PROCESS AND DEVICE FOR CLEANING SURFACES WHICH ARE HEAVILY SOILED WITH GREASE, STARCH AND/OR PROTEINS, ESPECIALLY IN THE FOOD PROCESSING INDUSTRY

Abstract: A process for cleaning surfaces which are heavily soiled with grease, starch and/or protein residues, especially for the food processing industry, in which the soiled surfaces are treated with an alkaline foam cleaning agent, characterized in that an effective amount of hydrogen peroxide solution is dosed to the chlorine-free alkaline foam cleaner at the latest 60 seconds before contact with the surface to be treated in order to obtain an effectively cleaning hydrogen peroxide foam. This avoids the use of chlorine which is harmful with respect to the environment, the hydrogen peroxide foam is surprisingly stable and the microbiological activity is unexpectedly good. A device which is especially appropriate for carrying out the process according to the invention is also provided.

Description: Process and device for cleaning surfaces which are heavily soiled with grease, starch and / or proteins, especially in the food processing industry. Field of the invention The invention concerns the technical field of cleaning heavily soiled surfaces in the food processing area, for instance in the meat and fish processing industries, vegetables processing or the pastry industry. The invention particularly concerns a process according to the concept as summarised in claim 1 as well as a device for carrying out the process according to the invention. Background of the invention In the food processing industry, in particular in heavily soiled areas, such as slaughterhouses or meat and fish processing industries, tenacious soiling through grease, protein and starch residues is the rule of the day. According to a practical state of the art, for cleaning such stubborn soiling, alkaline cleaning agents containing chlorine are regularly used. Because of the chlorine content of the cleaning agent, combined with an alkaline medium, the grease, starch and protein soiling is dissociated, whereby shorter molecule components are created from molecules with a longer chain, which are then capable of being emulsified by surfactants present in the cleaning agents. However, the high volumes of waste water created in this way cause severe problems because of their chlorine content. On the one hand, the environmental effect of waste water containing chlorine is not insignificant. On the other hand, if accidentally instead of an alkaline medium an acid medium exists or is created, gaseous chlorine may be generated, creating an occupational hazard. Therefore, the use of oxidising cleaning agents based on chlorine is generally problematic in the said industry areas. Hence the problem is posed to provide a less ecologically harmful cleaning process, which however, as regards its cleaning properties, is at least equal to processes using cleaning agents containing chlorine, or which exceed the cleaning action of the latter at equal or even lower dosages. A further purpose of the invention is to provide an appropriate device for carrying out the process. Definition of the invention These problems, as well as other problems which are not presented individually, are solved by a cleaning process of the type mentioned at the beginning, characterised by the features indicated by the characterising part of claim 1. Effective process modifications are protected by the sub- claims which are standing in relation to claim 1. With regard to a particularly appropriate device for performing the process according to the invention, the subject of claim 7 provides a solution for the problems underlying the invention. Favourable embodiments are the subject of the claims which relate to claim 7. Detailed description of the invention Because of the fact that an effective amount of hydrogen peroxide solution is added to the chlorine-free alkaline foam cleaner at the latest 60 seconds before contact with the surface to be treated, in order to obtain an hydrogen peroxide foam which is able to clean effectively, it is possible to substitute the alkaline foam cleaners which contain chlorine and which were being used generally up to now and which were causing environmental pollution because of their chlorine content. Because of the environmental harmlessness of a hydrogen peroxide solution, the environmental pollution is clearly reduced with a cleaning process according to the invention, in particular the substances used are a priori less harmful with respect to the environment. Furthermore, the cleaning process according to the invention is superior compared to the process according to the practical state of the art as regards occupational safety aspects. In case of accidental contact with acids or an acid medium, no toxic gases can develop from the cleaning system according to the invention. Finally, the cleaning process according to the invention provides further unexpected advantages as compared with the state of the art. Thus, it can be considered particularly surprising that it was possible after all that by using a hydrogen peroxide solution a foam cleaner is produced with sufficient foam stability. Apart from this, it could also not be expected that the cleaning action, which can be obtained with the cleaning process according to the invention, is a clear improvement on the most recent state of the