How Rotary Jet Heads Save Water, Energy, and Chemicals During Clean-in-place

Process designers recommendrotary jet headswhen cleaning requires a combination of high water pressure and chemicals to produce impingement action. In Clean-in-place (CIP),impingementrefers to the force of water under pressure and flow to adequately remove soils from the interior surfaces of tanks. Cleaning occurs when the concentrated fluid stream meets interior surfaces.

To achieve cleaning results, the jet heads use an optimized high-impact jet pattern to create jet pressure, or force of impact, to remove residues.

Designers choose rotary jet heads to clean tanks because they use less water, less energy, and less cleaning agent thanspray balls. Rotary jet heads rotate in precise, repeatable patterns to achieve full coverage inside the tank and because of the heads’ rotating action and water pressure, they use less water and take less time to clean than static jet devices.

Rotary Jet Cleaner
Tank Cleaning Pattern

How rotary jet heads work

清洁流体的流动使旋转射流头喷嘴在其垂直和水平轴上打开。在第一个循环中，喷嘴在罐表面上沉积粗糙的图案。随后的循环逐渐向图案中添加密度，直到在几个循环后达到完全覆盖。该操作完全自动，为用户提供有效的坦克清洁质量保证。

AsTable 1illustrates, the type of jet head to use depends on tank size, cycle time, and many other variables.

Table 1

Option 1 Option 2 Option 3 Option 4
Tank Size Small to mid-sized Mid-sized Mid to large-sized Large
扔长度（最大） 4-24 FT 19 FT 45-85 FT 65FT
Cycle Time 8-11 Min 10-14 Min 8-12 Min 8-20 Min
Working Pressure 40-1,000 PSI 30-400+ PSI 40-400+ PSI 40-400 PSI
Recommended Pressure 50-600 PSI 30-150 PSI 50-300 PSI 50-300 PSI
Working Temperature (max) 203°F 203°F 203°F 195°F
Ambient Temperature (max) 284°F 284°F 284°F 284°F
Standards 2.1 material certificate
upon request		 2.1 & 3.1 material certificate
upon request		 2.1 material certificate
upon request		 2.1 material certificate
upon request
Typical pressure, temperature, and jet pattern specifications for rotary jet heads in CIP remain constant across small and mid-sized tanks. As tank size increases, cycle time and pressure requirements for rotary jet heads also increase.

Download Alfa Laval Tank Cleaner Selection Guide

Complete self-cleaning system

Some rotary jet heads clean themselves inside and out to ensure that the flow of cleaning fluid covers external surfaces of the rotary jet head to reduce the risk of cross-contamination that would cause potential product waste.

  1. Overlap ensures self-cleaning of the body.
  2. 喷嘴的凹形形状确保了喷嘴本身的自清洁。
  3. Through two holes in the hub, jet streams ensure cleaning of the cone.
Alfa Laval Self-Cleaning Illustration

Selecting the right rotary jet head

The choice betweenrotarysprayheadsandrotaryjetheadsdepends on application requirements. Jet heads provide higher impingement — impact or mechanical force — than spray heads and are designed to offer the optimal output of force with the least flow and pressure.

Consider several factors when selecting jet heads and their configuration:

  1. Types of soil being cleaned

    一般而言，简单，易于清洁的水溶性土壤可以通过静态喷射球清洁，因为球使用化学品，热量和水来造成去除土壤的级联动作。旋转喷射头使用冲击难以清洁，干燥，粘稠，粘稠或油基产品。

  2. Vessel diameter

    Vessel diameter and shape determine the flow rate required to meet cleaning requirements.

  3. Available flow rate
    Vessel shape and size and tank cleaning device affect CIP flow rate requirements and pump needs, which must be calculated during CIP design.

  4. Available supply pressure
    Jet devices have different pressure requirements to operate correctly. Their pressure requirements must be accounted for during CIP design.

  5. Number and type of internal obstructions in the tank
    Even though rotary jet heads move, their effectiveness diminishes with the presence of obstructions in a tank such as heating coils, agitators, baffles, or ladders.

  6. Port size

    Port size determines jet head size and flow.

  7. Budget
    Budget considerations include the number and size of tanks, types of jet devices, system maintenance, and replacement parts.

How cycle configuration affects cleaning

In addition to jet head factors, four cycle factors affect the cleaning action of rotary jet heads during cleaning:time, action, chemicals, and temperature.

Time Duration of surface exposure to cleaning fluid.
Action Type of impingement the jet head delivers during cleaning, dependent on flow velocity and jet device design.
Chemicals Amount of chemical per unit volume contained within the cleaning fluid. This includes caustic, acid, and sanitizer.
Temperature Amount of heat energy within the cleaning fluid that can be transferred to a surface.
TACT Illustration
The pie graphs above illustrate various combinations of parameters. An increase in any one parameter decreases the other parameters.


Time

运行完整清洁序列所需的总时间可以包括许多不同的步骤（如准备，编程，洗涤和冲洗，干燥等），但清洁过程的临界“时间”元素是金额清洁溶液与产品土壤直接接触的时间。更长的接触时间可以等于更好的清洁，然而，增加的冲击可能导致更好的清洁循环。您的洗涤和冲洗循环时间可以间距短至2分钟，或者每次最多需要19分钟，具体取决于系统设计。

Since the time spent cleaning reduces the time spent producing a saleable product, the goal is to reduce cleaning cycle times as much as possible while still ensuring that the processing system is sufficiently clean and safe. An experienced cleaning expert can determine the right cleaning jet device and cycle times for a particular application based on product and system variables.

