Control system and method for controlling the concentration of electrolyzed water in CIP applications

Abstract

A control system for using an electrolytic solution for an automated recirculation or once-through cleaning system such as a clean-in-place (CIP) application is disclosed. A control system and method for using an automated chlorine output solution for a variety of cleaning applications is measurable over a wide pH range. The control system produces a consistent and predictable electrolytic solution and includes a measurement system for determining chlorine oxyanion concentration over a wide pH range, overcoming the sensitivity of chlorine monitors to pH and allowing the use of the control system to control a cleaning system.

Description

[0001] This application is a divisional application of application No. 201410642985.8. Field of the Invention

[0002] The present invention relates to the use of electrolysis technology, including electrolyzing aqueous solutions, for automated recirculation or once-through cleaning systems such as cleaning-in-place (CIP) applications. In particular, the present invention provides control systems and methods for producing consistent and predictable electrolytic solutions with measurable chlorine content for use in cleaning systems. Control systems are disclosed for automated chlorine output and measurement over a wide pH range for use in cleaning systems such as CIP systems and control of cleaning systems such as CIP systems. Background of the Invention

[0003] Cleaning in place (CIP) technology uses a combination of chemical and mechanical actions to clean the interior of a system without requiring time-consuming and labor-intensive system disassembly and manual cleaning. The CIP cleaning method is suitable for removing dirt from the internal components of tanks, pipelines, pumps and other process equipment. Methods and systems for CIP cleaning are often used, for example, to clean processing equipment with liquid product streams, such as those used in the food and beverage, pharmaceutical, textile and clothing industries. Further discussion of CIP operations can be found, for example, in U.S. Patent Nos. 6,197,739, 6,953,507 and 6,991,685, the entire disclosures of which are fully incorporated herein by reference.

[0004] The CIP operation usually includes the circulation of chemicals (such as detergents, antimicrobial agents, etc.) to regularly clean the system. Frequently, the CIP method includes a first rinse, i.e., the application of a cleaning solution, a second rinse with potable water, and then a repeat operation. The method may also include any other contact steps, wherein rinsing, acidic or alkaline functional fluids, solvents or other cleaning components such as hot water, cold water, etc. may contact the equipment at any step during the method. In addition, the final potable water rinse step may be omitted to prevent the equipment from being contaminated by bacteria after the cleaning and / or sanitization step. Before restarting normal processing, remove chemical residues from the system, and / or discard any product contacted by the cleaning chemicals.

[0005] There is an increasing need to develop suitable compositions for CIP applications, including chemicals that can be used for cleaning, sanitizing and disinfecting. There is also an increasing need to produce cleaning chemicals on-site. On-site chemical production can be achieved by electrolysis of water and electrolytes to produce alkaline detergent solutions of sodium hydroxide (NaOH), hypochlorite solutions or chlorine for use as detergents, bleaches, surface sanitizers and other disinfectant purposes. The electrolysis of water and salts using this method is well established. Alkaline solutions of sodium hydroxide (or "caustic" or "base") and acidic solutions of hypochlorous acid are formed. Depending on the structure of the electrochemical cell, various effluents can be produced. For example, a cell separated by one or more membranes produces both hypochlorous acid and sodium hydroxide. Alternatively, an electrochemical cell that is not separated by a membrane produces sodium hypochlorite salt (commonly known as bleach). The products obtained by the electrolysis of water and salt solutions provide a source of chlorine-based detergents and disinfectants with many cleaning and sanitizing capabilities. These chlorine-containing oxidants are biocides that effectively kill bacteria, viruses, parasites, protozoa, molds, spores, and other pathogens.

[0006] The use of electrolytic solutions for CIP applications produces high and variable concentrations of chlorine, requiring chlorine measurement to maintain concentrations sufficient for cleaning and sanitization without reaching levels that corrode the CIP system. As a result, accurate chlorine measurement is necessary for electrolytic CIP solutions. However, commercially available chlorine monitors are designed to detect chlorine levels at smaller concentrations, such as those associated with water treatment processes (about 0.5 ppm to about 3 ppm). See, for example, U.S. Pat. No. 5,422,014, which describes the pH limits of chlorine monitors, the entire disclosure of which is fully incorporated herein by reference. As a result, the pH variability of the chlorine content achieved by the electrolytic solution, the water supplied to the electrolytic solution, and / or the water used to dilute the electrolytic solution makes it impossible to use the electrolytic solution for CIP applications. The chlorine measurement required is impossible.

[0007]

[0011] It is therefore an object of the claimed invention to develop a control system and method for measurable, automated chlorine output for automatic recirculation or once-through cleaning systems such as CIP applications.

[0008] Another object of the present invention is to develop a system and method for using an electrolytic solution based on having a measured correct chlorine oxyanion concentration.

[0009] Another object of the present invention includes a system and method for automatic control of chlorine measurement over a wide pH range. SUMMARY OF THE INVENTION

[0010] The present invention provides a control system including a measurement system for determining chlorine oxyanion concentration over a wide pH range, overcoming the sensitivity of chlorine monitors to pH and allowing the control system and associated methods to be used for electrolytic solutions in various cleaning applications such as cleaning-in-place (CIP) applications. An automated method using an electrolytic solution having a measured chlorine oxyanion concentration is provided for CIP and other cleaning applications.

