CLEANING UMASS LOWELL - TURI Learning with Purpose OUTLINE REDUCING SODIUM HYDROXIDE IN PROCESS CLEANING • BkBackgroun d • Method • Preliminary results • Potential recommendations • Next Steps • Acknowledgements Learning with Purpose BACKGROUND • Sodium hydroxide (NaOH) is widely used in combination with hydrogen peroxide (H2O2) as an effective FCS cleaner. • NaOH (Caustic Soda) is classified as toxic chemical by Toxic Use Reduction Act (TURA). • When used in large quantity it pose significant chemical hazards to the processed food, employees and the environment Learning with Purpose OBJECTIVES • 1. EtblihEstablish a miiinimum concent rati on of NOHNaOH/H/ H2O2 for cleaning-in-place (CIP) at Kettle Cuisine (KC). • 2. Identify and test green alternatives of caustic soda for CIP processes. • 3. Reduce down-time, energy and labor cost for CIP processes. Learning with Purpose METHOD Scaling and weight: place stainless steel (SS)316 coupons in Mac & Cheese, heat at 180°F for 3 hours. Cleaning with NaOH/ H2O2 and weight: different concentration and temperature. Physical scrubbing with diluted phosphoric acid. QC ‐ ATP measurement Learning with Purpose MEASUREMENT • Dry weight changes among different steps • QC – ATP test – ATP, the energy molecule found in all living things, making it a perfect indicator to determine if a surface is clean or not. – To ensure no product contamination or biofilm development presents on SS surface. – The amount of ATP present in the sample , providing information on the level of contamination. Learning with Purpose PRELIMINARY RESULTS Table 1. Alternative experiments associated with concentration of NaOH/H2O2 and descaling temperature. 100% = simulated KC’s application (250 gallons of H2O, 8 lbs of HCL‐5000, 2 lbs of H2O2). Size of coupon: 1.5 inch x 1.5 inch. Conc. Of NaOH/H2O2 Temperature 100% 75% 50% 82°C √√√ 75°C √ 65°C √ Learning with Purpose PRELIMINARY RESULTS – DOSE DE‐SCALE RATIO ATP TTESTEST 14 103 ‐‐ 82°C ‐‐82°C 102 12 tio 101 U) a a L L 10 R 100 (R 99 8 98 values 6 Removal 97 ATP due 96 4 ii 95 Res 2 94 93 0 100% 75% 50% 100% 75% 50% Concentration of NaOH/H2O2 Concentration of NaOH/H2O2 (A) (B) Figure 1. (A) Weight removal test and (B) ATP test of SS316 coupons under 82 °C cleaning temperature. RLU: relative light unit. 0‐10 RLU: good; 11‐30 RLU: caution; over 30 RLU: failure. Learning with Purpose PRELIMINARY RESULTS - TEMPERATURE ATP TEST ‐‐ 75% NaOH/H2O2 14 12 10 (RLU) 8 lues 6 va ATP 4 2 0 82°C 75°C 65°C Concentration of NaOH/H2O2 Learning with Purpose RESULTS • Clean ing e ffec t o f 75% N aOH/H 2O2 with 82 °C75C, 75 °C, and 65 °C is able to pass ATP test. • Cleaning effect of 50% NaOH/H2O2 with 82 °C is able to ppgass ATP test, but its ATP values are higher than that of 75% NaOH/H2O2 . Learning with Purpose POTENTIAL RECOMMENDATIONS • In 2015 44,662 lbs of sodium hydroxide was used in the clileaning process. • It was anticipated that by 2017 taking production growth into account , an additional 9 ,379 pounds per year would be used. • Results show using 75% NaOH, considered as the new dosing concentration, about 15% (3.5 Tons) can be reduce annually while achieving same ATP results as 100%. • Reduce CIP temperature to 65oC = savings on energy bill! Learning with Purpose NEXT STEPS • Continuing to evaluate the concentration of NaOH/H2O2 (50%) w ith t emperat ure 82 °Cd50C and 50°C. • Screening alternatives will investigate the following: Phix XIV Chlorine Materials Hydrogen peroxide Ozone Peracetic acid/peroxyacetic acid Phosphoric acid Potassium hydroxide Learning with Purpose • TiToxics U se RdiReduction I nsti tute ACKNOWLEDGEMENTS • Kettle Cuisine; Alan • Xiaobo Liu, Manyun Yang, DiDuniya KjKajang Learning with Purpose.