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3NAROTS Process Solutions CIP PLANTS 3NAROTS Process Solutions CIP Plants ADDRESS No 63 Jalan Mutiara Emas 5 11 Taman Mount Austin 81100 Johor Bahru Johor Malaysia contact 3narots com Tel 60 149873698 Did not find what you were looking for Please contact 3Narots here we will be delighted to assist you

About 3Narots Process Solutions can now offer a series of CIP plants for the future developed and based on our vast practical experience among our Team and also important cost COMPLEXITY MADE SIMPLE 1 Contents effective 3 4 History 5 6 Introduction 7 8 Sanitizing Step 9 10 Type SIMPLE 11 12 Type STANDARD 13 14 Type SUPERIOR 15 16 Type COMBO 17 18 Type SUPERIOR COMBO 19 20 Type ADVANCED 21 22 Type SUPERIOR ADVANCED 23 24 Type ULTIMATE ZERO 2

About 3Narots Process Solutions can now offer a series of CIP plants for the future developed and based on our vast practical experience among our Team and also important cost COMPLEXITY MADE SIMPLE 1 Contents effective 3 4 History 5 6 Introduction 7 8 Sanitizing Step 9 10 Type SIMPLE 11 12 Type STANDARD 13 14 Type SUPERIOR 15 16 Type COMBO 17 18 Type SUPERIOR COMBO 19 20 Type ADVANCED 21 22 Type SUPERIOR ADVANCED 23 24 Type ULTIMATE ZERO 2

THE HISTORY I do believe that the reason for this lack of development is that these resource reduction measures cost money and are purely driven from an economical point of view not from an environmental protection point of view As incoming water and wastewater discharge pric When I started working in the Dairy Industry in 1973 CIP plants did not exist with basically all es rise these features become more economically viable Furthermore more countries equipment being cleaned by adding chemicals manually to a circuit heat circulating it worldwide are tightening their legislation in regard to the environment discharge so the internally flushing and all was dumped to the drain Timing was also done by the operator production companies are forced to reduce their environmental footprint Basically water and air pollution was controlled this way Solution to Pollution is Dilution The majority of the small Dairies did not have wastewater treatment plants either with a Recently some production companies are making some investments with these types of few sending their wastewater out to farmers for irrigation otherwise it was just led out to a reduction features being incorporated although they are not directly economically viable water stream The First CIP plant I came across in 1975 was in the Dairy College in Denmark but they do have indirect benefits through increased sales marketing as they profile training center this was basically a chemical dosing system into the CIP forward line and themselves as a Green company which is becoming far more recognized by consumers timing was done by a hole card mechanism All liquid was dumped into the drain 3Narots Process Solutions can now offer a series of CIP plants for the future developed Later in the 70 s CIP plant s with return systems started to develop to save water and and based on our vast practical experience among our Team and most importantly being chemicals there was still not much focus on the wastewater but safety was becoming a cost effective We feel it is now the time to introduce a modular series of CIP plants to ac real focus During the 80 s and 90 s CIP plants were developed with water recovery tanks commodate Production Plants and the worlds increasing demand for environmentally and solids recovery tanks meant to be re used in the production however satisfactory re friendly CIP applications with health safety also being paramount sults were rarely achieved Basically attempts to save water energy and reduce Lets Protect the World together wastewater were carried out by the Dairies Engineering Production staff and Consultants with not much development being contributed by the equipment suppliers During my 35 years as a commissioning engineer I have commissioned 50 CIP plants and if you add 3Narots Team s experience we have over 100 successfully commissioned plants both process and automation wise Here in the 2020 s there is far more focus on water resources and wastewater recycling we See that high pollution and less resource demanding CIP plants are being supplied and installed Basically 3Narots Team has not seen any significant development since mid 90 s from the process suppliers in regard to CIP systems As mentioned before most developments are by the production companies and their Consultants HANS ANDERSEN Managing Director 4