[0011] In one embodiment of the invention, the control system for automatic recirculation or once-through cleaning applications uses a solution of electrolytically generated chlorine oxyanions including, for example, hypochlorite, chlorite, chlorate, and perchlorate anions, including an electrolytic solution, wherein a first portion is in fluid communication with a chlorine sensor. Additionally, a pH modifier is in fluid communication with the first portion of the electrolytic solution to enable accurate measurement of chlorine oxyanion concentrations of about 10 ppm-1000 ppm, and an output to the cleaning application is provided. The control system is suitable for use in a variety of cleaning applications, including, for example, CIP cleaning or sanitization applications for food or beverage processing equipment, textile or clothing processing equipment, and surfaces including plates, glasses, silverware, and other food preparation, handling, and serving equipment that require cleaning or sanitization.

[0012] In another embodiment of the present invention, a control system for an automatic recirculation or once-through cleaning system for a chlorine oxyanion solution generated by electrolysis is described. According to the embodiment, the control system includes an electrochemical cell for in-situ generation of an electrolytic solution, wherein a first portion of the electrolytic solution is in fluid communication with a chlorine sensor. In addition, a carbon dioxide source is in fluid communication with a portion of the electrolytic solution measured by the chlorine sensor, which changes the pH of the portion of the electrolysis to enable accurate measurement of chlorine oxyanion concentrations of approximately 10ppm-1000ppm, and a system output delivers the electrolytic solution to the cleaning system.

[0013] According to another embodiment of the present invention, the portion of the electrolytic solution that is altered to perform the chlorine oxyanion concentration measurement can then be discarded or delivered back to the control system for additional circulation. In addition, the chlorine sensor output can be used to control the system itself. For example, according to one embodiment, the feedback signal can adjust the electrolytic solution level or the volume pumped through the system. In addition, the feedback signal can control the electrolytic solution itself. For example, according to another embodiment, the feedback signal can adjust the electrolytic solution concentration.

[0014] According to another embodiment of the present invention, a control system for measuring the chlorine oxyanion concentration of an electrolytic solution used in an automatic recirculation or once-through cleaning system includes an electrolytic solution concentrate source and a dilution water source for producing an electrolytic solution, a chlorine sensor in fluid communication with a first portion of the electrolytic solution, a pH modifier capable of controlling the pH of the first portion of the electrolytic solution to be between about 5.5 and 7.5 to ensure accurate measurement of a chlorine oxyanion concentration of about 10 ppm to 1000 ppm, and a feedback loop mechanism activated based on the chlorine sensor measurement to adjust the chlorine oxyanion concentration in the electrolytic solution.

[0015] Another embodiment includes a cleaning or sanitizing method using electrolytically generated chlorine oxyanions for an automatically recirculating or once-through cleaning system, comprising obtaining an electrolytic solution from a control system, and applying the electrolytic solution to a cleaning system in need of cleaning or sanitizing. Another embodiment of the present invention includes an antimicrobial treatment method using electrolytically generated chlorine oxyanions in an automatically recirculating or once-through cleaning system, comprising diluting an electrolytic concentrate in water to produce an electrolytic solution, wherein the chlorine oxyanion concentration is determined using the control system of the present invention, and applying the electrolytic solution to a cleaning system in need of antimicrobial treatment.

[0016] These and other embodiments of the invention are disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 A schematic diagram of one embodiment of the control system of the present invention for obtaining a measurement of chlorine oxyanion concentration from a portion of an electrolytic solution is shown.

[0018] Figure 2 Another schematic diagram of another embodiment of the control system of the present invention for obtaining a measurement of chlorine oxyanion concentration from a portion of an electrolytic solution is shown.

[0019] Figure 3 A schematic diagram of one embodiment of the present invention employing a CIP system controlled as a result of effective chlorine oxyanion concentration measurement is shown.

[0020] Figure 4 A schematic diagram of another embodiment of the present invention employing a CIP system that controls as a result of effective chlorine oxyanion concentration measurement is shown.

[0021] Figure 5 The effect of the electrolytic solution on the pH of the water source is shown.

[0022] Figure 6 The effect of the electrolytic solution on the pH of the water source is shown.

[0023] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] Embodiments of the present invention are not limited to specific control systems and methods for using electrolytically generated chlorine oxyanions for cleaning applications including in-situ cleaning (CIP) applications, which can be changed and can be understood by the skilled person. It should also be understood that all terms used herein are only for the purpose of describing specific embodiments and are not intended to be restrictive in any manner or scope. For example, the singular forms "one", "a kind" and "the" used in this specification and the appended claims may include plural indicators unless the content clearly indicates otherwise. Moreover, all units, prefixes and symbols can be expressed in their SI accepted form. The numerical ranges mentioned in this specification include the numbers defining the ranges, and each integer included in the defined range.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the meanings commonly understood by those of ordinary skill in the art to which the embodiments of the present invention belong. Many methods and materials similar to, modified or equivalent to those described herein can be used in the practice of the embodiments of the present invention without excessive experiments, and preferred materials and methods are described herein. When describing and claiming embodiments of the present invention, the following terms will be used according to the definition given below.

