Abstract:
An automated cleaning system for an endless belt conveyor. The cleaning system having a central control which controls pump supplying hot water, soap and a sanitizer to a plurality of controllable spray valves for plural spray bars.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a Continuation-In-Part of application Ser. No. 09/501,409, filed on Feb. 10, 2000, now U.S. Pat. No. 6,360,874. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to automated cleaning systems and more particularly to such a cleaning system for conveyors and conveyor belts such as those used in food processing plants. 
     BACKGROUND OF THE INVENTION 
     Meat processing and other food packaging plants have a multitude of conveyor systems that must be cleaned at least nightly in accordance with government regulations. In the past, workers have brought carts onto the plant floor with long hoses to clean the conveyors manually. The process consisted of 1) rinsing the conveyors with high-pressure hot water (˜140° F. @ 250 psi); 2) covering the conveyor with an industrial strength soap solution; 3) repeating the high-pressure hot water rinse to clear off the soap; 4) lifting the belts out of the conveyors so the aprons surrounding the conveyors and the belt guides underneath can be cleaned; 5) repeating the high-pressure hot water rinse to clear off any debris removed from the aprons or guides; 6) spraying a sanitizing solution on the conveyor. 
     Due to the stringent government regulations, this process is relatively standard in the food processing industry, although some variations may exist. The manual process does have several limitations, most obvious of which is amount of labor and time required for the process. The labor and time required to clean all of the conveyors in a single food processing plant will vary greatly depending on the number and length of the conveyors in the plant, but a typical plant is generally cleaned once per day. 
     SUMMARY OF THE INVENTION 
     In accordance with the objects listed above, the present invention is an automated conveyor cleaning system that performs most of the conventional conveyor cleaning steps without significant user intervention. The system involves outfitting the food processing plant with centralized high-pressure pumps, a chemical integration platform (“CIP”), and a plurality of strategically placed nozzle spray bars. The high-pressure pump allows for the rinse cycles to be performed at pressures higher than those used with a manual system. 
     The steps of the present invention are similar to those outlined above for a conventional system. The belts are first subjected to a high-pressure hot water rinse sent through the spray bars and nozzles by the central pumps. The same spray bars and nozzles are then used to coat the belts with detergent foam, after which the rinsing step is repeated. At this step the automated portion of the system pauses, so that the belts can be lifted out for cleaning underneath the belts and the conveyor aprons that surround the belts. To further aid the system, special lifters are used with certain types of conveyor belts to lift the belts out of the conveyor. 
     Once the side aprons are cleaned and the belts are returned to their operating location, the automated process continues with a high-pressure rerinsing to remove any debris left during the cleaning of the aprons or other manual cleaning. The spray bars then coat the belt with a low-pressure spray of sanitizing solution, which is allowed to dry in place. Preferably the spray bars are then purged with pressurized air to remove any excess sanitizer in the spray bars. 
     Programmable logic controllers (“PLCs”) are used with the CIP, with the inlet valves of the spray bars, and with the high-pressure pumps. The conveyors (that have some common properties) are grouped together and each such group is controlled by a PLC. For each plant there could be many such groups called zones. The PLCs are all networked, possibly by a proprietary fiber optic system or wireless Ethernet and are in turn networked with a supervisory control system (typically run on an NT PC). This allows for logging of the various parameters used for cleaning (i.e. temperatures, pressure, time) and the amount of water or chemicals used. 
     The system can also easily change the dilution rate for the chemicals (stored in bulk) at the CIP. The CIP will typically have three bulk chemicals connected thereto: an industrial soap, and two types of sanitizers (the sanitizers are alternated based on the bacteria type and its resistance to the sanitizer), and is capable of supplying the diluted chemicals to the entire plant. The operation of the high-pressure pumps is preferably driven, by variable frequency drives (“VFD”) and controlled by one of the PLCs mentioned above. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     So that the manner in which the above-identified features, advantages, and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiment thereof which is illustrated in the appended drawings. 