THE HISTORY I do believe that the reason for this lack of development is that these resource reduction measures cost money and are purely driven from an economical point of view not from an environmental protection point of view As incoming water and wastewater discharge pric When I started working in the Dairy Industry in 1973 CIP plants did not exist with basically all es rise these features become more economically viable Furthermore more countries equipment being cleaned by adding chemicals manually to a circuit heat circulating it worldwide are tightening their legislation in regard to the environment discharge so the internally flushing and all was dumped to the drain Timing was also done by the operator production companies are forced to reduce their environmental footprint Basically water and air pollution was controlled this way Solution to Pollution is Dilution The majority of the small Dairies did not have wastewater treatment plants either with a Recently some production companies are making some investments with these types of few sending their wastewater out to farmers for irrigation otherwise it was just led out to a reduction features being incorporated although they are not directly economically viable water stream The First CIP plant I came across in 1975 was in the Dairy College in Denmark but they do have indirect benefits through increased sales marketing as they profile training center this was basically a chemical dosing system into the CIP forward line and themselves as a Green company which is becoming far more recognized by consumers timing was done by a hole card mechanism All liquid was dumped into the drain 3Narots Process Solutions can now offer a series of CIP plants for the future developed Later in the 70 s CIP plant s with return systems started to develop to save water and and based on our vast practical experience among our Team and most importantly being chemicals there was still not much focus on the wastewater but safety was becoming a cost effective We feel it is now the time to introduce a modular series of CIP plants to ac real focus During the 80 s and 90 s CIP plants were developed with water recovery tanks commodate Production Plants and the worlds increasing demand for environmentally and solids recovery tanks meant to be re used in the production however satisfactory re friendly CIP applications with health safety also being paramount sults were rarely achieved Basically attempts to save water energy and reduce Lets Protect the World together wastewater were carried out by the Dairies Engineering Production staff and Consultants with not much development being contributed by the equipment suppliers During my 35 years as a commissioning engineer I have commissioned 50 CIP plants and if you add 3Narots Team s experience we have over 100 successfully commissioned plants both process and automation wise Here in the 2020 s there is far more focus on water resources and wastewater recycling we See that high pollution and less resource demanding CIP plants are being supplied and installed Basically 3Narots Team has not seen any significant development since mid 90 s from the process suppliers in regard to CIP systems As mentioned before most developments are by the production companies and their Consultants HANS ANDERSEN Managing Director 4

SOFTWARE We are using a newly developed control software which let us know exactly where each CIP media is in the circuit that in itself can save water and chemicals if installed on an existing plant STUDY INTRODUCTION 3Narots have conducted a case study for a Major SEA Dairy Product Manufacturer Currently they have a CIP plant installed corresponding to 3Narots Type Standard a 4 tank system installed 3Narots have recommended as Phase 1 to upgrade to a 3Narots 5 tank system Type Superior The study was carried out based on information provided by this client to CIP CLEANING IN PLACE CIP Cleaning In Place is an Application used in all Liquid Food Beverage Industries and is found in many variations For the past decade the focus to reduce the water consumption and generate less wastewater has rapidly increased hence the Product manufacturers demands for water wastewater reduction applications is in high demand To accommodate this 3Narots has designed and can supply a series of CIP plants meeting the market demands 5 3Narots The conclusion of this proposed upgrade is shown in below table CIP plant Unit Existing scenario Total volume of water send to drain m3 70 9 Total solids send to drain kg 50 4 Reduction of BOD load from solids Volume of water with chemicals send to drain m3 New scenario Saving per day Saving 21 2 49 7 70 2 4 48 95 95 7 5 5 6 1 9 25 3Narots and this client are currently discussing to what extent the project proceeds to including a further upgrade to type Superior Combo and integrating a market return milk system and expired samples which are major contributors to their wastewater treatment plants BOD loading