[0026] As used herein, the term "about" refers to variations in numerical amounts that may occur, for example, through typical measurement and liquid handling procedures used to prepare concentrates or use solutions in the real world; through inadvertent errors in such procedures; through differences in the manufacture, source, or purity of the ingredients used to prepare the composition or perform the method; and the like. The term "about" also encompasses different amounts due to different equilibrium conditions of the composition resulting from a particular initial mixture. Whether or not modified by the term "about," claims include equivalents of quantities that refer to variations in numerical amounts that may occur, for example, through typical measurement and liquid handling procedures used to prepare concentrates or use solutions in the real world; through inadvertent errors in such procedures; through differences in the manufacture, source, or purity of the ingredients used to prepare the composition or perform the method; and the like.

[0027] The term "chlorine" as used herein refers to chlorine compounds and chlorine oxyanions present in the solution produced by electrolysis (i.e., the electrolytic solution). According to the present invention, chlorine oxyanions can include, for example, hypochlorite, chlorite, chlorate, and perchlorate anions. Chlorine should also be understood to include the term "free chlorine", in which the total concentration of hypochlorous acid and hypochlorite ions is measured. It will be understood by those of ordinary skill in the art that different chlorine species predominate at different pH values ​​due to the reactivity of chlorine as a function of pH.

[0028] The terms "cleaning in place" and "CIP" used herein refer to various cleaning applications, including, for example, the cleaning of any internal and / or external components of a system. According to the present invention, CIP should also be understood to include circulating and / or self-contained or once-through cleaning methods. System components often include pipelines, containers, tanks, pumps and other process equipment that need to be cleaned by circulating or spraying cleaning compositions. System components are used in various industrial applications, including, for example, food and beverage, pharmaceutical, textile and clothing processing equipment. The use of such processing equipment in the food and beverage industry, for example, for industrial manufacturing of food and beverages, causes the surface to be contaminated by dirt due to contact with food or beverage products and such products remaining on the surface. Dirt can include carbohydrates, protein dirt, hard dirt, food oil dirt and / or other dirt and residues, which arise from the manufacture of liquid and solid food materials. CIP applications remove, clean, sanitize and / or disinfect the surfaces being treated and dirt that is often difficult to remove. Further explanation of process equipment fouling is described in U.S. Patent Application Serial No. 10 / 928,774, the entire disclosure of which is fully incorporated herein by reference.

[0029] As used herein, the terms "electrolytic solution", "electrolytically produced chlorine oxyanions", "electrolytic solution containing chlorine oxyanions", "electrolytic concentrate", etc., refer to any electrolytic solution source having a source of chlorine oxyanions. The output of the electrochemical cell may vary, depending on the structure of the cell and the components added to the system. However, the chlorine-containing electrolytic solution should be understood to include the same chemicals, namely chlorine (Cl2), chlorite (ClO2), chlorate (ClO3), hypochlorous acid (HOCl), hypochlorite ion (OC1-), perchlorate anion and sodium hypochlorite (NaOCl) (which may be referred to as anolyte, ECA, EO water, MOS, etc., as may be referred to as the "bleach" product). Those skilled in the art will understand that any chlorine-containing electrolytic solution may be included within the scope of the present invention for providing a control system for using electrolytically produced chlorine oxyanions for CIP applications.

[0030] As used herein, the terms "feed water", "dilution water" and "water" refer to any water source that can be used with the methods and systems of the present invention. Water sources suitable for use in the present invention include a wide range of qualities and pHs, and include, but are not limited to, tap water, well water, water supplied by a municipal water system, water supplied by a private water system, and / or water directly from the system or well. Water can also include water from a reservoir used, such as a circulating water tank for storing circulating water, a storage tank, or any combination thereof. It should be understood that regardless of the source of the incoming water used in the systems and methods of the present invention, the water source can be further treated within the manufacturing facility. For example, lime can be added for mineral precipitation, carbon filtration can remove odoriferous contaminants, additional chlorine or chlorine dioxide can be used for disinfection, or the water can be purified by reverse osmosis to exhibit properties similar to distilled water. Due to the diversity of water sources and subsequent treatment methods, there is a wide variability in the quality of the water fed to the CIP system of the present invention.

[0031] As used herein, the terms "weight percent," "wt %," "percent by weight," "% by weight," and variations thereof refer to the concentration of a substance, which is the weight of the substance divided by the total weight of the composition and multiplied by 100. It should be understood that as used herein, "percent," "%," and the like are intended to be synonymous with "weight percent," "wt %," and the like.

[0032] According to an embodiment of the present invention, a control system having an electrolytic solution for automatic recirculation or once-through cleaning systems such as CIP applications and a method of using the control system are provided. The system and method allow the use of controlled chlorine solutions for various CIP applications and provide significant benefits in CIP applications by providing a chlorine concentration control system over a wide pH range so that the electrolytic aqueous solution can be used for CIP applications. The system and method of the present invention are suitable for many CIP applications, including, for example, food and beverage manufacturing equipment, where various cleaning, disinfection or sanitization chemicals are commonly used. The present invention provides a means for using an electrolytic solution without any additional chemical detergent for CIP cleaning, rather than changing the known parameters of the CIP cleaning composition, such as the amount or concentration of the detergent or cleaning composition.

