Part One Chemistry and Problems of Industrial Water
1 Chemistry of Aqueous Solutions
1.1 Variables
1.1.1 Water
1.1.1 Hardness
1.1.1.2 Salinity
1.1.1.3 Alkalinity
1.1.1.4 pH
1.1.1.5 Conductivity
1.1.1.6 Scaling Tendency or Corrosion Tendency
1.1.2 Salts
1.1.2.1 Precipitation
1.1.2.2 Sequestration
1.1.2.3 Flocculation
1.1.2.4 Dispersion
1.1.2.5 Suspension
1.1.2.6 Anti-redeposition
Part One Chemistry and Problems of Industrial Water
1 Chemistry of Aqueous Solutions
1.1 Variables
1.1.1 Water
1.1.1 Hardness
1.1.1.2 Salinity
1.1.1.3 Alkalinity
1.1.1.4 pH
1.1.1.5 Conductivity
1.1.1.6 Scaling Tendency or Corrosion Tendency
1.1.2 Salts
1.1.2.1 Precipitation
1.1.2.2 Sequestration
1.1.2.3 Flocculation
1.1.2.4 Dispersion
1.1.2.5 Suspension
1.1.2.6 Anti-redeposition
1.1.3 Stability Constant
1.1.3.1 Theoretical Meaning
1.1.3.2 Practical Meaning
1.1.4 Critical pH
1.4.1 Effect on Bicarbonates
1.1.4.2 Effect on Phosphates
1.1.4.3 Effect on Sequestrants
1.2 Inorganic Competitors
1.2.1 Bicarbonates
1.2.1.1 Chemical Mechanism
1.2.1.2 Physical Mechanism
1.2.2 Silicates
1.2.3 Sulfates
1.2.4 Aluminates
1.2.5 Phosphates
1.3 Organic Competitors
1.3.1 Proteins
1.3.2 Starches
1.3.3 Fatty Acids
1.3.4 Other Carboxylic Compounds
1.3.5 Humic Substances
1.4 Self-Protected Contamination
1.5 Modifiers Affecting Deposits
1.5.1 Heating
1.5.1.1 Caramelization
1.5.1.2 Carbonization
1.5.2 Dehydration
1.5.3 Polymerization
2 Chemical-Physical Treatment
2.1 Softening
2.2 Deionization
2.3 Dealkalinization
2.4 Reverse Osmosis
3 Sequestrants
3.1 Definition
3.2 Coordination Groups
3.3 Sequestration Data
3.4 Food Cleaning Sequestrants
3.4.1 (Poly)phosphates
3.4.1.1 Hexametaphosphate (HEMP)
3.4.1.2 Pyrophosphate
3.4.1.3 Monomeric Phosphates
3.4.1.4 Tripolyphosphate
3.4.2 Phosphonates
3.4.2.1 Phosphonates and pH
3.4.2.2 Stability of Phosphonates
3.4.2.3 Phosphonates and Corrosion Inhibition
3.4.3 Hydroxy Acids
3.4.4 Poly(co-poly)acrylates
3.4.5 Aminopolycarboxylic Acids
3.4.6 Polysaccharides and Bentonites
Part Two Characterization of Chemicals Used in the Sanitation Process
4 Laboratory Tests
4.1 Turbidimetric Tests
4.1.1 Sequestration Test (Oxalate)
4.1.2 Nephelometric Titration
4.1.3 Sequestration Test (Hampshire)
4.2 Suspension Test
4.3 Dispersion Test
4.4 Static Test of Scale Forming
4.5 Dynamic Test of Scale Formation
4.6 Static Test of Scale/Soil Dissolution
4.7 Dynamic Test of the Dissolution of Scale/Soil
4.8 Chemical Stability Test
4.9 Solution Stability
4.10 Sequestrant Stability
4.11 EDTA and Calcium Titration
4.11.1 Titration of EDTA
4.11.2 Titration of Calcium Salts
5 Surfactants, Caustics, and Acids
5.1 Surfactants
5.1.1 HLB
5.1.2 Grouping of Surfactants
5.1.2.1 Anionic Surfactants
5.1.2.2 Nonionic Surfactants
5.1.2.3 Cationic Surfactants
5.1.2.4 Amphoteric Surfactants
5.1.3 Defoamers
5.1.4 Wetting Agents
5.1.5 Cleaning Agents
5.1.6 Disinfectants
5.1.7 Structural Boosters