SOFTWARE We are using a newly developed control software which let us know exactly where each CIP media is in the circuit that in itself can save water and chemicals if installed on an existing plant STUDY INTRODUCTION 3Narots have conducted a case study for a Major SEA Dairy Product Manufacturer Currently they have a CIP plant installed corresponding to 3Narots Type Standard a 4 tank system installed 3Narots have recommended as Phase 1 to upgrade to a 3Narots 5 tank system Type Superior The study was carried out based on information provided by this client to CIP CLEANING IN PLACE CIP Cleaning In Place is an Application used in all Liquid Food Beverage Industries and is found in many variations For the past decade the focus to reduce the water consumption and generate less wastewater has rapidly increased hence the Product manufacturers demands for water wastewater reduction applications is in high demand To accommodate this 3Narots has designed and can supply a series of CIP plants meeting the market demands 5 3Narots The conclusion of this proposed upgrade is shown in below table CIP plant Unit Existing scenario Total volume of water send to drain m3 70 9 Total solids send to drain kg 50 4 Reduction of BOD load from solids Volume of water with chemicals send to drain m3 New scenario Saving per day Saving 21 2 49 7 70 2 4 48 95 95 7 5 5 6 1 9 25 3Narots and this client are currently discussing to what extent the project proceeds to including a further upgrade to type Superior Combo and integrating a market return milk system and expired samples which are major contributors to their wastewater treatment plants BOD loading

SANITIZING The last step 6 sanitizing is carried out just after step 5 or as an individual step performed short time before the new Product is entering the object The sanitizing step is mainly for objects to ensure that there is no post pasteurization bacteriological contamination prior to filling packaging of the final product send out to the retailers There are 2 commonly used sanitizing methods Circulation of how water approx 10 minutes 80 C a very time and energy consuming method which is also harsh for the materials of the equipment it further requires an additional tank valves instrument and heat exchanger capacity hence CAPEX will increase Injecting sanitizing chemicals into the final rinse step 5 a method which is more and more being abandon because of the risk that the final consumer products can be contaminated with chemical residuals which in cases could be considered a health hazard Further if the sanitizing chemical contains active chlorine which shorten the lifetime of stainless steel 3Narots can supply equipment for both methods on all our CIP plants however we do not recommend it for the reasons mentioned above The acid used in step 4 is either a solution made from HNO3 or H3PO4 or which are both acting as a sterilizing agent due to their high oxygen content and low pH A lot of the chemical supplier deliver chemicals under various brand names with some additional agents in it but for all of them the main components are the 2 acids HNO3 or H3PO4 So technically you have performed a sanitizing in step 4 of the CIP cycle and is now left with the bacteriologically contamination issue from the water used for the final rinse To avoid such contamination it is important that your final rinse water treatment plant in step 5 is strictly controlled all the time and there would still be a risk for contamination INFORMATION CIP SANITIZING STEP A typically CIP cycle consist of the following steps 1 Pre rinse To eliminate that risk for bacteriologic contamination and as an alternative to the 2 sanitizing meth 2 Caustic circulation ods commonly used 3Narots recommend as an additional safety feature to ensure the bacteriologi 3 Intermediate rinse cal quality of the final rinse water to add an Ozone generator constantly injecting small quantity of 4 Acid circulation Ozone into the final rinse water tank and Ozone has the same ability to sanitize using Oxygen re 5 Final rinse leased from the Ozone and the residuals are fast volatile and become harmless To health after a 6 Sanitizing short period 8

