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Section C
Hygienic Piping Engineering
Learning Objectives
Content
1. Introduction
2. Application of Hygiene Piping
3. Pipes
4. Precautions in Hygiene Pipe Engineering
5. Good Sanitary Hygienic Design is Essential if
6. Basic Principles of Sanitary Design
7. Pipe Unions
8. Valves
9. Cleaning Station
10. Material of Construction (MOC)
11. Good Sanitary Design Features
12. Pipe Work
13. Surface Finish
14. Sanitary Pumps
15. Glass Pipe and Fittings
16. Plastic Pipe and Tubing
17. Welding of Sanitary Pipe, Fittings
18. Piping System Design for in Place Cleaning
19. Process Piping Requirements
20. Air - actuated Valves and Controls
21. Plant Layout
22. Production Section Layout
23. What Hygienic Design must Deliver?
24. Examples of Equipment/Piping Related Spoilage or Food- Borne Illness
25. Design of Exterior
26. Where to Get Help?
27. How to Avoid Contamination
28. How to Simplify Cleaning?
29. Hygienic Design Standards
30. Cleaning and Disinfection System
31. Maintenance of Hygienic Systems - Theory and Practice
32. Aseptic Product
33. Hygienic Pipes and Fittings Sizes
Summing Up
Self-assessment
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The piping engineer will gain the following skills after studying this section:
1. What is the purpose of hygienic piping?
2. How to apply general piping engineering principles for the hygiene sector
3. Comparison of steel pipe vs glass/plastic.
4. Hygienic piping standards?
1. Introduction
All surfaces in contact with the product (say food) must be inert to the product
under the conditions, of use and must not be caught, migrate to or be absorbed
by the product.
All surfaces in contact with food must be smooth and non-porous so that tiny
particles of product, bacteria, or insect eggs are not caught in microscopic
surface crevices and become difficult to distodge, thus becoming a potential
source of contamination.
3. Pipes
Standard followed: DIN 11850/ ISO 2037. The piping layout helps to determine
the functional safety of the product transport. It is important that all parts in
the network receive an equally intense treatment with the cleaning detergents,
and that the pipe network can run completely empty.
a) It is difficult to clean dead water zones where the vessels connect to the
main pipe. The use of double sealed vaIves or short T-pieces can avoid
these dead water zones.
b) Leftover product in bent sections of pipe: A bend in the pipe can be
avoided by stationing the supports sufficiently close to one another.
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• AII surfaces in contact with the product (say food) must be inert to the
product under the conditions of use and must not migrate to or be
absorbed by the product.
• All surfaces in contact with food must be smooth and non-porous so
that tiny particles of product, bacteria, or insect eggs are not caught in
microscopic surface crevices and become difficult to dislodge, becoming
a potential source of contamination.
• All surfaces in contact with the product must be visible for inspection
or it must be demonstrated that routine cleaning procedures eliminate
the possibility of contamination from bacteria/insects.
• All surfaces in contact with the product must be readily accessible for
manual cleaning or if not readily accessible, be readily disassembled for
manual cleaning, or if CIP techniques are used, it must be demonstrated
that the results achieved without being disassembled for manual
cleaning, or if CIP techniques are used, it must be demonstrated that
the results achieved without disassembly are the equivalent of those
obtained with disassembly and manual cleaning.
• All interior surfaces in contact with the product must be so arranged
that the equipment/piping is self employing or self draining.
• The piping must be so designed as to protect the contents from external
contamination.
• The exterior or non-product contact surfaces should be arranged to
prevent harbouring of soils, bacteria or pests in and on the equipment
itself as well as in its contact with other equipment, floors, walls or
hanging supports.
• In design, construction, installation and maintenance, it is important to
avoid dead space or other conditions which trap food, prevent effective
cleaning and may allow microbial growth to take place.
There is no Substitute for Common Sense, and no Specification can be Complete
Enough to Insure a Sanitary (Hygienic) Design
7. Pipe Unions
Pipe unions present a weak point in any system. The DIN 11851 standard is
used for pipe fittings. In hygiene piping design, welded bonds provide an
optimum safety when they are the result of inert gas welding.
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The standard design for a stainless screwed pipe connection (DIN 11851)
requires a profile jacket. In this type of construction, there is always a crack
between the socket and the thread. This disadvantage can be avoided by using
a special profile gasket. An alternative is a clamp union. so-called tri-clamp.
This consists of two identical clamp ferrules and a profile gasket, and is
designed to avoid cracks, having been pre-stressed at a designed tension. The
clamp joint can also be opened and closed without using a tool.
8. Valves
9. Cleaning Station
This requires good sanitar y design and installation because apart from
conveying material it is part of the ‘overheads’ which collect dust and dirt.
Badly installed or maintained pipe work can be expected to leak and may be a
source of direct contamination or, if the material is suitable, e.g. liquid sugar,
be a pest, control problem. Also, pipes going to and from the flow plate should
be stopped otherwise it will contribute to the wastage of the product.