[0033] According to the present invention, a system for generating automated chlorine levels in an electrolytic solution is provided. For use in cleaning applications such as CIP applications, the electrolytic solution requires a consistent, accurate and reproducible chlorine concentration without the need to continuously adjust the flow of the solution or other chemical additives. Chlorine-containing electrolytic solutions are typically in the range of about 10-1000 ppm chlorine, preferably in the range of about 10-200 ppm chlorine, and have a pH range of about 5-11, wherein changes in chlorine significantly affect the pH of the electrolytic solution. In addition, changes in the pH of the water fed to the electrolytic cell and / or used to dilute the electrolytic solution affect the pH of the solution and have a negative impact on the sensitivity and accuracy of the chlorine sensor.

[0034] The control system and method of the present invention provide consistent, accurate and reproducible user pH control of (a) a portion of an electrolytic solution measured by a chlorine sensor and (b) the chlorine oxyanion concentration used in a particular cleaning system, providing significant benefits in enabling the use of electrolytic solutions containing chlorine oxyanions in a variety of cleaning applications. According to one embodiment of the present invention, for CIP applications, the final pH of the portion of the electrolytic solution used to measure chlorine oxyanions with a chlorine probe or sensor is about 5.5-7.5, preferably about 5.5-7.0, most preferably about 5.5-6.5, and is maintained within a range of less than or equal to 0.75 pH units of the desired pH range, more preferably within a range of less than or equal to 0.5 pH units of the desired pH range, and most preferably within a range of less than or equal to 0.25 pH units of the desired pH range without requiring adjustment of the flow rate of the electrolytic solution and / or pH modifier. According to the present invention, the stabilized pH range of the electrolytic solution portion measured by the chlorine sensor eliminates chlorine sensor errors and allows the use of water having highly variable quality and pH supplied to the electrolytic cell and / or used to dilute the electrolytic solution.

[0035] In addition to the control system for maintaining a controlled pH of a portion of the electrolytic solution to enable the use of a chlorine oxyanion probe, the control system described herein provides feedback of the chlorine oxyanion content to the control system for automated control of the system. The control system of the present invention also allows the electrolytic solution chlorine oxyanion concentration to be controlled in response to the chlorine sensor concentration measurement.

[0036] Control System

[0037] Figure 1 and 2 An embodiment of the present invention is illustrated for obtaining a chlorine oxyanion concentration measurement from a portion of an electrolytic solution using a control system. As described, one embodiment of the present invention includes a chlorine oxyanion measurement system for automated control of a cleaning system using an electrolytic solution. Figure 1As shown in FIG. 1 , one embodiment of the present invention includes a control system 8 that includes, consists of, or consists essentially of an electrolytic solution (any electrolytically generated chlorine oxyanion source) 10, a pH modifier 12, a sensing cell 14, a distribution system 11 for providing fluid communication between a first portion of the electrolytic solution, the pH modifier, and the sensing cell, and a distribution system 17 for providing fluid communication between a second portion of the electrolytic solution and a CIP solution tank 16. According to the present invention, the second portion 17 of the electrolytic system is not required to be in fluid communication with the pH modifier 12 and / or the sensing cell 14 for chlorine oxyanion concentration measurement. The control system of the present invention provides pH adjustment of the first portion of the electrolytic solution, providing accurate measurement of chlorine oxyanion concentration from at least about 10 ppm to 1000 ppm.

[0038] Figure 2 Another schematic diagram of one embodiment of the present invention is illustrated, wherein a measurement of chlorine oxyanion concentration is obtained from a portion of an electrolytic solution. One embodiment of the present invention includes a user-controlled chlorine concentration control system 8 for CIP applications, which includes, consists of, or consists essentially of an electrolytic solution 10, a pH modifier 12, a mixing chamber 13, a sensing cell 14, a distribution system 11 providing fluid communication between a first portion of the electrolytic solution and the pH modifier to the sensing cell, and a distribution system 17 for a second portion of the electrolytic solution provided to a CIP solution tank 16 of the present invention. The mixing chamber 13 provides another section of fluid communication for mixing the pH modifier 12 with the electrolytic solution 10. For example, the mixing chamber 13 can be included to ensure proper mixing of the electrolytically generated chlorine solution 10 and the pH modifier 12 in accordance with the present invention.