Action

清洗过程是机械的行动force of the cleaning solution that physically dislodges soil from the surface. The amount of impingement needed--and therefore jet devices and pressure required--are important considerations.

Chemicals

The right chemical cleaning agents in the right concentrations make a significant difference in CIP efficiency. The main job of chemicals in any CIP process is to enhance cleaning.

Temperature

Calculating the precise solution temperature is critical to effectively cleaning a system while at the same time reducing energy costs. Some studies have shown that for every one-degree reduction in CIP solution temperatures there will be nearly a 1% reduction in the energy needed to heat the fluid.

Higher solution temperatures can increase the effectiveness of chemicals and mechanical action and can also reduce the amount of time needed to clean properly. Considering the cost of energy to heat the solution, it is important that the temperature of each individual cleaning stage be calculated and controlled as accurately as possible.

旋转射流的优点

Because rotary jet heads operate at higher operating pressure, they have the advantage of higher impact velocity, which concentrates energy and chemical cleaning agents at impingement points. At the point of impact, the high-velocity CIP stream spreads out, resulting in shear to “scrub” soil from the tank wall.

Rotary jet heads distribute cleaning water while turning on two axes:jets turn vertically while the head turns horizontally. As the jets of water rotate, they create an impingement action on the tank circumference, which allows soaking and cleaning with a greater force than spray balls because rotary heads direct the flow in narrow streams.



Rotary Jet Cleaner

Verifying jet coverage with Riboflavin testing

概要

To verify the completeness of jet coverage during a CIP cycle, it’s common to perform a Riboflavin test. Testing involves spraying a fluorescent dye solution on the interior of process tanks and cycling the CIP system to study resulting jet patterns and cleaning effectiveness.

Materials and equipment
  • Riboflavin powder
  • Long wavelength UV lamp for inspecting tank interiors
  • Water with a maximum of 30 PPM chloride (plant water) or deionized water
  • CIP supply pump: 40 psi [2.7 Bar (g)].
  • Water tank and water
  • Riboflavin solution jet device that creates a fine mist jet.
  • Calibrated pressure gauge(s).
  • Calibrated flow meter(s).
General requirements
  • Tank must be in its final installed position.
  • 抛光和/或电抛光罐后执行程序。
  • Plug or cap all holes, with proper gaskets in place. Components have to be stainless steel, PVC, or brass.
  • Have a manual flow control valve, flow meter, and pressure gauge at each CIP manifold inlet.
  • Rinse and dry the tank prior to testing.
Dye preparation
  • Mix one gram of riboflavin with ten liters of water in a clean polyethylene container to prepare a 200ppm solution (Seiberling, 2008, p. 174).
  • Transfer the solution to a suitable hand atomizer.
Set-up
  • Ensure tank is positioned in its operating orientation in the test bed and seal all tank openings with proper caps and gaskets.
  • Verify that the tank is clean, rinsed, and dried.
  • 验证清洁设备，喷头和魔杖是否已正确安装。
Pre-test procedure
  • Visually inspect the interior of the tank under UV light.
  • Record inspection results.
Dye application
  • Observe all confined-space safety regulations.
  • Enter tank.
  • Jet all interior tank surfaces with dye.
  • Exit tank without touching jetted surfaces.
  • Inspect the interior of the tank by illuminating all surfaces with a UV lamp to ensure complete coverage (dye fluoresces bright green under UV).
  • Re-jet areas that are not completely covered.
Rinsing
  • 2-minute ambient rinse
  • 1-minute draining
  • Repeat for a total of three rinses
Variables that impact test results

The purpose of the riboflavin test is to determine jet-head coverage. The test does not tell you the effectiveness of cleaning, which is a different validation process.

Dale Seiberling notes several variables that can affect the results of riboflavin testing for coverage:

  • Riboflavin concentrations
  • Rince times
  • Drain times
  • Rinse cycle repeats
  • Rinse cycle lengths
  • Rinse temperature
  • Vessel cleanliness
  • Method of riboflavin drying
  • Interfering white light
  • Intensity of the UV light
  • Interpretation of results (2008, p. 174)

Next Steps

As a hygienic processor, you understand how much reducing water, energy, and cleaning agent use will impact your bottom line.

That’s whereRotary Jet Headscomes in.

Designed to provide high impact cleaning over a defined time period, these devices are automatic and represent a guaranteed means of achieving quality assurance in tank cleaning.

Clean-in-place Buying Guide

此类清理解决方案的购买指南是设计，拥有或操作处理系统的任何人的全面资源，并希望有关CIP系统的所有方面的信息。

Clean-in-place Buying Guide

Read Guide

ABOUT CSI

Central States Industrial Equipment (CSI) is a leader in distribution of hygienic pipe, valves, fittings, pumps, heat exchangers, and MRO supplies for hygienic industrial processors, with four distribution facilities across the U.S. CSI also provides detail design and execution for hygienic process systems in the food, dairy, beverage, pharmaceutical, biotechnology, and personal care industries. Specializing in process piping, system start-ups, and cleaning systems, CSI leverages technology, intellectual property, and industry expertise to deliver solutions to processing problems. More information can be found atwww.xxshagua.com.

参考资料

Frank, J. W. & Seiberling, D. A. (2008). CIP jet device design and application. In D. A. Seiberling (Ed.), Clean-in-place for biopharmaceutical processes (pp. 159-174). Drugs and the Pharmaceutical Sciences 173.New York, NY: Informa Healthcare USA.