     It is noted, however, that the appended drawings illustrate only a typical embodiment of this invention and is therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. Reference the appended drawings, wherein: 
     FIG. 1 is a schematic view of the central facilities used in the present invention; 
     FIG. 2 is an isometric view of a typical manifold station used in the present invention; 
     FIG. 3 is a front view of a spray bar used in the present invention, showing its relation to a conveyor belt; 
     FIG. 4 is an isometric view of the spray bar shown in FIG. 3; 
     FIG. 5 is a side view of an alternate spray bar used in the present invention, showing its relation to a conveyor belt; 
     FIG. 6 is a front view of the spray bar shown in FIG. 5; 
     FIG. 7 is a close-up side view of nozzles on a secondary spray bar for use with cleated conveyor belts in the present invention; 
     FIG. 8 is an isometric view of belt lifters in a resting state for use with the present invention; 
     FIG. 9 is an isometric view of the belt lifters shown in FIG. 8 in an extended state; 
     FIG. 10 is an isometric view of the belt lifters shown in FIG. 9 in operation in relation to a conveyor system; 
     FIG. 11 is a system block diagram showing the SCADA and its connection to the system PLCs; 
     FIG. 12 is a conveyor belt cleaning spray bar with a center cleat cleaning spray bar; 
     FIG. 12 a  is a sectional view of a conveyor belt cleaning spray bar with a center cleat cleaning spray bar; 
     FIG. 12 b  is an illustration of a conveyor belt cleaning spray bar and center cleat cleaning spray bar nozzle configuration; 
     FIG. 13 is a front view of a belt constraint; 
     FIG. 13 a  is a top view of a belt constraint; and 
     FIG. 14 is an illustration of a system having a throttling valve. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1 the central facilities  10  of the present system are shown in schematic form. The central facilities  10  supply the necessary resources to an entire food processing plant for the present system to function, although it is conceivable to maintain a second or subsequent set of central facilities either as a redundant backup system or to divide the plant into two sections, each set of central facilities maintaining one section. It is preferable, however, to maintain only a single set of central facilities  10  to retain simplicity, as the central facilities  10  can be expanded to increase capacity plant-wide. 
     The central facilities  10  comprise sources for each of the resources used by the system. Namely, there exists a hot water source  12 , a compressed air source  14 , and a plurality of bulk chemical sources  16 ,  18 ,  20 . It is possible to keep the resource sources in a different physical location from the remainder of the central facilities  10 , although it is preferable to keep the bulk chemical sources  16 ,  18 ,  20  nearby. 
     As described below, the typical bulk chemicals in the preferred embodiment will comprise an industrial strength detergent  16 , and two sanitizers—one acidic  18  and one basic  20 . However, various other sanitizers can be utilized such as bleach, alcohol, or ammonia based sanitizers. The bulk chemical sources are in communication with a chemical integration platform (“CIP”)  22 . The CIP  22  comprises a conglomeration of pumps, a programmable logic controller (“PLC”)  23 , instrumentation (i.e. sensors and meters), and starters located typically on a single skid. The CIP  22  obtains concentrated chemical from the bulk sources  16 ,  18 ,  20 , possibly with the aid of transfer pumps  24 . It also receives water from a cool water source  26  to dilute with the concentrated chemical and keeps an ample supply of each chemical prediluted in batch tanks  28 . The PLC  23  monitors the level of diluted chemical in the batch tanks  28  and dilutes more as needed. The CIP  22  also contains the pumps to pump the diluted chemical from the batch tanks  28  to the remainder of the plant through the output lines  30 ,  32 ,  34 . In the prior art manual cleaning method, these chemicals would have to be manually prediluted and transported in the batch tanks to the various conveyor systems. 
     In addition to the software interlock that ensures that only one chemical distribution pump is in operation, the electrical wiring is hard wired such that only one pump can be energized at any given time. In normal operation, this method will eliminate the possibility of more than one chemical being supplied and the danger of the reaction of mixing two incompatible chemicals. 