[0039] The control system 8 may optionally include a feedback control mechanism 15 for the system, such as Figure 2 The feedback loop depicted in , or by a feedback control mechanism 15 for the system, e.g. Figure 2 , or essentially consisting of a feedback control mechanism 15 for the system, such as Figure 2. According to this optional embodiment of the control system, a pH probe is additionally contained within the sensing cell 14 and is used to determine the pH of the first portion 11 of the electrolytic solution measured by the chlorine probe. The pH probe signal activates a feedback mechanism of the pH modifier 12 (the acid and / or alkaline modifier described in the present invention) and / or the electrolytic solution 10. The feedback mechanism 15 preferably adjusts the feed rate of the pH modifier 12 into the first portion 11 of the electrolytic solution in order to adjust the pH and achieve the desired pH of the side stream of the electrolytic solution. Once the pH of the side stream reaches the desired level (determined by the pH probe), the chlorine probe can then be used to determine the concentration of chlorine oxyanions for control of the system. According to a preferred embodiment of the present invention, the control system achieves the desired pH concentration range by adjusting the feedback loop mechanism 15 of the flow rate of the pH modifier 12 of the control system.

[0040] Figure 3 and 4 Another embodiment of the present invention is shown, wherein the cleaning system such as a CIP system is controlled by having an effective chlorine oxyanion concentration measurement by a chlorine probe. According to another embodiment of the present invention, the correct measurement of the chlorine oxyanion concentration (the system for this measurement is disclosed in Figure 1 and 2 ) allows control of the CIP system itself, for example requiring desired performance changes of the CIP system.

[0041] Figure 3 A diagram showing one embodiment of the control system 8 is shown, which includes, consists of, or consists essentially of: an electrolytic solution concentrate 10, a distribution system 11 for providing fluid communication between a portion of a CIP solution tank 16 and a mixing chamber 13, a pH modifier 12, a sensor cell 14, and a sensor cell signal feedback 18 in communication with the sensor cell 14 and a CIP loop control 20, wherein the CIP loop control 20 is in communication with the CIP loop 22. According to the embodiment of the present invention, the control system provides feedback of the chlorine oxyanion content measured by the sensor cell 14 to the CIP loop control 20 and the CIP loop 22 to provide a mechanical type control of the cleaning system. As a result, the embodiment of the present invention allows the CIP system to respond to the chlorine probe measurement. For example, the chlorine concentration measurement obtained by the chlorine probe can initiate a recirculation mode of the CIP loop control 20. Alternatively, once a target chlorine oxyanion concentration is reached, the chlorine concentration measurement obtained by the chlorine probe can initiate an on / off mode of the CIP loop control 20.

[0042] Figure 4Another diagram of an embodiment of the present invention is shown, wherein the CIP system is further controlled by having an effective measurement of the chlorine oxyanion concentration through the sensing cell 14. Figure 4 The control system 8 of the present invention shown in the figure includes, consists of, or consists essentially of: a CIP loop 22, a distribution system 11 for providing fluid communication between a portion of the CIP solution tank 16 and the mixing chamber 13, a pH modifier 12, a sensor cell 14, and a sensor cell signal feedback 18 in communication with the sensor cell 14 and an electrolytic concentrate control 24 and / or a dilution water control 26, wherein the controls 24, 26 are respectively in communication with the electrolytic solution concentrate 10 and the dilution water 28.

[0043] According to this embodiment of the invention, the feedback 18 is capable of controlling the electrolytic solution concentrate 10, the dilution water 28 and / or the electrolytic cell (whose input source is either brine or water) from which the electrolytic solution concentrate is prepared, in response to the chlorine oxyanion concentration measurement obtained by the chlorine sensor and adjusting the chlorine oxyanion concentration output from the control system of the present invention. According to this embodiment of the control system, the electrolytic concentrate control 24 communicates the need to add the electrolytic solution concentrate 10 to the CIP solution tank 16, and the dilution water control 26 communicates the need to add the dilution water 28 to the CIP solution tank 16. As a result, the control system of the present invention provides feedback of the measured chlorine oxyanion concentration to the CIP system to allow the CIP system to respond to the chlorine probe measurement by adjusting the recirculation loop of the amount of electrolytic solution concentrate 10 and / or dilution water 28 provided to the CIP solution tank 16 to achieve the desired chlorine oxyanion concentration.

[0044] The control system 8 of the present invention comprises any electrolytically produced chlorine oxyanion source 10, i.e., a chlorine-containing electrolytic solution, for providing one-step cleaning, sanitization and antimicrobial effects for CIP applications. The electrolytically produced chlorine oxyanion source can be any electrolytic solution and / or electrolytic solution concentrate. According to one embodiment of the present invention, the electrochemical cell produces the electrolytic solution and / or electrolytic solution concentrate in situ. According to another embodiment, the electrolytic solution concentrate is diluted with dilution water to form the electrolytic solution. According to an alternative embodiment, a side stream of electrolytically produced chlorine is fluidically connected to the control system, wherein a target chlorine concentration is confirmed. According to another embodiment, the confirmed chlorine concentration of the side stream of electrolytically produced chlorine sends a signal to add the chlorine solution and optionally an additional water source to the CIP solution tank 16 for use in the CIP application of the present invention.

[0045] It can be recognized by the control system of the present invention that the pH of the electrolytic solution 10 or the electrolytic solution concentrate 10 can initially be about 5 to about 11, and the pH of the first part 11 of the electrolytic solution connected to the sensor cell 14 fluid is adjusted to a range of about 5.5-7.5, preferably about 5.5-7.0, and most preferably about 5.5-6.5 according to the control system of the present invention to obtain accurate chlorine oxyanion concentration measurement.