5.1.8 Biodegradability and Toxicity
5.1.9 BPD and REACh
5.2 Caustics
5.3 Acids
Part Three Application to the Food Industry
6 Bottlewashing
6.1 Pre-washing
6.2 Caustic Zone
6.2.1 Modifications Induced by Alkalinity
6.2.2 Label Removal
6.2.3 Self-Adhesive Labels
6.2.4 Ceramic Labels
6.2.5 Mold Removal
6.2.6 Plastic Bottles
6.2.6.1 Procedure for Testing for Stress Cracking due to Cleaning Solutions
6.2.6.2 Procedure for Testing for Haze Suppression
6.2.6.3 Procedure for Screening Defoamer Rinsability
6.2.7 Exhausted Solution
6.2.8 Sequestrants in Washing
6.2.8.1 Polyphosphates and Phosphates
6.2.8.2 Gluconate and Gluconic Acid
6.2.8.3 Phosphonates
6.2.8.4 Phosphono-Carboxylate Polymers
6.2.8.5 Acrylic Polymers
6.2.8.6 EDTA and NTA
6.2.8.7 Polysaccharides and Bentonites
6.3 Rinse Section
6.3.1 Rinse Design and Chemicals Application
6.3.1.1 Second Rinse
6.3.2 Sequestrants of Rinse
6.3.3 Inlet Position
6.4 Environmental Impact from Labels
6.5 Outcoming Bottles
6.5.1 Non-homogeneous Coating of Water on the Bottles
6.5.2 Bottles React with Phenolphthalein
6.5.3 Bottles Dry Leaving Whitish Streaks or Foggy Glass
6.5.4 Homogeneous White Scale Covers Bottles
6.5.5 External Non-homogeneous Deposit on the Bottle
6.5.6 Bottles Contain Residues
6.5.7 Bottles Drain Leaving More than 2 Drops of Water
6.5.8 Bottles Sparkling when Just Filled
6.5.9 Just-Filled Bottles Contain Micro-Bodies (or Some Time After Filling)
6.6 Microbiological Condition of a Bottlewasher
6.7 What Can or Cannot Be Cleaned
6.7.1 Removable Organic Soils
6.7.2 Inorganic Soil Removable with Acids
6.8 Concepts of Problem Solving in Cleaning Bottles
6.8.1 Glass Bottles
6.8.2 Plastic Bottles (PET, PEN)
6.8.3 Plastic Bottles (PC-HOD)
6.9 Cold Aseptic Filling (CAF) 238
6.9.1 CAF Technology
6.9.2 Microbiological Sensitiveness
6.9.3 Cleaning Programs
7 Lubrication
7.1 Theory of Lubrication
7.1.1 Friction
7.1.2 Lubricity
7.1.3 Variables of Lubrication
7.1.3.1 Quantity of Solution on the Track
7.1.3.2 Quantity of Lubricant on the Track
7.1.3.3 Speed of the Track
7.1.3.4 Temperature of the Track
7.1.3.5 Friction and Micro-friction
7.1.3.6 Dry Tracks
7.1.3.7 Bottles, Cans, and Composite Containers (Cartons)
7.1.3.8 Type of Beverage
7.2 Soap-based Lubrication
7.2.1 Buffering Power and Alkalinity Donors
7.2.2 Types of Fatty Acids and their Concentration
7.2.3 Sequestrants
7.2.4 Keeping Tracks Clean
7.2.5 Fluidifying and Antigelling
7.2.6 Foam Control
7.3 Amine-Based Lubricants
7.3.1 Types of Lubricating Molecules
7.3.2 Anionic Interference
7.3.3 Sequestrants
7.3.3.1 Glycine
7.3.3.2 Lauryldimethylamine [CH3 (lauryl) CH2-N(CH3)2] (LDMA)
7.3.3.3 Fatty Alcohol Ethoxy Carboxylate (FAEC)
7.3.4 Cleaning and Microbial Control
7.3.5 Biofouling in the Delivery Plant
7.3.6 Chlorine Dioxide in Preventing Biofouling
7.3.7 Foam Control
7.4 Imidazoline-Based Lubrication
