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INTRODUCTION
The canning industry produces hundreds of different canned food items. These items
include fruits, vegetables, juices, fish and seafood, meats, soups, baby foods, milk, and
many specialty items. The total production is several billion kilograms. Next time you
visit your local supermarket, notice the area set aside for the canned food products. It is
substantial.
The job of your local cannery is to take the raw fruit, vegetable, etc., and process it. The
end product is a can of processed raw material that can be saved for many months due
to the processing and the ability of the can to protect the product. How does a cannery
do this?
by hand. Peas and lima beans are frequently separated into more and less mature
portions by flotation in a salt solution, the operation being performed continuously in
automatic machines.
Trimming, if necessary, is done by hand by operators trained in locating and removing
blemishes. Sometimes trimming is the only cutting necessary to prepare the foods for
the desired style of pack. However, when the foods are to be canned other than whole,
they are cut, sliced, diced, halved, or peeled, usually by machines specially designed
for each product.
In each of these steps the raw food is continuously inspected, but a final inspection is
made by experienced persons to pick out mashed or broken pieces, pieces of food that
are off-colour, or any foreign matter which may have passed the cleaning, washing and
trimming operations.
Blanching
Some foods then are immersed in hot water or exposed to live steam in an operation
known as the "blanch". This pre-cooking usually is accomplished in equipment
especially designed for individual products. In general, the raw foods are conveyed
through hot water or steam by various mechanical devices which subject them to a
particular temperature range for the proper period of time.
Blanching of vegetables and some fruits serves to expel air and gases, to inactivate
enzymes and thus arrest changes in flavour, and to wilt products (such as spinach) so
that more may be filled into the container. Shrimp are precooked in a salt blanch to curl
and shrink them for proper filling.
Proper blanching, by removing occluded gases, reduces strain on the seams of cans
during processing, particularly where the filled cans are not thermally exhausted.
Filling
After necessary preparatory steps, the raw foods are ready to be filled into metal or
glass containers. The containers are conveyed by automatic runways through washers
to the point of filling.
Most filling is done by machine. Foods canned in larger pieces, such as peaches, pears
and salmon, may be filled into containers by hand. The container always is filled as
completely as possible with the solid product and packing medium -- juice, salted and/or
sweetened water, or sugar-syrup -- then is added, according to the product and style of
pack.
Depending on the size of container and nature of the product mechanical filling is
carried on at speeds up to 1,200 containers a minute.
Ensuring Vacuum in Containers
The objective of obtaining vacuum in containers is to remove air and gas so that
pressure inside the container following the process and cooling will be less than
atmospheric. The vacuum (1) helps keep can ends drawn in -- an index of a sound
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cleaning is excellent for the typical canning plant. When the plant is in operation there is
little time for cleaning so the method must be fast and efficient ... foam cleaning is just
that. The advantages of foam cleaning are: dwell time, high visibility, no splashback of
chemical, no strong odours, ease of dispensing, and speed of application. The foam
allows dwell time which is important in dissolving and removing food soils. Further, foam
will seep into crevices and hard to reach places of intricate equipment. Foam cleaning
is fast, easy to apply, easy to rinse, and most importantly it is effective in cleaning food
soils.
High pressure cleaning is another method of cleaning popular in the canning industry.
High pressure cleaning is fast but it does use more water and cleaning compounds and
there is a danger from splashback. While foam clings to food surfaces and dissolves
the soils, high pressure applies the impingement to remove tenacious builds ups.
Central high pressure systems are usually used. High pressure pre-rinse and post rinse
are most effective when used in conjunction with a foam program.
Steam cleaning has been particularly effective in the cleaning of certain pieces of
canning machines.
A final type of cleaning common to the canning industry is Cleaning In Place (CIP) type
cleaning. With the production of ketchup, tomato paste, cream-style corn, puree and
juice operations, CIP cleaning is predominant. These systems are cleaned by the
circulation of cleaning solution through the lines and equipment. In a similar manner,
insides of kettles, vats, and cookers are often soak cleaned with agitators on.
From these general cleaning methods we can clean most any area of the canning plant.
These methods described for specific areas, along with some special applications,
follows.
Washing of Fruits and Vegetables
We have four products approved for use for the washing of fruits and vegetables. They
are F-3170, OXYCLEAN, BXA-325, and CHLORINALL G. These products can be used
in the flume system, reel washer, tumbler washer, spray washer, etc., as long as the
product receives a potable wash spray rinse after its use.
F-3170 can be used at a 1% solution for washing fruits and vegetables. Normally
F-3170 is used in conjunction with caustic peeling of fruits and vegetables.
BXA-325 can be used as low as 50 grams per 100 litres.
OXYCLEAN can be used as low as 100 grams per 100 litres. OXYCLEAN and BXA-325
help in keeping down the slime buildup on the flumes and washers and both products
are low foaming.
