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Case Study 1: Cleaning Analysis of Dairy Plants

An analysis of cleaning procedures and results was conducted at Ambala Dairy Processing Plant in Haryana. Two processing lines were tested before, during and after a trial of a simplified cleaning process using products from SVS and GEA

ATP Luminometry

Hygiena ATP Meters are regularly employed in the food and dairy industries to test for the presence of a protein (Adenosine TriPhosphate) that exists wherever there is bacteria present. All living things use ATP for metabolism and movement. 

The meter uses a unique method of reactivity, illumination, and analysis of the light-waves produced by ATP. A clean surfaces will have little to no ATP present, a dirty surface may read very high amounts of ATP. 

As the above chart shows, the desired range is between 0-10 Lumens, 11-30 indicates some improvements needed, a score of over 31 indicates a clear cleaning process failure. 

In this case of this line, the "Before Trial" ATP Test showed a score that was 30-40 TIMES higher than what would be desired by an inspector. 

Process Changes were Made...

The current protocol in place included a 7-Step Process, cleaning with a 1.5% Caustic Cleaning Solution, followed by a rinse with a 1.5% Nitric Acid Solution - with multiple clear water rinses in between. 

The new protocol will be reducing the required steps to just 4 and reducing the necessary strength of solution by 33-60%.  

The Results

The Hygiena ATP Meter was employed to test the surfaces being cleaned after each phase of the cleaning: After the caustic detergent, then again at the conclusion of the acid rinse. 

The reduction in soil and bio-burden load was amazing!

After the first pre-rinse, and circulation-cleaning with Circo-Top AFM (at 33% less detergent consumption), the score dropped from 403 to just 14

After the second rinsing phase, with Circo-Top SFM and a final rinse, the surface was tested again - obtaining a PERFECT SCORE of 0!

Case Study 2: Analysis of CIP Process of Val Tank 

An analysis of Clean-In-Place Process using chemicals from SVS and GEA was conducted at the Rohtak Plant in Haryana.  The below "Before" and "After" images and data are offered. A switch to Circo-Top AFM and Circo-Top SFM is under review, and again, concentration of detergency - resulting in chemical savings - was reduced from what had been in the previous cleaning protocol.

Before: Images

Before: ATP Reading

Heavy build-up of lime deposits and organic material resulting in reading that is nearly 500 TIMES higher than acceptable. 

After: Images

After: ATP Reading

After the standard, 2-Step CIP Process with Circo-Top AFM, followed by Circo-Top SFM, the results are now well within the range of acceptability. 

Case Study 3: Testing of Product & Process in a Milk Tank & Silo

An analysis of Clean-In-Place Process using chemicals from SVS and GEA was conducted.  The below "Before" and "After" images and data are offered. A switch to Circo-Top AFM and Circo-Top SFM is under review. In this case, even the water used for cleaning had a level of ATP that was 10 TIMES higher than what would be an acceptable level [65]. 

Before: Images

Before: ATP Reading

After: Images

After: ATP Reading

Case Study 4: Product & Process Trial - Milk Tanker & Cooling Tank

A trial of  SVS and GEA products and processes was conducted in a DeLaval (Closed Type) Cooling Tank at the Surat Milk Plant.  The below "Before" and "After" images and data are offered. A switch to Circo-Top AFM and Circo-Top SFM is under review. In this case, even the water used for cleaning had a level of ATP that was 10 TIMES higher than what would be an acceptable level [65]. 

Comparative Testing Product and Process in Stages 

Having only one tank available for testing, the cleaning process was repeated twice; first with the incumbent cleaning chemical system, then with the GEA Circo-Top System. The results are amazing!

ATP Test #1: A benchmark reading was taken ahead of the first cleaning.
ATP Test #2: A reading was taken directly after CIP cleaning with the incumbent product.
ATP Test #3: A final reading was taken after the final acid-rinse and clear water rinses.
ATP Test #4: A reading after the first re-wash with GEA Circo-Top AFM Detergent & Disinfectant.
ATP Test #5: A reading taken after the acid-wash/rinse step with GEA Circo-Top SFM detergent.
ATP Test $6: A final reading secured after the final clear-water rinse following the 2 wash cycles.