7.5 Lubrication Based on Fatty Quaternary Ammonium Compounds (FQACs)
7.6 Silicone-Based Lubricant
7.7 Dry Lubrication
7.8 Stress Cracking
7.9 Concepts of Problem Solving in Lubrication
8 CIP (Cleaning in Place)
8.1 CIP Classification
8.1.1 Total Loss CIP
8.1.2 Partial Recovery CIP
8.1.3 Total Recovery CIP
8.2 CIP Parameters
8.2.1 Flow Velocity
8.2.2 Flow Rate
8.2.3 Temperature
8.3 Dairy
8.3.1 Treatment with Heat Exchange
8.3.1.1 Conversion of Stainless Steel Oxides
8.3.2 Raw Milk Line
8.3.3 Separator
8.3.4 Churning
8.3.5 Curdmaking Process
8.4 Processed Food
8.4.1 Evaporator
8.4.2 Dough-Kneading Machine and Extruder
8.4.3 Pasteurizer and Sterilizer
8.4.4 Cooking, Baking, and Frying
8.4.5 Smoke Chambers
8.4.6 Blanching
8.4.7 High-Temperature Scraped Sterilizer
8.4.8 Fresh Cut Produce (4th Gamme)
8.4.8.1 Cleaning and Disinfection Procedures
8.4.9 Mechanical Cleaning of Equipment
8.5 Winery
8.5.1 Cleaning in the Cellar
8.5.2 Stabilization of Wine
8.5.3 Cleaning and Disinfection of Wooden Barrels
8.5.3.1 Disinfection of Wood
8.6 Enzymatic Cleaning in Food Detergency
8.6.1 Protease
8.6.2 Lipase
8.6.3 Amylase
8.7 Chemicals for Cleaning Tenacious Contamination
9 Acidic Cleaning
9.1 Infinite Dilution
9.2 Sequestrants
9.3 Cleaning of Molds
9.4 Cleaning of Chocolate Molds
9.5 Acidic Cleaning in a Brewery
9.5.1 Acids
9.5.2 Sequestrants
9.5.3 Surfactants
10 Open Aqueous Systems Exchanging Heat
10.1 Tunnel Pasteurizers
10.1.1 Deposition and Scale
10.1.2 Microbiology
10.1.3 Corrosion
10.1.4 Dome Staining
10.1.5 Chemical Treatments
10.1.5.1 Scale and Biofouling
10.1.5.2 Corrosion
10.1.5.3 Packaging Damage
10.2 Cooling Tower
11 Foam and Gel Cleaning
11.1 Foam
11.2 Gel
11.3 Foam-Gel Synergism
11.4 Body Structure
11.5 Sequestrants
11.6 Foam/Gel Free OPC
11.7 Practical Problem Solving in 0PC
11.7.1 Bluish Stains
11.7.2 Yellowish-White Stain
11.7.3 Fat Removal in Patches
11.8 Equipment for Pressure Washing
11.8.1 Centralized Equipment
11.8.2 Decentralized Equipment
11.8.3 Loss in Pressure
11.8.4 Loss in Temperature
11.8.5 Generation of Aerosol
12 Membrane Cleaning (Crossflow Filtration)
12.1 Membrane
12.2 Module
12.2.1 Plate and Frame
12.2.2 Hollow Fibers
12.2.3 Tubular
12.2.4 Spiral Wound (SW)
12.2.5 Pleated
12.2.6 Modules
12.3 Diafiltration and Chromatography
12.4 Electrodialysis
12.5 Ultrasound Applied to Membrane Processings
12.6 Fields of Application
12.7 Cleaning
12.7.1 Alkalinity
12.7.2 Sequestrants
12.7.3 Surfactants
12.7.4 Enzymatic Systems
12.7.5 Acids
12.8 Cleaning Procedures
13 Milk Production
13.1 Mastitis
13.2 Cow and Milk
13.3 Milking CIP
13.4 Bulk Milk Tanks
13.5 Raw Milk Quality Standards
14 Biofilm
14.1 Microbiological Background
14.2 Formation and Growth of Biofilm
14.2.1 Surface Condition
14.2.2 Environmental Conditions
14.3 Practical Significance
14.4 Cleaning and Disinfection
14.4.1 Alkaline Cleaning
14.4.2 Acidic Cleaning
14.4.3 Disinfection