     Also located in the central facilities  10  are high-pressure pumps  36  for the hot water supply  12 . Space may be reserved in the central facilities for additional pumps, in the event, for example, that plant capacity is expanded. In a similar manner, the types and quantities of chemicals may also be expanded. FIG. 1 shows an example of central facilities  10  having two pumps  36  and space reserved  38  for one additional pump  36  in the event of future expansion. Like the CIP  22 , the hot water pumps  36  will have a PLC  37  attached thereto controlling the pumps&#39; operation. The water in the hot water supply  12  should preferably be between 100° F. and 180° F. and the pumps  36  should preferably maintain the plant&#39;s supply of hot water at at least 300 psi. Current governmental regulations require water temperature of less than 180° F. for safety reasons. Applicants have found that 140° F. is optimal, given current regulations. However, should regulations change, hotter water temperatures would be preferable and are within the scope of the present invention. Applicants have also found that 500 psi water pressure is optimal for the present invention, however, higher pressures may be used. The pumps  36  supply hot water to the plant through the output line  40 , and should preferably use variable frequency drives (“VFD”). The centralized pumps  36  allow for significantly higher pressure water to be used than what is safely obtainable using a manual cleaning system. Furthermore, it is conceivable to have the pumps  36  pump cold water for rinsing during some stages of the cleaning process to save money and reduce condensation in the plant. 
     The compressed air is directed from its supply  14  straight to the output line  42 , and on to the remainder of the plant. A portion of this air, however, may possibly be diverted to the CIP  22  for its use and to a separate output line  44  for instrumentation use. 
     Referring now to FIG. 2, a typical manifold station  46  for the preferred system is shown. A plurality of these manifold stations  46  are dispersed throughout the plant. The manifold station  46  taps each of the supply lines  48 , which run throughout the plant. There are typically six supply lines  48 , one for each output line ( 30 ,  32 ,  34 ,  40 ,  42 ,  44 ) located at the central facilities. Each manifold station  46  will typically have four valves one for the hot water supply  50 , and one for each of the three diluted chemical types  52 ,  54 ,  56 . The manifold station  46  should preferably have a single manifold drain  58 . Additionally, each manifold station will have backflow prevention (not shown) to protect the potable water supply. Such backflow prevention is well-known in the art. Each manifold station  46  is controlled by a nearby PLC  47 , although multiple manifold stations  46  may be controlled by a single PLC  47 . In the preferred embodiment the plant is divided into a few separate zones, each manifold station belonging to exactly one zone, and each zone having exactly one PLC  47 . This arrangement allows for the conveyors in one section of the plant to be cleaned while the remainder of the plant stays operational. 
     From the main high-pressure water loop, as an option, the system could provide many branches with a pressure-reducing valve for hose drops to allow manual washing. From the main chemical loop that is carrying diluted chemicals, as an option, the system could also provide diluted chemical hose drops that provide diluted chemical for manual chemical spray. This eliminates workers handling of the chemicals and also insures proper chemical concentration. These hose drops and diluted chemical drops can optionally be located at the manifold station depicted in FIG.  2  and connected thereto or the hose drop and diluted chemical drop can be branches from the main loop of the fluid communication system. 
     The PLC&#39;s  47  used to control the manifold stations  46 , as well as the PLC  37  for the hot water pumps  36  and the PLC  23  for the CIP  22  can be any off-the-shelf type of PLC that is readily available. The inventors have found that the Momentum™ available from the Modicon® Corporation of Andover, Mass. is particularly suitable for the present invention. The PLC&#39;s are all interconnected and in communication with a supervisory control and data acquisition (SCADA) unit  94 . The connection between the PLC&#39;s and the SCADA  94  may be made by any conventional networking architecture, such as Modbus, Ethernet, or DeviceNet or any similar proprietary architecture. Each PLC preferably also has an operator panel  96  connected thereto. FIG. 11 shows a typical system block diagram of the interconnection of the SCADA  94 , the PLCs, and the operator panels  96 , connected with a ring network  98 . 
     The SCADA  94  can take the form of a simple controller with input mechanisms as simple as a touch keypad. The preferred embodiment of the SCADA  94  is, however, a computer workstation, such as one based on an Intel® architecture running Microsoft® Windows® NT/2000 and SCADA software, such as that available from Intellution, Inc. of Norwood, Mass. The PLC&#39;s are programmed with logic controller software, such as ProWorx NxT® available from Taylor Industrial Software of Edmonton, AB. The SCADA is responsible for sending control signals to the various PLCs as is described in further detail below. In case of a SCADA failure, the system may be operated directly from each PLC individually, for example by use of an operator panel  96 . 
