CASE HISTORY #3609

CLEANING A RIBBON BLENDER

BACKGROUND
A large agrochemical products manufacturing company was interested in improving the cleaning procedure in their dry
products formulation line. The interest in evaluating STERIS Corporation's cleaning agents in this dry formulations area arose
following the successful implementation of a cleaning solvent substitution program using STERISs aqueous-based cleaning
agent, CIP 100 Alkaline Process and Research Cleaner, at one of their large liquid products manufacturing plants.
In the dry formulations process, inert and technical (active) materials are charged together, blended, milled and batched out,
after which they go through granulation and clarification lines. Multiple product formulations are manufactured in the same
process equipment, thus requiring cleaning to meet pre-established residue limits in the low ppm levels.
Since the equipment used in the process was not designed for handling liquids, the cleaning process consisted of manually
cleaning the process equipment with personnel entry. To help improve this labor-intensive and time-intensive cleaning
process, it was decided to evaluate the feasibility of cleaning-in-place (CIP) the equipment with an aqueous cleaning agent
dispensed through spray nozzles. The objective was to have a simple CIP system fabricated in-house without having to do
major equipment modifications.
A horizontal ribbon blender was chosen for the cleaning evaluation and trial.

LABORATORY EVALUATION
Samples of the residues that were present in the blender after the manufacturing process were sent to STERIS, and a PACE
consulting and evaluation service concerning the cleaning procedures was performed. The process consists of simulating the
worst case soiling conditions using stainless-steel coupons, and then screening various cleaning chemistries to determine the
appropriate cleaning agent and parameters. The product residue on the surface consisted of two types of component
chemistries.
Laboratory evaluation showed that one of the residue components (A) could be cleaned better with an alkaline cleaning agent,
CIP 100 cleaner, while the other component (B) could be cleaned better with an acidic cleaning agent, CIP 200 Acid-Based
Process and Research Cleaner. Coupon coating studies were done to simulate the actual residue deposition on the surface,
which included coating both components one after the other.
Based on the evaluation, it was recommended that cleaning be done first by a 1 oz/gal (0.78%) concentration of
CIP 100 cleaner at 140F (60C) for at least 15 minutes, followed by 4 oz/gal (3.1%) CIP 200 cleaner at 140F (60C) for 15
minutes. The amount of residue coated onto stainless-steel coupons to simulate soiling and cleaning during the PACE
evaluation was about 20 mg/cm2 of component (A) and 15 mg/cm2 of component (B), which represented worst case
conditions.

FIELD TRIAL CONDITIONS

A simple recirculating CIP system was fabricated by the customer to perform the CIP cleaning. It consisted of two rotating
spray nozzles installed in the blender. The location, size, and type of the nozzles were determined based on the size, internal
surface area, and configuration of the horizontal ribbon blender. The discharge from the blender drained to a 100 gallon
stainless steel tank with steam heating capability, which was used as the holding and recirculation tank for the rinse water and
cleaning solution. The discharge from this tank was connected to a 2 HP, 3500 rpm centrifugal pump, which was connected
through an in-line filter to the spray nozzles.
The cleaning process consisted of a water pre-rinse for five minutes, an alkaline wash with CIP 100 cleaner for 30 minutes,
water rinses for a total of 15 minutes, an acidic wash with CIP 200 cleaner for 30 minutes and final water rinses for 15 minutes.
The water rinses were done by filling the CIP tank with water, pumping it through the spray nozzles and discharging the
solution without recirculation directly to the drain. The wash cycles involved recirculating the cleaning solution at the
appropriate concentrations, 1 oz/gal (0.78%) for CIP 100 cleaner and 4 oz/gal (3.1%) for CIP 200 cleaner. The blender was
turned on during the cleaning process.
The temperature during the wash cycles was approximately 158F (70C). The potable water rinses were at around 122F
(50C). The pressure was 40 psi at the discharge of the pump and 36 psi close to the spray nozzles. This resulted in a flow rate
of about 35 gpm.
410-500-3609 (08/01/13)

SAMPLING AND ANALYTICAL RESULTS

Samples from all the rinse water cycles were collected. Surface swabbing was also done on the side wall of the blender, the
outer ribbon and the inner ribbon of the blender. The visual observation of the blender after the trial and the results of the
analyses far exceeded the Customers expectations. The residue levels obtained from the swabbing are not detailed here, but
were all less than 0.5 mg/cm2 and met the residue limit specifications for both components of the residue.
Based on the success of this preliminary trial, steps are being considered to further refine and automate this cleaning
procedure. Further trials are being conducted using other pieces of equipment at the site.

For further information, please contact:

STERIS Corporation
5960 Heisley Road
Mentor, OH 44060-1834 USA
440-354-2600 800-444-9009
www.STERISLifeSciences.com

410-500-3609 2013, STERIS Corporation. All rights reserved.

(08/01/13)

This document is intended for the exclusive use of STERIS Customers, including architects or
designers. Reproduction in whole or in part by any party other than a Customer is prohibited.