[0046] According to the present invention, the electrolytic solution 10 provides a minimum concentration of chlorine oxyanions for antimicrobial efficacy, sanitization and cleaning. One embodiment of the present invention includes a chlorine source having about 20 ppm to about 1000 ppm chlorine. According to another embodiment, the source is an electrolytic solution having about 10 ppm to about 200 ppm chlorine, preferably about 30 ppm to about 200 ppm, and more preferably about 50 ppm to about 200 ppm chlorine. According to a preferred embodiment, the electrolytically generated chlorine oxyanions are in the range of about 10 ppm to about 200 ppm and provide cleaning, sanitization and antimicrobial efficacy without causing corrosion of CIP systems that are typically composed of stainless steel components.

[0047] The control system 8 of the present invention comprises, consists essentially of and / or consists of a chlorine sensor to determine the chlorine oxyanion concentration of the first portion of the electrolytic solution contained in the sensing cell 14. The first portion 11 of the electrolytic solution flows through the sensing cell for chlorine concentration detection and measurement. As will be appreciated by those skilled in the art, the present invention is not limited by the type of chlorine sensor or monitor selected. For example, any current monitor, colorimetric monitor, selective ion electrode monitor or polarographic membrane probe may be used in accordance with the systems and methods of the present invention to provide consistent control of chlorine and pH levels.

[0048] According to an optional embodiment of the present invention, the sensing cell 14 containing the chlorine sensor may additionally contain a plurality of sensing elements, including, for example, a pH sensor. According to embodiments of the present invention in which both the chlorine and pH sensors are contained in the sensing cell 14 of the control system 8, the electrolytically generated chlorine solution 10 passes through the sensing cell 14 in which both the chlorine sensor and the pH sensor are contained, and measurements of the chlorine species and the pH are obtained. Certain embodiments of the present invention that contain a feedback mechanism to control the pH of the electrolytic solution in order to accurately measure the chlorine concentration contain a pH sensor.

[0049] According to another embodiment of the control system 8, the sensor cell 14 and any plurality of sensors or probes contained therein can be monitored by a user. For example, one embodiment of the present invention includes a communication means to report process control parameters to a user to confirm that the electrolytic solution has achieved a target chlorine and / or pH concentration.

[0050] According to another embodiment of the present invention, the distribution system for providing fluid communication within the control system 8 can be any fluid communication or connection means, including, for example, a circulation system and / or a pump system. Any fluid communication or connection can also include an introduction T-shaped object for adding the electrolytic solution 10, the pH modifier 12 and / or the dilution water 28. The distribution system for providing fluid communication can further include at least one flow control valve for establishing an adjustable flow rate of the electrolytic solution 10, the pH modifier 12 and / or the dilution water 28.

[0051] The control system 8 of the present invention comprises, consists essentially of, and / or consists of a pH modifier 12 in fluid communication 11 with a first portion of the electrolytic solution in the sensing cell 14. Suitable pH modifiers according to the present invention may include, for example, gaseous and / or liquid acidulants and alkaline buffers, including, for example, carbon dioxide gas, sodium hydroxide, calcium hydroxide, potassium hydroxide, sodium or potassium carbonates or bicarbonates, and / or mono-, di-, or tri-protic inorganic acids, such as hydrogen chloride. According to one embodiment, the pH modifier is an acidulant buffer introduced into the electrolytic solution to lower the pH and thereby improve chlorine sensor sensitivity due to measurement errors obtained by chlorine measurement systems in water systems having a pH value above about 8. According to a preferred embodiment, an acidulant buffer may be added at the introduction tee in the fluid communication mechanism 11 to adjust the pH value of the first portion of the electrolytic solution measured in the sensing cell 14. Preferably, carbon dioxide gas is added as an acidulant at a fixed flow rate to buffer the first portion of the electrolytic solution, thereby adjusting the pH of the solution to a range suitable for use with a chlorine sensor. As will be appreciated by the skilled artisan, the use of a buffer such as carbon dioxide gas adjusts the pH by forming carbonic acid when dissolved in the solution to reduce the solution pH to approximately 5-7, preferably 5.5-6.5, based on the amount of carbon dioxide added to the first portion of the electrolytic solution.

[0052] According to a preferred embodiment, the flow rate of the carbon dioxide acidification buffer is constant and does not require manual adjustment to maintain the target pH range of the first portion of the electrolytic solution to obtain accurate chlorine concentration measurements. The control system 8 maintains the desired pH range of the first portion of the electrolytic solution of about 5.5-7.0, most preferably about 5.5-6.5, within about 0.7 pH units, preferably within about 0.5 pH units, and most preferably no more than about 0.3 pH units from the desired pH range. According to one embodiment of the present invention, when the first portion of the electrolytic solution is also provided to the sensing cell at a constant feed rate, a carbon dioxide flow rate of about 300 ml / minute is established to maintain the pH range of the electrolytic solution of about 5.5-7.5 over a wide range of chlorine content in the first portion of the electrolytic solution, i.e., about 10 ppm to about 200 ppm.