     Connected to each manifold station  46  is a plurality of spray bars  60 ,  60   a . A typical spray bar  60  can be shown in FIGS. 3 and 4, or an alternative embodiment  60   a  is shown in FIGS. 5 and 6. The preferred spray bar  60 ,  60   a  will have an upper  62 ,  62   a  and lower leg  64 ,  64   a , each leg having a plurality of nozzles  66 . The spray bars  60 ,  60   a  are preferably mounted to the underside of a conveyor system such that the legs straddle the conveyor belt  68  as it moves in the inverted or underside position (that is the carrying surface of the belt  68  is faced down). This allows the spray bars  60 ,  60   a  to be permanently mounted without obstructing flow of product on the belt  68 . Each conveyor belt  68  will have at least one spray bar  60 ,  60   a . Certain belt configurations, such as those with cleats  70 , will have an additional spray bar  72  designed specifically to clean the cleats  70 . An example of such a configuration is shown in FIG.  7 . As can also be seen in FIG. 7, a guide  69  may be used to constrain the conveyor belt  68  during spraying. 
     The spray bar can optionally be strategically located at the idler end of the conveyor (closer to the pulley) so that the water is sprayed while the hinges are opening on the hinged (Intralox) type conveyors. It also helps in chemical retention after the solution is sprayed on the belts. The chemical will stay on top of the belt. 
     As discussed above, two different spray bars for cleaning the belt and cleats can be utilized. The same effect can be achieved by integrating the regular (flat belt) upper spray bar with a center cleat spray bar. The resultant is a new spray with nozzles at different angles to clean the flat belt and also the cleats. This reduces the water consumption. 
     Referring to FIGS. 12,  12   a  and  12   b , the upper leg portion  102  of the spray bar has a single row of nozzles  103  designed with an angle  105  cutting against the direction of conveyance  113  optimal for cleaning the belt  101 . The center leg portion of the spray bar  104  has two rows of nozzles  107  optimally angled with angle  109  to clean the cleats  111 . FIG. 12 b  is provided only as an illustration of the nozzle arrangement. The lower leg portion of the spray bar  106  has a single row of nozzles  115  similar to that of the upper leg portion  102  and has an angle  117  cutting against the direction of conveyance  113  and optimal for cleaning the belt  101 . 
     The nozzles  66  of the lower leg  64 ,  64   a  of the spray bar  60 ,  60   a  are preferably angled against the direction of movement of the belt  68  to create a cutting effect with the hot water, however such angling is not required to practice the invention. If an angle is used, it will be slight, but the optimal angle will vary with the conveyor configuration. For example, a flattop belt may use an angle of about approximately 15° and a typical angle for a cleated belt may be in the vicinity of 35° (from vertical). FIG. 7 shows the nozzles  66  configured to clean the cleats  70  on the belts  68  so equipped. The angles of the nozzles  66  for cleaning the cleats  70  are typically greater than the main lower nozzles  66 , but the angle will vary depending on the size of the cleat. When the secondary spray bars  72  are used for cleated belts, they should preferably be located near (between 2 and 3 feet) the primary spray bar  60 ,  60   a.    
     FIGS. 3 and 4 show one embodiment of the spray bar  60 . In this embodiment a flexible hose  74  pending from the manifold station  46  delivers whatever resource is provided there. The hose  74  leads into a “T” connector  76 , which simultaneously supplies the upper and lower legs  62 ,  64  of the spray bar  60 . The upper leg  62  of the spray bar  60  is passed through retainers  78  connected to the conveyor, one proximate to the “T” connector  76  and one distal thereto. 
     An alternate spray bar  60   a  is shown in FIGS. 5 and 6. In this embodiment both legs  62   a ,  64   a  of the spray bar  60   a  are connected by a hard pipe  65  to the inlet  67  of the spray bar  60   a . This provides a more durable connection than the embodiment shown in FIGS. 3 and 4. As can also be seen in FIG. 6, both the lower and upper legs  62   a ,  64   a  of the spray bar  60   a  are retained by the conveyor  80 , both proximate and distal to the spray bar inlet  67 . It can also be seen from FIG. 5 that the lower leg  62   a  of the spray bar  60   a  is offset downstream (in relation to the belt travel) from the upper leg  64   a . This allows the nozzles  66  on the upper leg  62   a  to be aimed straight downward and the nozzles  66  on the lower leg  64   a  to be angled as previously discussed, and still contact the belt  68  at the same point but on opposing surfaces. 