15 Environmental Sanitation
15.1 Environmental Particles
15.2 Physical Control
15.2.1 Air Filtration and Clean Rooms
15.2.2 Ultraviolet Radiation
15.3 Control by Chemicals
15.3.1 Atomization and Aerosolization
15.3.2 Chemicals
15.3.2.1 Aldehydes
15.3.2.2 Nitrogen Derivatives
15.4 Mold Control and Prevention
16 Ultrasound Cleaning
17 Corrosion and Corrosion Inhibition
17.1 Calculation and Monitoring of Corrosion
17.1.1 Intensity and Rate
17.1.2 Electrochemistry
17.2 Stainless Steel and Chloride
17.3 Chromium and Chemicals
17.4 Aluminium and Causticsj Acids
17.5 5 Copper and its Alloys
17.6 Zinc (Galvanized Steel)
17.7 Biofilms
17.8 Reliability of Supply
17.9 Post-Installation Treatment of Stainless Steel
17.9.1 Procedures and Recommendations
17.9.2 Example of Complete Program
17.9.3 Example of Simplified Program
17.9.4 Gaskets
18 Disinfectants and Sanitation Technology
18.1 Water
18.2 Manufacturing Environment and Types of Microorganisms
18.3 Disinfectants
18.3.1 Main Disinfectants for the Food Industry
18.3.2 Biocides from the Haber-Willstatter Reaction
18.3.3 How to Choose a Disinfectant
18.3.3.1 Basic Behavior Typifying the Application of Disinfectants
18.4 Physical Disinfection
18.4.1 Disinfection by Heating
18.4.2 Disinfection by UV Radiation
18.4.3 Disinfection by Filtration
18.4.4 Disinfection by Electrolyzed Water
18.4.5 Disinfection by Cold Plasma
18.4.6 Disinfection by High Pressure
18.4.7 Disinfection by Pulsed Electric Field
18.5 Regularity and Perseverance in Sanitation
18.6 Sanitation Plan
18.6.1 Early Stage
18.6.2 Planning
18.6.3 Validation
18.6.4 Application
18.6.4.1 Assessment of the Sanitation Result
18.7 Rapid Controls of Sanitation
18.7.1 Bioluminometer
18.7.2 Proteins Test
18.8 European (EN) Microbiological Tests
18.8.1 Bactericidal Activity
18.8.1.1 EN 1040
18.8.1.2 EN 1276
18.8.1.3 EN 1656
18.8.1.4 EN 13727
18.8.2 Fungicidal Activity
18.8.2.1 EN 1275
18.8.2.2 EN 1650
18.8.2.3 EN 1657
18.8.2.4 EN 13624
18.8.3 Sporicidal Activity
18.8.3.1 EN 14347
18.8.3.2 EN 13704
18.8.4 Main Tests Methodology
18.8.4.1 NF EN 1276 Procedure
18.8.4.2 NF EN 1650 Procedure
18.8.4.3 NF EN 13697 Procedure
18.8.4.4 NF EN 13704 Procedure
18.9 Hand Washing and Disinfection
18.9.1 Handwashing Products Structure
18.9.2 Handwashing Disinfectants
18.9.2.1 Products Performing Cleaning and Disinfection
18.9.2.2 Products for Terminal Disinfection after Washing
19 Waste Water Treatment
19.1 Understanding Terms
19.2 Purification Process
19.2.1 Preliminary Treatments
19.2.2 Chemical Treatment
19.2.3 Settling, Concentration, and Dewatering
19.2.4 Biological Treatment
19.2.5 Final Treatments
20 Boiler Treatment
20.1 Deaeration and the Generation of Noncorrosive Steam
20.1.1 Generation of Noncorrosive Steam
20.2 Scale Prevention
20.3 Chemical Treatments
20.4 Chemical Cleaning
21 Due Diligence (HACCP)
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