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High Efficiency Cleaning with Chematic

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by

Matt Dobrez

on 8 October 2013

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Transcript of High Efficiency Cleaning with Chematic

High Efficiency Cleaning with Chematic
"Our cleaning science gets you
back to business faster"
MANUAL
Clean Out of Place
Clean In Place
Cleaning
Methods
Critical Process Parameters of Cleaning
Time
Action
Chemistry
Temperature
Type of Cleaning Changes Process Parameters
Manual
Automated
T.A.C.T.
Cleaning Eudragit Coatings
Challenging Residues
Eudragit RL/RS
Eudragit NE/NM
Proper
Cleaning of Eudragit Benefits
Improve Safety
Enhanced Cleaning
Save Time
Save Money
- Reduce operator exposure to hazardous chemicals
- Reduce/eliminate haze
and residue
- Improve reliability
- Limit hand wiping & scrubbing
- Decrease disassembly
- Reduce Cleaning Time
Understanding The Residue: Eudragit
Soil Characteristics
• Insoluble polymers
Cleaning Process Needs
• Insoluble nature requires special measures -
to permit chemistry to penetrate
• Application in multiple layers creates other challenges
• Forms a barrier on surfaces
• pH independent
• May be applied in multiple layers
• Combined with color coating and other excipients
Understanding The Chemistry:
Chematic Cleaners
Chematic NE/NM
Chematic RL/RS
• Mildly alkaline detergent
• Designed to clean Eudragit NE/NM
• Mildly acidic detergent
• Designed to clean Eudragit RL/RS
Understanding The Application:
Chematic Cleaners
• Choose the right detergent for the soil
• Determine optimum cleaning
temperature for the soil
• Pre-rinse vs. no pre-rinse
CASE STUDY: Eudragit NE 30 D
Original Process with Traditional High Alkaline Detergent:
• Coating pan (60 inch) - CIP equipped
• One pan load - 24 hour dirty hold time
• Hot water rinsing, a highly alkaline cleaner, power washing and manual scrubbing to remove residue;
exposing operators to hazardous chemicals & ergonomic issues
• Residue does NOT dissolve; peels & forms balls that clog the perforations and have to be picked from the equipment
• Process took minimum of 8 hours and was very labor intensive for operators
• Could take 12-16 hours; inconsistent cleaning resulted in big variables in production scheduling
Successful Process with Chematic NE/NM Cleaner:
• Chematic NE/NM Cleaner dissolved the residue - no longer blocking perforations
• Pre-rinse step was eliminated
• Clean time and manual intervention were significantly reduced
• Time to clean was consistently 3 hours
• Operator exposure to hazardous chemicals was eliminated
• No scrubbing means less ergonomic issues
• Now have a validated state
Original Process
Chematic NE/NM Cleaner
T
A
C
T
Cleaning process takes 8 hours
and is very labor intensive and
unsafe for operators
Cleaning process time decreased
to 3 hours and is safe for operators
CIP equipped coating pan but,
requires power washing and
manual scrubbing first
Minimal manual intervention.
Right detergents permits CIP process
Traditional highly alkaline
detergent causes residue to ball
up and clog perforations
Mildly alkaline detergent that
dissolves the residue
Hot water rinses and washing
at 70ºC - 80ºC
Rinsing and washing at 50ºC - 60ºC
BEFORE
AFTER
Conclusions from Case Study:
Eudragit NE 30 D

• Safer process for operators
• Less labor intensive process
• Minimum time savings
of 5 hours per cleaning
• Consistent & validatable process
yields better scheduling
Value of Cleaning Improvements
Reduce Safety concerns
Reduce labor cost
Reduce contamination
and product quality issues
Increased production time
Reliable Cleaning
Ease of validation
CASE STUDY: Eudragit RS 30 D
Original Process with Solvents
• Fluid bed
• Manual cleaning
• Labor intensive
• Used solvents and scrubbing
• Damaging equipment
• Took 24 hours to clean
Successful Process with Chematic RL/RS Cleaner:
• Less labor intensive process
• Eliminated the need for IPA usage
• Simplified the process by utilizing spray devices
• No manual scrubbing required to remove the residue
• Robust and reproducible cleaning operator to operator
• Total cleaning time reduced from 24 hours to 4 hours
Original Process
Chematic RL/RS Cleaner
T
A
C
T
Cleaning process takes 24 hours
and is very labor intensive and
unsafe for operators
Cleaning process time decreased
to 4 hours and is safe for operators
Manual cleaning requires power
washing, manual scrubbing and
wiping with IPA
Chemistry applied with chemical
spray wands
Solvents used
Mildly acidic detergent dissolves
the residue; No scrubbing or IPA
required
Hot water rinses and washing
at 70ºC - 80ºC
Rinsing and washing at 50ºC - 60ºC
BEFORE
AFTER
Conclusions from Case Study:
Eudragit RS 30 D

• Safer process for operators
• Less labor intensive process
• Time savings: From 24 hours
down to 4 hours
• Significant increase capacity
Value of Cleaning Improvements
Reduce Safety concerns
Reduce labor cost
Reduce contamination
and product quality issues
Increased production time
Reliable Cleaning
Ease of validation
• Not reproducible; variations operator to operator
• More consistent & robust
cleaning process
Conclusion
• Apply the correct T.A.C.T. parameters to
improve cleaning - including the selection
of the right chemistry
• Improve safety & increase operating efficiencies
by using detergents formulated to clean Eudragit
Evonik & Dober Partnership
Industry leader in time release coatings paired with the industry leader in cleaning of Eudgragit
• Application Assistance
• Validation Assistance
• Scale-up Assistance
• Trial Assistance
Questions?
Kristina Wesley
Dober
630.410.7300
kwesley@dobergroup.com
chematic@dobergroup.com
www.dobergroup.com
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Full transcript