SANITIZING The last step 6 sanitizing is carried out just after step 5 or as an individual step performed short time before the new Product is entering the object The sanitizing step is mainly for objects to ensure that there is no post pasteurization bacteriological contamination prior to filling packaging of the final product send out to the retailers There are 2 commonly used sanitizing methods Circulation of how water approx 10 minutes 80 C a very time and energy consuming method which is also harsh for the materials of the equipment it further requires an additional tank valves instrument and heat exchanger capacity hence CAPEX will increase Injecting sanitizing chemicals into the final rinse step 5 a method which is more and more being abandon because of the risk that the final consumer products can be contaminated with chemical residuals which in cases could be considered a health hazard Further if the sanitizing chemical contains active chlorine which shorten the lifetime of stainless steel 3Narots can supply equipment for both methods on all our CIP plants however we do not recommend it for the reasons mentioned above The acid used in step 4 is either a solution made from HNO3 or H3PO4 or which are both acting as a sterilizing agent due to their high oxygen content and low pH A lot of the chemical supplier deliver chemicals under various brand names with some additional agents in it but for all of them the main components are the 2 acids HNO3 or H3PO4 So technically you have performed a sanitizing in step 4 of the CIP cycle and is now left with the bacteriologically contamination issue from the water used for the final rinse To avoid such contamination it is important that your final rinse water treatment plant in step 5 is strictly controlled all the time and there would still be a risk for contamination INFORMATION CIP SANITIZING STEP A typically CIP cycle consist of the following steps 1 Pre rinse To eliminate that risk for bacteriologic contamination and as an alternative to the 2 sanitizing meth 2 Caustic circulation ods commonly used 3Narots recommend as an additional safety feature to ensure the bacteriologi 3 Intermediate rinse cal quality of the final rinse water to add an Ozone generator constantly injecting small quantity of 4 Acid circulation Ozone into the final rinse water tank and Ozone has the same ability to sanitize using Oxygen re 5 Final rinse leased from the Ozone and the residuals are fast volatile and become harmless To health after a 6 Sanitizing short period 8

WE MAKE COMPLEXITY SIMPLE 9 TYPE SIMPLE This is a 3 tank system which was common 30 Years ago It is not commonly used anymore due to its excessive consumption of water generation of wastewater hydraulically BOD load wise This can be supplied with multiple lines 3Narots does recommend it unless your facility is very small and the CIP is rarely used 10

WE MAKE COMPLEXITY SIMPLE 9 TYPE SIMPLE This is a 3 tank system which was common 30 Years ago It is not commonly used anymore due to its excessive consumption of water generation of wastewater hydraulically BOD load wise This can be supplied with multiple lines 3Narots does recommend it unless your facility is very small and the CIP is rarely used 10

WE MAKE COMPLEXITY SIMPLE 11 TYPE STANDARD This is a 4 tank system where a recovery water tank is added It is a commonly used system supplied and installed in hundreds of facilities because the 4th tank reduces the water consumption considerably compared to Type Simple however it does not reduce the hydraulic BOD COD loading of wastewater This can be supplied with multiple lines 3Narots does recommend this either due to its high wastewater hydraulic BOD load 12

WE MAKE COMPLEXITY SIMPLE 11 TYPE STANDARD This is a 4 tank system where a recovery water tank is added It is a commonly used system supplied and installed in hundreds of facilities because the 4th tank reduces the water consumption considerably compared to Type Simple however it does not reduce the hydraulic BOD COD loading of wastewater This can be supplied with multiple lines 3Narots does recommend this either due to its high wastewater hydraulic BOD load 12

This is a 5 tank system which collects water containing product solids In some cases it can also be re used in other products but not recommended WE MAKE COMPLEXITY SIMPLE 13 TYPE SUPERIOR The solids are typically concentrated and processed into animal food The excess water from concentration is cleaned and turned into re use Process water This is highly recommended as it reduces the water consumption and the hydraulic BOD COD load of wastewater Please see case study above on page 2 for further details This can be supplied with multiple lines 3Narots recommends this system as a minimum for all Commercial Production facilities 14

This is a 5 tank system which collects water containing product solids In some cases it can also be re used in other products but not recommended WE MAKE COMPLEXITY SIMPLE 13 TYPE SUPERIOR The solids are typically concentrated and processed into animal food The excess water from concentration is cleaned and turned into re use Process water This is highly recommended as it reduces the water consumption and the hydraulic BOD COD load of wastewater Please see case study above on page 2 for further details This can be supplied with multiple lines 3Narots recommends this system as a minimum for all Commercial Production facilities 14