art. Finally, the professional could not foresee without anything else that the foam system consisting of two components possesses, apart from a cleaning activity, also a microbiological activity, which is increased unexpectedly in comparison with the use of individual components. The alkaline foam cleaner to be used in the cleaning process according to the invention consists of at least two components, which should be mixed shortly before application. In this respect, "shortly" means, in the sense of the invention, that one of the components, i.e., the chlorine- free alkaline foam cleaner, has to be mixed with the other component, i.e., the hydrogen peroxide solution, not later than 60 seconds before the contact with the surface to be treated. If this interval is clearly exceeded, oxidative deterioration of the cleaning components contained in the alkaline foam cleaner may develop. One should strive to mix both components as shortly as possible before application to the surfaces to be cleaned. This corresponds with a preferred modification of the process according to the invention, i.e. to add the hydrogen peroxide solution to the chlorine-free alkaline foam cleaner at the latest 10 seconds before contact with the surface to be treated. The cleaning process according to the invention is characterised as being particularly effective when the hydrogen peroxide solution is added to the alkaline foam cleaner within a period of time in the range of 0.01 to 1 seconds before contact of the hydrogen peroxide foam, which is being released during the addition, with the surface to be treated. Thereby, pre-mixing of both components of the foam cleaning system to be applied according to the invention may be done in any manner which is known to the professional and which is appropriate at the same time. Thus it is e.g. possible to mix the chlorine-free alkaline foam cleaner and the hydrogen peroxide solution batch-wise together and then to use them within a short period of time. Contrary to this, however, it is much more preferred to add the hydrogen peroxide solution continuously to the alkaline foam cleaner solution. In this context, both components to be kept separately until shortly before the application, for example as concentrates, may be adjusted by means of water under pressure to the application concentration. It is particularly advantageous to dose the hydrogen peroxide solution in such a quantity as is required for the consumption of the hydrogen peroxide foam which is active in the cleaning of the soiled surfaces. With respect to batch-wise mixing, this continuous process furthermore has the advantage that it is capable to practically prevent completely the premature dissociation of the H 2 0 2 into inactive components in the alkaline cleaning solution. In the alkaline medium, H202 is converted much more into the active H02 anion, which then should be considered to be the actual oxidising bleach component. In this way, because of the minimal mixing and contact times during the continuous process, the efficiency of the hydrogen peroxide foam cleaner according to the invention is clearly enhanced as compared to a batch-wise procedure. The process according to the invention may be performed in a particularly advantageous way by using special mixing devices, which enable intensive mixing of both components of the foam cleaning system according to the invention at extremely short mixing times, while allowing the air supply which is required for producing the foam. For this purpose, for instance, special injection systems, which will be described further following hereafter, are particularly appropriate. One of the components of the foam cleaning system according to the invention concerns a chlorine-free alkaline foam cleaner. The chlorine-free alkaline foam cleaner may be present as a pre-concentrate, which preferably is liquid and consists of : (i) 3 - 30 wt. % alkali hydroxide (ii) 1 - 10 wt. % alkyl amine oxide with the general formula I CmH2m+l NO (CnH2n+l ) x (CnH2n+l ) y (I) whereby m is an integer from 8 - 18, n is 1 or 2 and x and y are integers from 0-2, and x + y = 2, (iii)2 - 10 wt. % usual ingredients and (iv) made up to 100 wt . % with water. This pre-concentrate is diluted at the time of application or shortly before to a concentration of between 0.1 and 5 weight per cent, preferably 0.1 - 2.5 weight per cent, particularly advantageously 0.15 - 2 weight per cent active ingredients (i) + (ii) , usually with water or aqueous media, for instance water under pressure. An essential component of the chlorine-free alkaline foam cleaner is the component (i) . Among the alkali hydroxides capable of being used are LiOH, NaOH, KOH. Of these, KOH and NaOH are preferred, and NaOH is particularly preferred. The alkali hydroxides may be used in solid form or in the form of a solution for producing the chlorine-free alkaline foam cleaner. Usually they are present in the dissolved form in the foam cleaner, or at least they are dissolved in the application solution. Component (ii) of the chlorine-free alkaline foam cleaner is also an essential component. Alkyl amine oxides according to the general formula I are known as such and are familiar to the professional. The compounds mentioned are either commercially available or may be synthesised according to known processes. The alkyl amine oxide according to the general