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When a pipeline is being installed which has couplings that use gaskets, be
sure that the correct gasket is used and that the pipe work and coupling are
both correctly aligned and tightened,
GRIT Ra (MICRONS)
36 3.8
80 1.9
120 1.45
180 0.85
240 0.42
320 0.35
Pumps are so made that the impellers, gears or pistons can be easily removed
for cleaning, thus making them adaptable for handling hygiene products. The
pump may be fitted with a friction seal, instead of packing, and the body and
rotors of the pumps are made of white metal, bronze or stainless steel. The
pump housing is fitted with sanitary pipe connections.
A. Material
1. All metal pump parts having any surface in contact with the product
shall be constructed of metal consisting of stainless steel, nickel alloy,
or equally corrosion resistant material that is non-toxic and non-
absorbent.
a) All product-contact surfaces shall be finished to an equivalent of
not less than, 120 grit finish property applied.
b) All outside surfaces shall be smooth and easily cleanable.
B. Construction
1. Openings: Inlets and outlets shall confirm with the 3A sanitary standards
for fittings.
2. Shaft seal: Seal shall be of the sanitar y type easily removable for
inspection and cleaning, and shall be constructed of material not
injurious to food products.
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Glass sanitary pipe made at a special tough pyrex glass is available in the
market and a good many successful installations are in use in United States
basically for the dairy industry. The glass pipe is of interest for two principal
reasons: first as a substitute for stainless steel and, second because it can be
used in many locations without dismantling for cleaning, thereby saving
considerable labour in clean-up time. The transparent nature of the glass makes
it possible to examine the pipe visually after cleaning by circulatory methods,
and detect deposits if there are any.
Standard stock sizes are 1,11/2.2.3.4,6 inches inside diameter.
Lengths are 10 feet; longer or shorter are special.
Normal operating temp: 0 -212 degF.
The sanitary stainless steel pipe was first used commercially with welded
fittings around 1948.
3A standards for sanitary pipe and fittings:
A. Material
B. Construction
C. Gaskets
Single service gaskets of the sanitary type or removable rubber type gaskers
that can be easily cleaned shall be used with gasket type fittings.
The solderless recessless type fittings are sometimes used. The pipe passes
entirely through the fitting and the joint between the pipe and the fitting is
actually on the end of both the fitting and the pipe, out of direct contact with
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any product which passes through the pipe The fitting is attached by slipping
the fitting over the end of the pipe to the proper position and then expanding
the pipe into the fitting by means of an expander of the same general type as
that used in expanding boiler tubes in a boiler.
Many food equipment cleaning processes are now being conducted by re-
circulation techniques, utilising a combination of chemical and physical effects
to remove the soil from the product - contacting surfaces. This procedure is
referred to as a CIP (Cleaned-in - place) operation, and process system, valves,
and process equipment susceptible to this technique are said to be of CIP design.
In- place cleaning may be applied to piping systems and associated process
equipment by recirculating detergent, and sanitising solutions through circuits
comprising this equipment from a suitable recirculating unit consisting of a
pump and supply tank. Recirculation cleaning of transport tankers, bulk - milk
pick - up tankers, storage tanks, and processing vats in another reqarding
area, with the cleaning of this equipment is accomplished by spraying the
detergent onto the soiled surface.
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This type of planning demands considerable thought but pays off in reduced
product loss improved sanitation, and savings in manhours of clean – up and
processing labour. If it is necessary to conduct product handling operations
and cleaning operations simultaneously, engineering design should make it
possible to do so without any physical connection between product - containing
systems and detergent containing systems.
Air actuated sanitary valves became available to the dairy and food processing
industr y in 1958. The advantages of air-actuated valves as compared to
conventional plug - type sanitary valves are as follows:
1. They may be remotely actuated by manual or automatic means.
2. They may be mechanically cleaned in conjunction with CIP piping
systems.
• The ideal plant layout integrates the departmental areas in a logical way
to provide for a smooth flow of materials and services.
• Plant layout basically depends upon the amount of land space available,
shape of the site particularly with respect to road and rail access.
• It must be noted that a good layout does not require lavish or luxurious
buildings.
• It does mean spending so as to maximise the probability of good
management producing safe, wholesome food economically.
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The exterior of the machine is not something that can be tackled in isolation.
It is an integral part of the complete design.
The exterior of a machine, or plant , is those parts of the equipment for which
the operator, or cleaning staff, would normally be responsible. This includes
not only the outer surfaces of the machine, but also the product areas, for
which the operator has responsibility.
If a basic process is, in itself, one which creates dirt, dust and unhygienic
conditions, attempt to replace that process with a cleaner one.
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It takes a design engineer about two years to develop sanitary design skills.
The engineering criteria are not particularly complex , and they can be mastered
fairly quickly. Nonetheless, more time is needed to acquire a better
understanding of the different manufacturing processes and their particular
design needs.