This is a 6 tank system with 2 NaOH tanks 1 for Raw Product lines and 1 for Pasteurized 15 WE MAKE COMPLEXITY SIMPLE TYPE COMBO Product lines In many facilities 2 or more complete Standard systems are installed to avoid the risk of cross contamination of specific bacterial spores which can survive in the NaOH solution The HNO3 tank remains common because it s high O2 content is a sterilizer itself This system can be supplied with multiple lines 3Narots combines these 2 plants into 1 system hence reducing CAPEX 16

This is a 6 tank system with 2 NaOH tanks 1 for Raw Product lines and 1 for Pasteurized 15 WE MAKE COMPLEXITY SIMPLE TYPE COMBO Product lines In many facilities 2 or more complete Standard systems are installed to avoid the risk of cross contamination of specific bacterial spores which can survive in the NaOH solution The HNO3 tank remains common because it s high O2 content is a sterilizer itself This system can be supplied with multiple lines 3Narots combines these 2 plants into 1 system hence reducing CAPEX 16

TYPE SUPERIOR COMBO NaOH 2 solution circulation 30 minutes Intermediate flush 10 minutes HNO3 solution 1 2 20 minutes This is a 7 tank system with 3 NaOH tanks 1 for Raw Product lines 1 for Pasteurized Product lines and 1 for Dirty lines Dirty lines are units which have a large volume of burned on product deposits remaining after a production cycle with the most common being High Final flush 20 minutes This typical CIP cycle will require Temperature Pasteurizers UHT plants and Evaporators Water 6 700 liters These units are often CIP cleaned by a Stand alone Single Use system which means that NaOH 30 67 kg HNO3 50 24 kg the chemicals used are dumped after each CIP step together with all the 3 steps flush water resulting in high water consumption high hydraulic BOD COD loading of the wastewater A basic calculation demonstrating how much a 10 000 l h UHT plant using a 1 cycle CIP stand alone single use consumes is below 17 Preflush 10 minutes Internal volume 1 000 liters 3Narots collects all the water and chemicals cleans all streams and re uses apart from the separated solids and chemicals solutions which contain burned on products Both separated wastes are concentrated and dispatched as animal food or chemical waste disposal 18

TYPE SUPERIOR COMBO NaOH 2 solution circulation 30 minutes Intermediate flush 10 minutes HNO3 solution 1 2 20 minutes This is a 7 tank system with 3 NaOH tanks 1 for Raw Product lines 1 for Pasteurized Product lines and 1 for Dirty lines Dirty lines are units which have a large volume of burned on product deposits remaining after a production cycle with the most common being High Final flush 20 minutes This typical CIP cycle will require Temperature Pasteurizers UHT plants and Evaporators Water 6 700 liters These units are often CIP cleaned by a Stand alone Single Use system which means that NaOH 30 67 kg HNO3 50 24 kg the chemicals used are dumped after each CIP step together with all the 3 steps flush water resulting in high water consumption high hydraulic BOD COD loading of the wastewater A basic calculation demonstrating how much a 10 000 l h UHT plant using a 1 cycle CIP stand alone single use consumes is below 17 Preflush 10 minutes Internal volume 1 000 liters 3Narots collects all the water and chemicals cleans all streams and re uses apart from the separated solids and chemicals solutions which contain burned on products Both separated wastes are concentrated and dispatched as animal food or chemical waste disposal 18

This is a 8 tank system where 1 tank has been added for collecting diluted NaOH TYPE ADVANCED 19 WE MAKE COMPLEXITY SIMPLE Whenever there is a media change in a CIP cycle there will always be a dilution phase at the beginning and the end of a step which generates a volume of low concentration chemical solution with which there is no room in the chemical solution tank These diluting phases are normally sent to drain with resulting in increased water consumption and hydraulic BOD COD load of wastewater 3Narots collects these diluting phases in a tank concentrates the solution up to normal and sends it back to the chemical solution tank The water from concentration is cleaned and re used as Process water 20

