Manufacturing Food Futures Conference March 2016 InnovateUK funded Martec Feasibility Study

1. Hygienic Efficiency
Manufacturing Food Futures
Annual Conference
EPSRC Centre for Innovative Manufacturing in Food
Holywell Park, Loughborough
23rd March 2016

2. Hygienic Efficiency
Self Optimising CIP
©2016 Martec of Whitwell Ltd

3. Hygienic Efficiency
Martec Profile
 Clean-in-Place & Hygienic Pigging specialists
 Hygienic manufacturing (food & pharma)
 Best practice design, manufacture,
commissioning & operational guidance
 Practical advice and solutions
 From guidance to full turnkey supply
©2016 Martec of Whitwell Ltd

4. Hygienic Efficiency
What is Clean-in-Place?

5. Hygienic Efficiency
Clean-in-Place (CIP)
definition
 Automated cleaning method
 Not requiring disassembly (labour, time & damage)
 Consistent cleaning
 Validated
©2016 Martec of Whitwell Ltd

6. Hygienic Efficiency
 When is it clean?
©2016 Martec of Whitwell Ltd

7. Hygienic Efficiency
 Defined cleaning time (err on caution)
 Worst case soil load
 Over cleaning by default
 Wastes
 Water
 Energy
 Detergent
 TIME
CIP current practice
©2016 Martec of Whitwell Ltd

8. Hygienic Efficiency
 Defined cleaning time
 Worst case soil load
 Over cleaning by default
 Wastes
 Water - 159 Giga Litres
 Energy – 37 Tera W/h & 11 Mega Tonnes CO2 emission
 Detergent
 TIME
CIP current practice
©2016 Martec of Whitwell Ltd

9. Hygienic Efficiency
 30% of all energy & water consumption
 5 Hours /day
 Mid size dairy £300k/year savings potential
 £100M total Food industry savings estimate
©2016 Martec of Whitwell Ltd

10. Hygienic Efficiency
Time
64%
Water
12%
Energy
12%
Chemicals
12%
CIP Costs
data analysis of 100,000 CIP cycles in over 40 diaries worldwide
©2016 Martec of Whitwell Ltd

11. Hygienic Efficiency
Cleaning in Place Handbook. Tetra Pak sales document.

12. Hygienic Efficiency
Equipment
involved
What to
monitor
How to
monitor
Research Framework
©2016 Martec of Whitwell Ltd

13. Hygienic Efficiency
Knowing when clean
 In pipe via Ultrasonics
©2016 Martec of Whitwell Ltd

14. Hygienic Efficiency
Ultrasonic methodology
 Across pipe
 Through cross section of wall fouling
 Reflection off the wall
 Along pipe
 What frequencies?
 How sensitive can we measure?
©2016 Martec of Whitwell Ltd

15. Hygienic Efficiency
Knowing when clean
 In vessel via Optical
©2016 Martec of Whitwell Ltd

16. Hygienic Efficiency
Riboflavi
n
Ice CreamYogurt
Optical methodology
©2016 Martec of Whitwell Ltd

17. Hygienic Efficiency
Riboflavin
Yogurt
Ice Cream
Optical methodology
©2016 Martec of Whitwell Ltd

18. Hygienic Efficiency
RGB Green Channel BW
©2016 Martec of Whitwell Ltd

19. Hygienic Efficiency
Ice Cream
©2016 Martec of Whitwell Ltd

20. Hygienic Efficiency
Processing sensor
outputs
 Artificial Intelligence
 Integrate sensor measurements (Ultrasonic & Optical)
 Decision making algorithm
 Is it clean/ confidence of decision
 Actions from decision
©2016 Martec of Whitwell Ltd

21. Hygienic Efficiency
Objective
 A system monitoring real time the cleaning process as it
occurs feeding back decisions into the control system.
 Adapting for all soiling conditions
 Adjusting for optimised delivery
 Self-Optimising Clean-in-Place
©2016 Martec of Whitwell Ltd

22. Hygienic Efficiency
 Supervisory board opportunities
 End processors with large CIP capabilities
 Diary
 Ready meals
 Drinks
 Petfoods
©2016 Martec of Whitwell Ltd

23. Hygienic Efficiency
Ian Sterritt
Managing Director
Martec of Whitwell Ltd
12 Midway Business Centre, Bridge Street Industrial Estate,
Clay Cross, Chesterfield, Derbyshire, S45 9NU
01246 860 855
07790 310 112
Ian.Sterritt@martec-conservation.com
www.martec-conservation.com
©2016 Martec of Whitwell Ltd