     With most conveyors there will also be a belt lifting apparatus  82  displayed in FIGS. 8-10. The belt lifting apparatus  82  is used in the majority of conveyors  80  except those without sufficient slack to be lifted, such as metal belts. FIG. 8 shows the belt lifters  82  in the resting (or contracting) state, which is used during normal operation and during the automated phases of the cleaning cycle. The belt lifter  82  comprises a pair of axles  84 ,  86 , a pair of pivot arms  88  that rotate about one axle  84 , a pair of extenders  90  that rotate about the other axle  86 , and a pair of rollers  92  located at the end of the pivot arms  88  respectively. The extenders  90  are coupled respectively to the pivot arms  88 , and are preferably pneumatically controlled, although a hydraulic, electrical or manual arrangement would also be feasible. The manual belt lifting device can have a crank handle for extending and retracting the lifters. Depending on belt width, the belt lifter  82  may comprise only a single pivot arm  88 , extender  90 , and roller  92  (for narrow belts) or more than two pivot arms  88 , extenders  90 , and rollers  92  (for wider belts). For safety reasons, it is desirable to have the actuation of the extenders  90 , and thereby the belt lifters  82 , spread over several seconds. 
     For the more narrow belts (for example, less that approximately 12′ wide), the belt may have only a single lifter to raise the belts. With only a single lifter, the belt has a tendency to fall off the lifter arm roller when lifted. The lifter mechanism can be designed and built with a constraint device that restricts the movement of the belt when it is lifted up and prevents it from falling off. FIGS. 13 and 13 a  show a front view and a top view, respectively, of one embodiment of a belt constraint  122  for single arm lifters  123 . The belt constraint is attached to the conveyor support structure  124 . The legs  126  of the constraint straddle the conveyor belt  128  on either side and extend upward above the belt and are canted inwardly toward one another bottom to top, when the single belt lifter lifts the narrow belt  128 , the belt constraint  122  prevents the belt from falling off the lifter. The belt constraint can take on other embodiments that have constraint members or legs that extend upward on either side of the belt. 
     During the manual cleaning phase of the present system (described in more detail below) the extenders  90  are extended from their contracted resting state. This extended state is shown in FIG.  9 . The extenders  90  are noticeably closer in length to the pivot arms  88  when in the extended state than when in the resting state. Each belt  68  on which belt lifters  82  are used will have more than one belt lifter  82 . An example belt  68  with the belt lifters  82  in the extended state is shown in FIG.  10 . As readily seen from the drawings, the slack of the belt  68  is taken up by the rollers  92  and the apron of the conveyor  80 , as well as other components normally hidden under the belt  68 , are exposed for manual cleaning. 
     For safety reasons, it is not recommended to have the extenders  90  activated by the SCADA unit  94 , but this arrangement is possible. In the preferred embodiment, the control for pneumatically activating the extenders is located in each zone at the operator panel  96 . 
     The entire system has two modes of operation—sequential and automated. In a typical automated mode, an operator located at the SCADA unit  94  indicates which zones are to be cleaned. The SCADA  94  sends a signal to the PLC  37  for the hot water pumps  36  to start. Once the pumps are started, the SCADA  94  sends a signal to the PLC  47  for the manifold stations  46  in the zone(s) to be cleaned to commence the initial phases. The initial phases consist of rinsing the belt  68  with the high-pressure hot water, covering the belt  68  with foam from a low pressure spray of the industrial detergent  16 , and repeating the high-pressure rinsing phase to remove the foam. The PLC  47  for a zone to be cleaned receives those signals and opens the valves  50  for the hot water for predetermined length of time, then closes the hot water valves  60  and opens the detergent valves  52 . After another predetermined length of time, the PLC  47  closes the detergent valves  52  and reopens the hot water valves  50 . Applicants recommend that the belts undergo between one and four revolutions of the belt  68  during each spray cycle. The PLC  47  may also open the valves in its zone sequentially so that only a portion of its spray bars  60  are active at any given time. 