[0053] Cleaning Methods

[0054] According to one embodiment of the present invention, a method for cleaning, sanitizing, disinfecting and antimicrobial efficacy in an automatic recirculation or once-through cleaning application such as a CIP application is disclosed. As will be appreciated by those skilled in the art, the method for cleaning, sanitizing, disinfecting and antimicrobial efficacy is achieved based on the level of chlorine provided to the CIP system in need of treatment. According to a preferred embodiment, a method for a one-step cleaning and sanitizing process is achieved. According to another preferred embodiment, a method for antimicrobial treatment is achieved.

[0055] Methods of cleaning, sanitizing, disinfecting and antimicrobial efficacy in CIP applications can be performed according to known equipment uses and structures, which are modified according to the description of the present invention to incorporate the control system of the present invention. One embodiment of the method of using electrolytically generated chlorine oxyanions according to the present invention includes contacting the clean electrolytic solution obtained by the control system of the present invention with the surface to be treated. According to the use of the control system of the present invention, the electrolytic solution used according to the method of the present invention has a measurable, desired chlorine concentration over a wide pH range.

[0056] Embodiments of the invention include the use of the electrolytic solution for cleaning, sanitization, disinfection and antimicrobial efficacy for various CIP applications including, for example, food or beverage processing equipment, textile or clothing processing equipment, or dishes, glasses, silverware and other food preparation, handling and serving equipment. The CIP applications of the invention may include any circulating or non-circulating cleaning system.

[0057] According to a preferred embodiment, the electrolytic aqueous solution is contacted with the equipment to be treated by utilizing fluid communication such as an internal fluid loop with a pump and a return loop system providing a circulation system to supply the solution. According to an alternative embodiment, the electrolytic aqueous solution is contacted with the equipment to be treated by a spraying device capable of washing the equipment and thus providing a non-circulating system. According to a non-circulating embodiment, the spraying device is used to wash a system such as a container, which is then directed to a drainage system or a pipeline directly directed to the drainage system, wherein no recirculation is established. The step of contacting the electrolytic aqueous solution with the equipment may include introducing the solution and unheated, ambient temperature or heated water. The cleaning method may also include the step of rinsing the equipment.

[0058] Certain embodiments of the method of cleaning, sanitizing, disinfecting, and performing antimicrobial efficacy on a CIP system may include applying the use solution or introducing the use solution into the system at a constant or variable flow rate. Additionally, the method for cleaning a CIP system may be at a temperature ranging from the input water temperature to above 70° C. Additionally, the method for cleaning a CIP system may include a contact time of at least about 10 seconds to about 120 seconds, preferably at least 30 seconds.

[0059] As will be appreciated by those skilled in the art based on the present disclosure, the cleaning, sanitizing, disinfecting and antimicrobial treatment methods of the present invention may be further optimized according to changes in cleaning time, temperature, pressure, concentration of detergent or cleaning composition, machinery operating the CIP cleaning application, and soil type.

[0060] All publications and patent applications in this specification are indicative of the general level of skill in the art to which the invention pertains. All publications and patent applications are incorporated herein by reference to the same extent as if each individual publication and patent application were specifically and individually indicated by reference. Example

[0061] Embodiments of the present invention are further defined in the following non-limiting examples. It should be understood that these examples, although indicating certain embodiments of the present invention, are provided only for the purpose of illustration. Those skilled in the art can determine the fundamental features of the present invention from the above discussion and these examples without departing from its spirit and scope, and can make various changes and modifications to embodiments of the present invention so that it is suitable for various purposes and conditions. Therefore, in addition to those shown and described herein, various modifications of embodiments of the present invention are obvious to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.

[0062] Example 1

[0063] A model Q45H / 62 chlorine monitor (ATI, Analytical Technologies Inc., Collegeville, PA) was used as the chlorine measurement system and was combined with a pH probe, a flow system through the probe housing, and a controller in accordance with the present invention to convert the electrical signal from the pH on the Cl2 probe into a measurable signal. The ATI meter has the ability to use the pH measurement to correct for the sensitivity of the Cl2 probe as pH changes.

[0064] The system was analyzed for its ability to determine Cl2 concentration with and without pH correction.The pH probe was standardized prior to the experiment, and the Cl2 probe was standardized with a pH 7.0 solution titrated with Cl2 concentration using iodine titration.

[0065] Solution No. pH <![CDATA[Total Cl2]]> 1 5.5 30 2 5.5 50 3 5.5 70 4 7 30 5 7 50 6 7 70 7 8.5 30 8 8.5 50 9 8.5 70

[0066] Solution run order 1 4 7 2 5 8 3 6 9 8 5 2 7 4 1 9 3 6

[0067]

[0068]

[0069] Example 2

[0070] Effect of Adding Electrolyzed Water to 15 Grain Tap Water and 0 Grain Reverse Osmosis Water: The effect of adding EO solution to a water source was determined to determine the pH of different water types as a function of concentration. Different volumes of EO solution were used to achieve useful chlorine levels within the range used for water treatment (0.5-3 ppm) and the range expected for CIP applications (10-200 ppm). Chlorine concentration was determined using the iodine titration method for measuring available chlorine in aqueous solutions.