formula I shows a cationic behaviour under acidic conditions (pH < 3) , however, under the alkaline or neutral pH values to be maintained according to the invention they behave as non- ionic surfactants. The alkyl amine oxides mentioned show a particularly high foam stability. Among the compounds according to the general formula I, particularly suitable are those in which: m = 8 - 16 n = 1 x = 1 and y = i Furthermore, compounds for which m = 10 - 14 are preferred. Component (iii) contains all usual ingredients, which are applied in conventional alkaline foam cleaners, among others also in chlorine containing foam cleaners. The usual ingredients include the builders, like alkaline substances (e.g. potassium and sodium carbonate, sodium silicate); co plexing agents (e.g. sodium diphosphate, sodium triphosphate, nitric acetic acid (NTA) , nitrilo trimethyl phosphonic acid, 2 phosphonobutane-1, 2, 4- tricarboxylic acid, 1-hydroxyethane-l, 1 diphosphonic acid, N- (2-hydroxyethyl) imino diacetic acid, ethylene diamino tetra acetic acid (EDTA) , 1,2,3,4 cyclopentane tetracarboxylic acid, citric acid, o-carboxymethyl tartaric acid, o-carboxymethyl oxysuccinic acid) ; and ion exchangers (e.g. poly (acrylic acids), poly(acrylic acid co- alkylalcohols) , poly(acrylic acid comaleinic acid), poly (α-hydroxy acrylic acids), poly (tetramethylene-1, 2 dicarboxylic acids), poly (4-methoxytetramethylene-l, 2 dicarboxylic acids), sodium aluminium silicates). Furthermore, the usual ingredients include among others bleaching substances, with the exception of chlorine- containing compounds (e.g. perborate); bleach activators (e.g. tetra acetyl glycoluril, tetra acetyl ethylene diamine (TAED) , sodium-p-iso nonanoyl oxybenzene sulphonate (iso-NOBS) ; bleach catalysts and bleach stabilisers. Other possible ingredients could include additives such as enzymes (e.g. serin proteases, metalloproteases, SH- proteases, carboxyproteases, amylases, upases) ; so-called "soil anti-redeposition agents" (e.g. carboxy methyl cellulose derivatives (CMC) , carboxy methyl starch (CMS) ; foam regulators (e.g. fatty acid amides, fatty acid alkanol amides, betaine, sulpho betaine, alkyl poly glycosides, alkyl benzene sulphonates, alkyl sulphonates, fatty alcohol ethoxylates and/or propoxylates) ; corrosion inhibitors (e.g. soluble sodium silicate); perfumes; colorants; fillers (e.g. sodium sulphate); and formulating additives (e.g. alkyl benzene sulphonates, urea, alcohols, polyglycol ethers) . With the indicated amounts of (i) to (iii) , and by adding up to 100 wt. % with water, it is possible to produce a pre-concentrate of a chlorine-free alkaline foam cleaner, which can be used not only as a pre-concentrate, but also directly as an application concentrate, provided the water content exceeds 85 weight per cent. The other component of the two component system to be used according to the invention is standard hydrogen peroxide solution. For this purpose it is particularly preferred, in order to produce the alkaline hydrogen peroxide foam, to dose 30% H2O 2 solution to the chlorine-free alkaline foam cleaner, whereby the amount is selected in such a way that the application concentration with respect to the H202 concentration in the hydrogen peroxide cleaner is between 0.1 and 1 weight per cent. The H202 amount is preferably 0.2 - 0.6, especially preferred for the purpose is 0.3 - 0.5 weight per cent. As already mentioned, both solutions are most advantageously dosed separately by means of an injector system, so that the application concentrations may be individually adjusted to the degree and type of soiling present. This measure can be realised in an extremely effective way by using a special injector system. Therefore, the object of the invention is also a device for performing the process, enabling separate dosing of both solutions. Through the special design of the turbulence chamber and the way the compressed air is added, particularly an improved foam structure is obtained. Apart form this, surprisingly also a particularly fine and long- lasting foam was obtained. Following hereafter, the invention is explained in more detail by means of examples and comparative examples. The cleaning performance of a foam cleaning system according to the invention was tested on standard types of soiling, whereby it was surprisingly shown that the system according to the invention surpassed commercially available alkaline foam cleaners containing chlorine as regards dirt removal. The tested standard types of soiling consisted of: 1. Grease / flour soiling with : - 30 % molten lard - 30 % wheat flour 3 % corn flour - 37 % distilled water 2. mashed chicken liver 3. milk paste with - 60 % skimmed milk powder - 40 % distilled water Test procedure : 1. A clean, dry stainless steel plate, with dimensions 10 x 10 cm, is weighed. 2. The standard soiling is applied to the plate. Excess soiling is removed with a serrated knife. 3. After 2 hours drying at 40 °C, the plate is weighed again. 4. The plate is immersed in 5 % test solutions and stored during various periods of time, depending on the type of soiling : grease / flour 60 minutes chicken liver 30 minutes milk 15 minutes 5. At the end of each test period, the plate is removed from the solution and immersed for 30 seconds in distilled water, to remove residual solution. 6. The plate is dried at 40°C during the night and weighed again. 