This is a 8 tank system where 1 tank has been added for collecting diluted NaOH TYPE ADVANCED 19 WE MAKE COMPLEXITY SIMPLE Whenever there is a media change in a CIP cycle there will always be a dilution phase at the beginning and the end of a step which generates a volume of low concentration chemical solution with which there is no room in the chemical solution tank These diluting phases are normally sent to drain with resulting in increased water consumption and hydraulic BOD COD load of wastewater 3Narots collects these diluting phases in a tank concentrates the solution up to normal and sends it back to the chemical solution tank The water from concentration is cleaned and re used as Process water 20

This is a 9 tank system where 1 tank has been added for collecting diluted HNO3 TYPE SUPERIOR ADVANCED 21 WE MAKE COMPLEXITY SIMPLE Whenever there is a media change in a CIP cycle there will always be a dilution phase at the beginning and the end of a step which generates a volume of low concentration chemical solution with which there is no room in the chemical solution tank These diluting phases are normally sent to drain with resulting in increased water consumption and hydraulic BOD COD load of wastewater 3Narots collects these diluting phases in a tank concentrates the solution up to normal and sends it back to the chemical solution tank The water from concentration is cleaned and re used as Process water 22

This is a 9 tank system where 1 tank has been added for collecting diluted HNO3 TYPE SUPERIOR ADVANCED 21 WE MAKE COMPLEXITY SIMPLE Whenever there is a media change in a CIP cycle there will always be a dilution phase at the beginning and the end of a step which generates a volume of low concentration chemical solution with which there is no room in the chemical solution tank These diluting phases are normally sent to drain with resulting in increased water consumption and hydraulic BOD COD load of wastewater 3Narots collects these diluting phases in a tank concentrates the solution up to normal and sends it back to the chemical solution tank The water from concentration is cleaned and re used as Process water 22

TYPE ULTIMATE ZERO This is a 10 tank system where 1 tank has been added for collecting emergency wastewater or used as temporary storage for the liquid when you do internally CIP of 1 of the CIP tanks again with the content which have temporary stored in the emergency tank CIP of CIP can also be supplied for other types of CIP plants with or without the temporary storage tank also know as CIP of CIP The emergency tank is further used if there for some reason should be an interruption of the As the name indicates your water consumption and generation of wastewater will become where the CIP media s are and what it is after the reboot almost Zero Normally when you perform CIP of CIP the whole tank content is send to drain resulting in un necessary water and chemicals waste also the hydraulic BOD COD load of wastewater 23 3Narots pump the tank content into the emergency tank perform CIP of CIP and fill the tank is increased control system e g power cut which might result in that the control system cannot see When the CIP cycle is started again all first flush will be diverted to the emergency tank The tank can then be analyzed and Management will determine if necessary to dispatch to an eventual public or own wastewater treatment plant or can be re use as e g recovery water 24

TYPE ULTIMATE ZERO This is a 10 tank system where 1 tank has been added for collecting emergency wastewater or used as temporary storage for the liquid when you do internally CIP of 1 of the CIP tanks again with the content which have temporary stored in the emergency tank CIP of CIP can also be supplied for other types of CIP plants with or without the temporary storage tank also know as CIP of CIP The emergency tank is further used if there for some reason should be an interruption of the As the name indicates your water consumption and generation of wastewater will become where the CIP media s are and what it is after the reboot almost Zero Normally when you perform CIP of CIP the whole tank content is send to drain resulting in un necessary water and chemicals waste also the hydraulic BOD COD load of wastewater 23 3Narots pump the tank content into the emergency tank perform CIP of CIP and fill the tank is increased control system e g power cut which might result in that the control system cannot see When the CIP cycle is started again all first flush will be diverted to the emergency tank The tank can then be analyzed and Management will determine if necessary to dispatch to an eventual public or own wastewater treatment plant or can be re use as e g recovery water 24

3NAROTS Process Solutions CIP PLANTS 3NAROTS Process Solutions CIP Plants ADDRESS No 63 Jalan Mutiara Emas 5 11 Taman Mount Austin 81100 Johor Bahru Johor Malaysia contact 3narots com Tel 60 149873698 Did not find what you were looking for Please contact 3Narots here we will be delighted to assist you