CHLORINALL G would be too high foaming for this use, in most cases, because of the
turbulence of the washing operation.
The reason for fruits and vegetables being washed is to remove field soils, insecticides,
etc., but spoilage type bacteria must also be removed. BXA-325 and OXYCLEAN
contain chlorine and assist greatly in removing various types of bacteria. Again,
remember that these products have to be rinsed by potable water at the end of the
washing cycle.
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25 ml per litre and the water and foam solution temperatures should be 15 to 30C.
The general alkaline cleaning is done once daily or between each production shift. The
acid descaling can vary, depending on water conditions. This procedure may be
needed anywhere from twice weekly to once per month.
Blanchers
The blanchers are usually constructed of stainless steel and can be cleaned by using
CHLORINALL G, CHLORINALL H at 1:20 or A-420 with FOME-ADD at a concentration
of 1 to 30 in 85C. water. This procedure should be done after every production shift or
on a daily basis. Because of the nature of the blanching operation a great deal of scale
and protein buildup occurs. This is a step in the process similar to pre-cooking in which
the product passes through 80C to 95C water or a steam bath. Because of the
buildup an acid product is needed for protein and water scale removal. By foaming
FAS-GLO, ACID-O-CLEAN, LUSTREX, or PRO-CLEAN at 1:20 on the blancher, light
buildup can be removed. Often, the buildup is quite severe especially in hard water
areas, and DETARTREUR has to be used. The procedure is to make a 10% solution in
65C water and allow this solution to circulate through the blancher for 1 to 2 hours.
The solution should be dumped and the blancher rinsed with cold water. This procedure
should be done at least once every two weeks.
Fillers
Fillers can be cleaned by the foam method with CHLORINALL G, CHLORINALL H,
OXYCLEAN and FOME-ADD, in 60C. water. Concentrations will depend upon the
severity of the soil. Many times, you will find fillers that are constructed of soft metals. In
this case you would have to use products which are metal safe, like CHLORINALL G or
CHLORINALL H. It is very helpful to pre-rinse the fillers before they are foamed, since
there is often a syrup or brine solution involved.
Exhausters
These units usually do not require considerable amounts of cleaning unless there has
been a great deal of spillage involved. CHLORINALL G, CHLORINALL H, OXYCLEAN
and FOME-ADD will normally do a good job. Again, remember, if you foam these
products on the surface, use water at 60C. If you are working with soft metals, you
then have to use a product like CHLORINALL G or CHLORINALL H.
Occasional acid descaling may be needed by using FAS-GLO, ACID-O-CLEAN, or
PRO-CLEAN at a 1 to 20 concentration at 65C. The acid cleaning should also be in a
foam solution. Depending upon water hardness conditions, this may be done once per
week or once per month.
Sealers, Closers, and Seamers
The cleaning of this type of equipment is very similar to the cleaning of the fillers. Some
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according to the individual canner's formula, plus, of course, the cooking in a tank,
usually with exposed rotating steam coils. There are then holding tanks or pre-cookers
in which the batch is kept hot before it is pumped to the filler to be put in cans or glass
containers.
The above is more or less the process for ketchup. Tomato paste differs in that a
vacuum pan is used instead of a normal cook tank. A vacuum pan is a cook tank under
pressure with a partial vacuum, thus making it possible to cook the product at a lower
temperature which helps retain colour and flavour. Also involved in both ketchup and
paste production is a finisher which is a screen through which the product is pumped in
order to remove small fibers and particles. The "finishing" process usually precedes the
cooking process.
With cream-style corn, a heat exchanger is often involved as with tomato paste on
occasion.
The best product for circulation cleaning is OXYCLEAN. Because of the cooking
process there is a problem with burnt-on residue and a high alkaline product such as
OXYCLEAN is needed. The solution, at 1 to 125 in 60C. water should be pumped into
the first tank in the series, usually an ingredient addition tank, then through the finisher,
the cooker or vacuum pan, heat exchanger, and through to the filler, where the solution
is dumped. Depending on the severity of the buildup, additions of OXYCLEAN may
have to be made in various tanks, especially the cooker, vacuum pan, and directly
before the heat exchanger. The screen or screens in the finisher should be dismantled
and soaked in a 1 to 50 solution of A-420 or F-685 at 82C.
A water rinse should precede and follow the alkaline cleaning process. The final rinse
water should be checked with pH paper to insure that there is no alkaline residue.
Occasionally, an acid treatment my be needed to remove water scale. ACID-O-CLEAN
or DETARTREUR at 1 to 50 in 60 to 70 water should be circulated throughout the
system.
For sanitizing we recommend the use of IX-91 diluted 1 to 500 in cold water or not over
30C water. This process does not require a final rinse.
Conveyor Belts
One of the biggest problems in a typical canning plant is the cleaning of the conveyor
belt. There are thousands of feet of belts in the average cannery, and they must be
kept clean. Again, the foam method is the most applicable for the general clean-up.