7. Subsequently, the percentage removed dirt is calculated. All tests are checked by means of double samples and controlled by means of a reference sample. If the reference sample deviates more than 10% from the average values, the test is repeated. The commercially applied foam cleaners used for comparison purposes contain next to polyacrylates for hardness stabilising : The cleaning results which can be achieved with these are not as good as the dirt removal obtained with the present system : Microbiological activity The foam system described possesses, apart from a cleaning activity, also a microbiological activity, which is unexpectedly enhanced as compared with the individual components. The microbiological behaviour was tested by means of a modified European suspension test based on two test germs which frequently occur in the food industry, staphylococcus aureus and pseudomonas aeruginosa, and compared with a 30 % hydrogen peroxide solution at pH 8 (see K.H. Wallhauser, 'Praxis der Sterilisation- Desinfektion-Konservierung' , 4th ed., Georg Thieme Verlag, Stuttgart, 1988) and also compared with a commercially available alkaline foam cleaner. The latter contains, besides hardness stabilisers, about 11% alkali hydroxide and 3% alkyl amine carboxylate. An example of the realisation of the injection device for carrying out the process according to the invention is explained in further detail, with reference to the drawings, following hereafter. Fig. 1 shows a sectional representation of a preferred execution of the injection device and Fig. 2 shows a front view of the injection device in the direction as pointed by the arrow II in Fig. 1. The injection device shows a hexagonally shaped metal housing body 1, for accepting a jet assembly 2, which is screwed into an axial body boring 3. The jet assembly 2 includes a jet duct 4 which is shaped as a propulsion jet with a cone shaped section 4a and a cylindrical section 4b. A flow channel 5 designed as collecting jet is connected onto the propulsion jet 4, which flow channel shows a first cylindrical section 5a in the direction of flow, which passes into a second cylindrical section 5b of which the flow cross-section is larger than that of the first section. In doing so, the first section 5a of the flow channel 5 which is designed as a collection jet shows a larger flow cross-section than the cylindrical channel 4 b of the propulsion jet 4. In the direction of flow, immediately after propulsion jet 4, the jet assembly 2 shows a circular groove 6, so as to form a circular space 7 in housing body 1 in which two inlet bores 8,9 terminate, which bores run transversally with respect to the axial boring in the housing. For connecting the tubes, which are not shown in the figures, two connections 10, 11 are provided, which are bolted to the injector body 1 and each of which are showing a butterfly valve with adjusting screw 10a, 10b and a return valve. The circular space 7, in which the inlet bores 8,9 terminate, is placed, via a transverse passage boring 12, immediately behind propulsion jet 4 in the direction of flow, and is connected to the flow duct of collection jet 5 and is laterally sealed against body 1 by means of two sealing rings 13, 14 which are fitted into two circular grooves of the jet assembly. The rear section of the axial body boring in the direction of flow shows a larger cross-section than the middle section. This section forms a cylindrical turbulence chamber 15, in which the cylindrical body 16 of jet assembly 2 extends. Above the outlet orifice 16a of jet assembly 2, the injector body 1 shows a boring 17 which runs transversely and which is blocked on one side by a stopper 18. A connector 19 for a compressed air feed hose is screw fitted into boring 17 on the other side of the housing body. An inlet channel 20 with a cone shaped and a cylindrical section is provided in the housing body in the direction of flow ahead of the injection assembly 2, which passes into the cylindrical section of the flow channel 4 of the propulsion jet. The injection device operates as follows. Water under high pressure is fed through inlet 20 to the injector. Because of the reduction of the flow cross-section in propulsion jet 4, the flow speed of the transport medium is increased. The water leaving propulsion jet 4 sucks the foam cleaning agent which is fed through inlet boring 8 into the circular space 7 and the hydrogen peroxide solution which is fed via the inlet boring 9 through the transverse boring 12 into jet assembly 2, so that the fluids are mixed and are flowing from the jet assembly into the turbulence chamber 15, where the foam forming starts through the feeding of compressed via the compressed air connection 19. The dosing of both solutions may be performed thereby separately by means of the adjustment screws 10a, 11a. The cleaning foam is drained away by means of a tube which is not shown in the figures and which is connected to outlet 21 of the injector. Because the compressed air which is fed above the outlet orifice of the jet assembly into the circular space of the turbulence chamber 15, which is formed by the walls of axial boring 2 and the jet body 16, is directed sideways by the jet body, the flow of air has the same flow direction as the flow of fluid. Therefore foaming is improved and the use of chemicals is reduced.

