1

Advancements in Cleaning Technologies

Coatings and Coating Equipment

Cleaner with ChematicFormulated Detergents

2

Agenda

• Cleaning Coatings• T.A.C.T• How do we clean• Know your residue• Opadry• Eudragit• Cleaning techniques• Value

3

Coatings Color and Time release

• What are we cleaning?– Coating pans, Fluid beds, Mixers, Pumps,

Hoses• How are they currently cleaned

– Manual scrubbing, Sprayers, CIP, COP• What are the problems

– Time consuming– Repeatable results– Worker safety– Disassembly of equipment– HAZE Left behind

4

Where do you Start?

The GoldenGolden Rule of Cleaning

5

T.A.C.T The Variables of cleaning

Time

Action

Concentration/Chemistry

Temperature

6

Understanding the Cleaning

TACT

imectiononcentration/Chemistryemperature

Critical Process Parameters for Cleaning

7

Removal Mechanisms of Formulated Detergents

– Wetting– Solubilization– Sequestration

– Saponification

– Chelation

– Emulsification– Degradation

Modifying surface tensionIncreasing solubilityReacting with ions to prevent insoluble by-products (e.g., soap scum)Formation of water soluble salts (alkali hydrolysis)Using - charges to form stable complexes with + metal ionsCreating a stable oil / water mixtureInactivation through a number of means, usually hydrolysis or oxidation

Each detergent constituent has one or more rolesto play in the removal of soil…:

8

HowPeople Clean

• Manual

• Clean-Out-Of-Place –COP

• Clean-In-Place – CIP

9

Cleaning better with T.A.C.T

How do we clean better

10

Understand you goalsNature of Soil

• Opadry®– TiO2 based, HPMC

Talc, Zinc oxide

– Temperature effect

– Leaves haze

– Hand wiping

– Disassembled needed

– Pans designed

• Eudragit®– Polymer based

– pH Dependent

– Several application

– Manual cleaning

– Temperature effect

– Layered

11

Improving cleaningOpadry II® & Eudragit®

• Reduce haze and residue

• Limit hand wiping & scraping

• Decrease disassembly

• Reduce cleaning Time

• Improve reliability

12

Opadry®Key Factors of cleaning

• Temperature– Hot water is Bad– Cold water removes residue better

• Cleaning Process– Pre-rinse

• Separates soil can be problematic– Impingement

• Increased spray or agitation will improve removal– Detergent application

• Multiple applications maybe needed• Formulation is critical to

13

Detergents SelectionChematic 400 series

• Chematic 410 & 405– Two years in

development

– Formulated to remove Opadry II products

– Limits need for wiping

– Reduces disassembly

14

The Opadry II® cleaning process

• Opadry II®• White, Gray, YellowYellow, Orange, Blue

– 5% Chematic 410 at 30°C for 45 minutes– 5% Chematic 410 at 37°C for 45 minutes– Rinse - 37°C– Rinse - 30°C

15

The Opadry II® cleaning process (con)

• Opadry II® Brown

– 5% Chematic 405 at 33°C for 45 minutes– 5% Chematic 405 at 37°C for 45 minutes– Rinse - 37°C– Rinse - 30°C

16

Lab trial results

17

Results after Chematic Cleaning

18

Conclusion

• Limit wiping and disassembly with new Chematic 405 & 410

• Temperature is critical to maintain the product bond

• Hot water will reduce cleaning• Impingent helps in the cleaning process.• Do not let product dry in lines.

19

Cleaning Eudragit®

Time release coating

20

Eudragit® Cleaning key factors

• Dependent on pH• Layered batches• Addition of other

materials changes cleaning

• Manual cleaning• Requires scraping• Time consuming• Use of solvents

21

Cleaning Studies guidelines• Eudragit® L-100, L-100-55, L-30-55

– Chematic 82CIP Spray Applications: • Concentration: 2-10% v/v, depending on

application Temperature: 60-70ºC • Manual Cleaning: Concentration: 2% v/v

Temperature: 50-60ºC

• Eudragit® RS-P0, RS-100, RS-30D– Chematic 453Concentration:

• 10% v/v Temperature: 70ºC• 70ºCPost rinse should be Hot (70-80ºC) water

22

Results

• Using proper chemistry and Application

• Cleaning time reduced for 24 hrs to 3 hrs

• Simple application

23

Chematic 400 seriesChematic 405 & 410 & 453

• Mild pH• Low foaming• Detectable Method

– IMS (Ion Mobility Scan)– HPLC – TOC

• Application– CIP– COP– Manual

24

Things to consider

• Eudragit formulation

– Adding plasterers, talc, est.. will change cleaning

– Number of layer will increase cleaning time

– Temperature is critical to cleaning

25

Value of cleaning improvements

What is it worth?

26

Value of cleaning

• Reduce cleaning time– Labor cost– Increased production

time– Reduce safety

concerns– Easy validation– Simpler Reliable

cleaning

27

Coating pan Cleaning

Not Quantified

Value of Recovered Production Time

$425,000Value to Customer in Man Hours

3,125 / yrTotal Saving in Cleaning Hours

1.5 hrsChematic 410 Cleaning

6.5 hrsPrevious Cleaning

16Number of Coating Pans

28

E quipm ent O ptim ization

O ld M ethod C lean ing T im e Personnel M anhoursM JC T im e 13.45 2 26.9 58.6%M IC T im e 2 1.5 3 6.5%R un T im e 7.4 1.5 11.1 24.2%Setup T im e 3.25 1.5 4.875 10.6%

45.875C am paign (lo ts ) 7 .5

ave Per lo t 3 .526666667

N ew M ethodM JC T im e 8 2 16 45.7%M IC T im e 2 1.5 3 8.6%R un T im e 7.4 1.5 11.1 31.7%Setup T im e 3.25 1.5 4.875 13.9%

34.975C am paign (lo ts ) 14

ave Per lo t 2 .428571429

Average per lo t 1 .098095238

Equipm ent N o . o f Lo ts Equipm ent (hr)022 Lots per m onth 35 38.43333333022 Lots per year 420 461.2Increase in Production (Lots) 62.32Percent Increase in Production 14.8%

29

Conclusion

• Achieve better cleaning faster through new technologies and science

• Understand the T.A.C.T and it uses

• Understand the value of cleaning

• Set goals and value

30

Questions?

James SullivanDober

jsullivan@dober-group.com1.800.323.4983