     Once the initial phases are completed in the automated mode, it is preferable for the operator to lock out the conveyors, so that the conveyor belts  68  in the zones being cleaned will not run, but it is possible to operate the belt lifters  82  while the belts  68  are running. For belts  68  equipped with belt lifters  82 , the belt lifters  82  are activated lifting the slack in the belts  68  out of the conveyor  80 . Certain types of belts  68 , such as those made of metal, without sufficient slack, are left in place. Cleaning personnel then use conventional cleaning methods to manually clean components of the conveyor  80  other than the belt  68 . This includes the conveyor apron and the components under the belt  68  normally hidden from sight. This method of lifting the belts  68  is unquestionably safer and quicker than the prior art method of using crowbars to pry the belts out of the conveyor system. In the case of belts  68  without sufficient slack for belt lifters, manually cleaning of the aprons is done with the belts in place. 
     Once the manual cleaning phase is completed, the belt lifters  82  are returned to their resting state and, if the belts  68  are locked, the operator unlocks them. The operator indicates at the SCADA  94  that the final phases are to commence. The final phases consist of again rinsing the belts  68  to remove any debris loosened during the manual phase and a sanitizing phase. The rinsing phase is carried out identically to the previous rinsing phases, whereby the zone PLC  47  opens the hot water valves  50  at the manifold stations  46 , either in unison or sequentially. The PLC  47  then closes the hot water valves  50  and opens the appropriate sanitizing valves  54 ,  56 . The SCADA  94  will signal the PLCs  23 ,  47  which sanitizer is to be used. The preferred embodiment is a system having two sanitizer types although more or fewer may be used. When two are used one may be acidic  18  and the other may be basic  20 . However, as discussed above, other sanitizers, such as bleach, can be utilized. This rotation of sanitizer type is intended to prevent the formation of resistant strains of bacteria that adapt to one type of sanitizer, and is well-known in the art. Optimally, a final step may be included, whereby after PLC  47  closes the sanitizer valve  54 ,  56 , it opens manifold drain  58  for a period of time to release any fluids trapped in the manifold station  46 . The PLC  47  would then close the manifold drain  58  and purge the spray bars  60 ,  60   a  with air from the compressed air source  14 . The purging prevents clogging of the nozzles  66  and prevents sanitizer from dripping on the belts  68  during operation. 
     The final step of purging the Intellijanitor system can be accomplished by purging all lines (downstream of valves) with air to remove any remnant liquid. The following day or the next time the Intellijanitor system is started, there is a likelihood of getting water hammer (on high-pressure rinse) because of empty water lines. Therefore, performance of a pre-fill procedure allows the water at house-pressure (say 70-psi) to fill all pipes, thereby providing some back-pressure while running the high-pressure rinse step. In addition to the pre-fill procedure, a control valve is used and this valve is designed as a throttling valve to take abuse of high-low pressure swings in the operation of the cleanup system. Use of a throttling valve eliminates the need to utilize more expensive valves at the manifold that are designed to withstand the pressure swings and water hammer. Use of the throttling valve design allows the system to also be utilized with various line sizes because the throttling valve allows the system to withstand sudden pressure swing or water hammer. 
     For example, assume there are five (5) downstream valves that are connected to different spray bars. The control valve or throttling valve is upstream of this bank of five (5) downstream valves  132 . During the high-pressure rinse, the PLC sends a signal to open the first valve in the bank while the control valve or throttling valve  134  is still closed and holding, for example, 500-psi pressure. Once the first valve is opened, then the control valve  134  slowly opens up. Please note that each downstream valve can be opened for a preset time. A few seconds before the closing cycle of the first valve, the control valve  134  throttles down to substantially close, for example, about approximately 80% closed. This reduces the flow and pressure of the fluid. Now the second valve in the bank  132  opens up and the first valve in the bank of valves is closed. After the second valve is completely open, then the control valve opens up from, for example, 20% open to, for example, 100% open. The same cycle continues for the rest of the valves in the bank  132 . For the final fifth downstream valve, the control valve is closed first and then the fifth valve closes. This rinse cycle can be repeated for a single downstream valve and its respective spray bar repetitively for each rinse cycle or can be sequentially cycled through a bank of downstream valves as described above or any multiple combinations and variations thereof. Please note the number of banks or valves in a bank may vary to more than five (5) or less than five (5). The pressures and the open and closed percentages may vary depending on the dynamics of the given system. The amount or percent of opening and closing of the throttling valve may vary depending on the given system. Also, a single downstream valve can be communicably connected to and control multiple spray bars. 