Claims: CLAIMS 1. Process for cleaning surfaces which are heavily soiled with grease, starch and / or protein residues, especially for the food processing industry, whereby the soiled surfaces are treated with an alkaline foam cleaner, characterised in that an effective amount of hydrogen peroxide solution is dosed to the chlorine-free alkaline foam cleaner at the latest 60 seconds prior to the contact with the surface to be treated, so that an effectively cleaning hydrogen peroxide foam is obtained. 2. Process according to claim 1, characterised in that the hydrogen peroxide solution is dosed at the latest 10 seconds prior to the contact with the surfaces to be treated. 3. Process according to claim 1, characterised in that the hydrogen peroxide solution is dosed to the alkaline foam cleaner within a period of time in the range of 0.01 - 1 seconds prior to contact of the hydrogen peroxide foam, which is formed, with the surfaces to be treated. 4. Process according to any one of the preceding claims, characterised in that the hydrogen peroxide solution is continuously dosed in such a quantity as is used up by the hydrogen peroxide foam for effectively cleaning of the soiled surfaces. 5. Process according to any one or more of the preceding claims, characterised in that a foam cleaner is used which is diluted to an application concentration of 0.1 to 5 wt . % alkali hydroxide, which consists of a fluid concentrate of (i) 3 - 30 wt. % of an alkali hydroxide (ii) 1 - 10 wt. % of an alkyl amine oxide with the general formula I CmH2m+l NO (CnH2n+l) x (CnH2n+l) y (I) in which : m - an integer from 8 - 18, n = 1 or 2 x = 0, 1 or 2 y = 0, 1 or 2, and x + y = 2. (iii)2 - 10 wt. % of the usual ingredients and (iv) the rest made up to 100 wt. % with water. 6. Process according to claim 5, characterised in that a 30 % hydrogen peroxide solution is added for producing the alkaline hydrogen peroxide foam, by dosing in such an amount that the application concentration calculated on basis of H202 is between 0.1 and 1%. 7. Device for carrying out the process according to any one of the claims 1 to 6, with a housing body (1) which is provided with an inlet (20) for feeding pressurised water, a propulsion jet (4) which is placed in the direction of flow behind the inlet and a collection jet (5) which is placed behind the propulsion jet, which is flow-connected with an inlet (10) for feeding the foam cleaning agent and an inlet (11) for feeding the hydrogen peroxide solution, whereby the collection jet (5) shows an elongated jet body (16) which extends into a turbulence chamber (15) which is fitted with an inlet (19) for the feeding of compressed air and an outlet (21) for the hydrogen peroxide foam which is effective in the cleaning process and said inlet and outlet are fitted in the direction of flow ahead of the outlet orifice (16a) of the jet body. 8. Device according to claim 7, with the characteristic that the turbulence chamber (15) essentially has a circular shape. 9. Device according to claim 7 or 8, with the characteristic that the jet body (16) which extends into the turbulence chamber essentially has a circular shape.

Inventors: JOHN ANDREAS, JOHN, ANDREAS
Applicants: UNILEVER NV, UNILEVER PLC, UNILEVER N.V.
Application year: 1997
Main classification: C11D17
IPC codes: B08B3, C11D1, C11D3, C11D7, C11D11