CHLORINALL G at approximately 1 to 20 at 60C. does an excellent job of keeping
neoprene, rubber, and canvas belts clean.
At the beginning of the canning season the belts are usually in bad condition and a
strong solution of ACID-O-CLEAN, applied with FOME-ADD or in 60C. water
approximately 1:2 to 1:10, should be used to remove protein and hard water scale
besides the usual stains. ACID-O-CLEAN or FAS-GLO will probably be needed
periodically during the canning season also, probably on a basis of once or twice a
month.
An example of continuous belt sanitizing consists of spraying a sanitizer on the belts at
the discharge end of the belt while in production. Either IX-91 can be used at 25 ppm or
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CL-18 at 100 ppm. The sanitizer can also be sprayed on by using a Hudson Sprayer or
a DOSATRON
Continuous belt cleaning has also been done by using a spray bar system whereby a
solution of OXYCLEAN, is automatically sprayed on the belts and rinsed through the
same system. The HYDROCHEM 911 is used for this, through a system of quick
disconnects. The rinse can also be provided through this system.
Walls, Floors, Ceilings
For general cleaning of walls, we recommend the use of CHLORINALL G or
CHLORINALL H in 60C. water through the FOAMASTER 890 or 865 This method can
also be used on ceilings. These products will be safe on painted walls and ceilings.
Also, these chlorinated products reduce odour, and help control mould due to the
chlorine content.
If the walls are concrete or plastic, you can use SUPER KLEEN or CHLORINALL G.
If mould is present, use a chlorinated cleaner at approximately 1 to 16 down to 1 to 32
in 60C. water, which will remove most of the mould buildup. Agitation with a stiff
bristled nylon brush may be necessary as well as more than one application if the
mould has had a chance to adhere tenaciously to the walls and ceilings. In processing
areas, after rinsing the product from the surface, use D-600 at a concentration of 16 ml
per litre of water, which will give you 1600 ppm of quat. At this concentration of D-600,
the sanitizer will kill mould on contact. D-600 is registered as a fungicide by Agriculture
Canada at 16 ml per litre of water.
Another method of retarding mould growth would be to spray STAY CLEAN on the
walls and ceilings after they are cleaned and sanitized. STAY CLEAN does not support
bacteriological growth and, thus, is a deterrent to mold, besides making the walls and
ceilings easier to clean in the future.
For cleaning tough soils on concrete floors where floor scrubbers are being used, we
recommend F-3826 at 25 grammes per litre of warm water. F-3826 should not be used
on other than quarry tile or concrete floors. For cleaning warehouse floors, we
recommend the use of GENERAL CLEAN, FORMULA 268 or OP-430. GENERAL
CLEAN and FORMULA 268 are designed for the cleaning of concrete floors with
application through a power floor scrubber. GENERAL CLEAN cleans and seals
concrete by building up a clear, protective coating which is non-slippery. The
recommended concentrations for GENERAL CLEAN or FORMULA 268, since they are
highly concentrated products, are 1 to 40 down to 1 to 160 with room temperature
water.
If a powdered product is desired, OP-430 is effective on tile on concrete floors. It should
be used at a concentration of 12 to 25 grammes per litre of water. The most basic way
of using OP-430 would be to pre-rinse the floor, spread OP-430 around, allow the
product to soak in for 15 to 30 minutes, and rinse. Stubborn areas way need agitation
with a stiff bristled nylon brush.
If the floors are painted, you can recommend the use of NEUTRA CLEAN.
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Sanitizers
After cleaning of all equipment, we would recommend the use of a final sanitizer. The
use of a final sanitizer will reduce the number of bacteria present on the equipment,
thus insuring a lower number of bacteria in the product. D-600 or IX-91 can be applied
via a DOSATRON or through an existing high pressure system.
Off-Season Operations
At the end of the season's production, all the machinery should be well cleaned, rinsed,
and dried. Once this has been done, a coat of STAY CLEAN or PROTECT will protect
paint from peeling, metal from rusting, etc. This procedure will more than pay for itself
at the start of the next season.
GLOSSARY
Blancher
Closing Machine
Conveyors/Belts
Cooling Canals
Water bath used to quickly cool the canned product after cooking
to prevent over cooking.
Cutter/snipper
Filling Machine
Flumes
Graders
Grinders
Peelers
Retorts
canned product.
A)
Continuous cooker/cooler reel type cooker that continuously
feeds in cans, cooks and cools the cans and discharges the
cans.
B)
Crateless retorts - cookers that are fed cans from above,
cook the cans and then drop them from the bottom, usually
into a cooling canal.
C)
Horizontal/vertical retorts batch retorts that cook the cans
after they have been stacked in wire baskets. An older,
slower process.
Vacuum Pan
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