     Referring to FIG. 14, for illustration of one embodiment, three chemical input lines  136 , one air line  138  and one high-pressure center line  140  is shown. The three chemical lines and the high-pressure water lines can each have a regulating throttling valve or control valve  134 , or optimally, one control valve can be positioned just downstream of the junction  142  of the four lines for throttling control of all four lines. 
     The chemicals are preferably sprayed at a low pressure that ideally ranges from 5 to 100 psi. Applicants have found that approximately 15 psi is optimal for the low-pressure sprays. Thus, for this low pressure, depending on the system and line sizes a throttling valve may not be required. 
     The entire time to complete cleaning in the automated mode is half that of the conventional, prior art method. This time savings allows a cleaning to be done in the middle of the day, between shifts for instance. Furthermore, this invention allows a sanitizer (perhaps a third type thereof) to be continuously sprayed on the belts during normal operation. Additionally, because the present system requires only a minimum of one revolution of each belt per cycle, as compared to five in the prior art method, the present system uses significantly less water and chemical than the conventional method, even though the spray bars  60 ,  60   a  may have a significantly higher water consumption rate than the hoses used in the prior art manual method. Actual water consumption can of course be calculated by multiplying the consumption rate per belt revolution by the number of revolutions. 
     In the alternative sequential mode, the operator instructs the SCADA  94  to commence each phase individually (i.e., rinsing, covering, sanitizing). After each individual phase is completed the system pauses until the operator indicates that he or she wishes to proceed. 
     It is preferable following the sanitizing phase to purge the nozzles and spray bars of any remaining liquid. This is accomplished at the direction of the SCADA  94  by the zone PLC&#39;s  47  using the compressed air supply for the plant. 
     The present invention is suitable for retrofit on a wide variety of conveyor systems. In particular, the present system seems well suited for the 100, 200, 300, 400, 800, 900, 1800, 2000, and 2200 series Intralox® acetal conveyor belts (flattop, nub top, and cleated) from the Laitram Corporation of New Orleans, La. It will also work with Volda and Diamond Back PVC conveyor belts, as well as polymer or steel slat conveyor belts and many other varieties. It is also possible to factory install components for the present system in the conveyor system. 
     In practice, a quality control inspection is then performed to insure that remaining level of bacteria on the conveyor equipment is within safe levels typically regulated by the government. If the bacteria levels exceed safe levels, the entire cleaning process must be repeated for that conveyor. Initial testing has shown that the present system requires recleaning 40% less often than the conventional, prior art method. 
     Optionally, the present system allows for logging of certain information that the prior art method cannot easily accommodate. For instance, the SCADA  94  can keep a log of how much water is consumed in the process, as well as quantities for each of the chemicals, and other operating parameters. Furthermore, for inspectors&#39; use, it can record the water temperature for each cleaning cycle and the type of sanitizer that was used on a given day, etc. 
     The SCADA unit controls and monitors all the Zone PLC, pump PLC, Chemical Distribution System, records and displays pressure, flow and temperature of the water or chemical that is being used. It displays the real time status of all instrumentation and also shows the status of the cleaning operation. For example, it can display which valve is open and the group of belts being washed. Maintenance personnel can identify any possible failures in the system. It can also act as a powerful data acquisition tool. Quality Control can analyze the graphs for any given day and time for the amount of water or chemical being used, pressure and temperature of the water or chemical being used. The data gathered by SCADA can be utilized in analyzing the effectiveness of the cleaning cycles, the cleaning fluids and chemicals, and water temperatures and pressures. If contaminants are detected, the cleaning operation data can be reviewed and analyzed. 
     As an alternative embodiment to the conveyor cleaning system as described above, the spray bars can be appropriately mounted to the conveyor structure while having no fluid connection to the manifold station or the main loop. The stand-alone spray bar can be adapted with a hose connection such that a fluid source base can be manually connected thereto, and thereby manually providing a source of fluid. This alternative embodiment can be useful for existing facilities where modification of the facility infrastructure is not a viable option. 
     While the foregoing is directed to the preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims, which follow.