The most common design faults which cause poor cleanability are: poor
accessibility, inadequately rounded corners, sharp angles and dead ends.
Some useful definitions: Accessible: Easily exposed for regular cleaning and
inspecting with simple tools such as those normally carried by cleaning
personnel., Readily accessible: Easily exposed to sight and touch for regular
cleaning and inspecting without the use of tools.
One of the common features of poor sanitary design is the existence of inherent
‘dead spots’ or ‘dead ends’. They are better described as ‘filth traps’. It needs
to be remembered that micro-organisms are very small, and that what is
visually small to a human are to microbes the ‘ wide open spaces’ where they
can multiply. Furthermore, if the cleaning does not remove material because
design features shield it, then this becomes a ‘designed in’ source of
contamination. It is therefore axiomatic that sharp corners, crevices and dead
ends anywhere in the product are unsanitary.
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• Cleaning System:
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“ Be clear that management is accountable for the sanitary status of plant and
equipment. Good sanitar y design together with the proper application of
technically effective cleaning systems are needed to achieve and maintain a
satisfactor y sanitar y status. Poor sanitar y status is caused by the
management's lack of knowledge together with its attitudes and policies.”
HACCP:
HACCP stands for Hazard Analysis and Critical Control Point (HACCP). The
HACCP system as a way of working is as applicable to cleaning systems as it
is to production systems. HACCP is developed for a specific situation in an
actual plant.
Guard panels are made from stainless steel sheet about a metre square. One
side (the top) is curved to hook over a supporting tubular rail when the filler
is in use. Handles are provided to lift the panel on and off this rail. The base of
the panel is held in place by a channel section. The panel is not interlocked
with the filler which can therefore be run with the panel removed during
cleaning.
When cleaning of the filler starts , the panels are removed for separate cleaning.
After the line and filler are cleaned, the panels are replaced. The purpose of
cleaning is to remove spillage which if left could cause an offensive smell and
corrode the metal. Visual cleanliness is sufficient. An analysis is given in table
1 below, which may raise some unexpected points. It is worth noting that a
real advantage of the HACCP approach is that it promotes open – ended lateral
( wide – ranging) thinking in a multi-disciplinary team as well as producing a
useful analysis. It is also worth noting that the analysis must be in the detail
needed to deliver the required results.
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• Dry cleaning: Dry cleaning methods are used where the products are
hygroscopic or where water can react to form hard deposits which are
difficult to remove. The principal Public Health risk is that failure to
control moisture can permit the growth of pathogens, e.g. Salmonella
spp., in the processing environment which then contaminate any food
being processed. Environments usually dr y cleaned include plants
producing flour, chocolate, peanut butter, dry milk products, dry soup
and snack mixes, and dry infant formulae. Dry cleaning is essentially
the mechanical removal of soils using sweeping, brushing, wiping, and
vacuuming.
• Wet cleaning: This may be done out of place or in place or, on large
equipment, by a mixture of both methods as appropriate.
Remove food products and open containers from the area surrounding the
equipment to be cleaned.
Dismantle the equipment to expose the surfaces to be cleaned.
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CIP is mainly used for cleaning liquid handling systems. It comprises a number
of steps:
1. Drain the system of product.
2. Prepare the circuit(s), e.g. by switching controls to ‘clean’, installing
key pieces or flowplates, confirming availability of detergents, etc.
3. Pre-rinse to remove product residues (gross soil)
4. Circulate hot detergent to remove residual soil.
5. Rinse with potable water of suitable quality. This rinse is the intermediate
rinse if chemical sanitising and / or acid scale removal is included in
the CIP cleaning. It is the final rinse if there is no further step in the CIP
cleaning.
6. Sanitise to reduce microbial numbers to an acceptable level.
7. Final rinse with potable water of suitable quality.
In complex cleaning systems which are often large, a mixture of COP and CIP
methods outlined above are usually used.
• Assessment of Cleaning
• Introduction:
• Maintenance is done to ensure that equipment/ piping system continues
to work within design tolerances or specifications. It must be carried
out in a way which avoids contamination of ingredient materials, products
or packaging materials and also permits effective cleaning before
production re-starts.
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Summing Up
We have learnt in this lesson about the importance of a hygienic piping system
and the role of piping engineer in it. It is concluded that with proper hygienic
engineering, we can ser ve humanity with safe products in food/
pharmaceuticals and the agro sector.
Self-assessment
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References
References
Section A
Thermal Insulation
1. H.F. Rase and M.H. Barrow, Project Engineering of Process Plants, John
Wiley & Sons Inc., New York , 1957 , PP: 476-479
2. W.C. Turner and J.F. Malloy, Thermal Insulation Handbook, Robert E.,
Krieger Publishing Co. Malabar, McGraw-Hill book Co., New York, 1981,
PP 212-263
Section B
Costing of Pipelines
Section C
Hygenic Piping Engineering
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