[0071]

[0072]

[0073]

[0074] The results demonstrate the effect of EO solution on pH when added at levels above the range typically used for water treatment (0.5-3 ppm). As the chlorine concentration increases (e.g., average chlorine content in EO solution of about 10-200 ppm), the pH of the solution increases. The results are significant due to the sensitivity of chlorine sensors to changes in pH due to the pKa of hypochlorous acid (chlorine). In addition, the effect of EO solution is variable depending on the type of water (i.e., hard water versus reverse osmosis water). The use of a reverse osmosis water source results in a greater pH change with increasing amounts of chlorine than a hard water source.

[0075] The demonstration of pH variations as a result of source water quality and dosing ratios of EO solutions which will have varying chlorine contents (incompatible with the use of chlorine sensors which rely on a constant pH range to sense chlorine species) confirmed the need for the control system of the present invention. Figure 5 and 6 The dramatic increase in pH variation observed when chlorine was added in amounts equivalent to chlorine-containing EO solutions (ie, 10-200 ppm) demonstrated the need to control pH in order to obtain consistent and accurate chlorine detection in order to overcome the deficiencies of chlorine monitors.

[0076] Example 3

[0077] Effect of pH on membrane covered polarographic sensor and controller: The response of the polarographic sensor was analyzed to determine the effect of pH on the sensor's response to chlorine concentration. A Model Q45H / 62 Chlorine Monitor (ATI, Analytical Technologies Inc., Collegeville, PA) was used to test different pH ranges and determine the effect on the sensor's response.

[0078] An aqueous solution containing a fixed concentration of EO water (titrated with an average Cl2) was circulated through a flow through chamber containing the chlorine electrode of the ATI meter. The flow through chamber also contained a pH probe for monitoring the pH of the test solution and the response of the probe to chlorine.

[0079] The chlorine probe was calibrated with an EO solution at 50 ppm available chlorine and a pH of 7.0. The pH of the EO solution was adjusted up and down with 0.1 M NaOH or 0.1 M HCl, respectively. The total volume change due to the addition of this solution was less than 1%, ensuring that any changes in the electrode response were entirely due to changes in pH. The test was conducted at three different concentrations, namely, about 30, 50 and 70 ppm average chlorine concentration. The chlorine concentration was titrated at the beginning and end of the test using the iodine method for measuring the average chlorine in the water.

[0080] 65.35ppm average C12 start

[0081] 65.12ppm average C12 end

[0082] pH reading error 7.78 57.4 -7.95 7.48 61.2 -4.15 7.2 65.4 0.05 6.98 69.8 4.45 6.78 73.2 7.85 6.64 74.4 9.05 6.26 80.9 15.55 5.75 85.4 20.05

[0083] 45.8ppm average C12 start

[0084] 45.3ppm average C12 end

[0085] pH reading error 9.15 32.3 -13.5 7.52 39.8 -6 7.12 45 -0.8 6.86 49.3 3.5 6.6 53.2 7.4 6.37 56.3 10.5 6.09 59.1 13.3 5.85 60.7 14.9

[0086] 28.0ppm average C12 start

[0087] 28.2ppm average C12 end

[0088] pH reading error 9.54 17.7 -10.3 8.66 20.9 -7.1 7.51 24.4 -3.6 6.9 29.3 1.3 6.39 33.3 5.3 5.86 36.3 8.3

[0089] The results demonstrate that commercially available chlorine sensors have significant errors as the pH of the EO solution shifts (upward or downward outside the preferred range of about pH 5-7). The change in pH can be based on the quality of water used to dilute the EO solution and / or the amount of chlorine in the solution. The results also demonstrate that the error of the chlorine sensor increases as the average chlorine concentration increases, demonstrating the need for the control system of the present invention when the chlorine concentration of the electrolytically generated chlorine solution is in the range of about 10 ppm to about 200 ppm.

[0090] Example 4

[0091] Response of the chlorine sensor to EO solutions at various pH values ​​with and without added CO2: A stock solution of EO water was prepared from EO concentrate produced by a MIOX Sal-80 generator equipped with an "Ox-cell" electrolytic cell, with a concentration of 40 ppm available chlorine. The chlorine concentration was determined using the iodometric method for measuring chlorine.

[0092] The 40 ppm EO solution had a native pH of 7.5 and was pumped through a chamber containing a chlorine sensor and a pH probe (previously calibrated). The 40 ppm EO solution was introduced into the control system at a rate of 600 ml / min at the mixing tee. CO2 gas was added to the mixing tee as an acidifier at a rate that caused the pH of the solution to drop to 6.10, involving a CO2 flow rate of approximately 300 ml / min. With a solution pH of 6.10, the chlorine probe was calibrated to output a signal determined to be 40 ppm chlorine.

[0093] The CO2 is then turned off and the pH of the EO solution returns to pH 7.5. When the CO2 is turned back on, the pH drops back to 6.1, at which point the ppm chlorine indicated by the chlorine probe controller is measured. The CO2 is turned off again and the pH of the EO solution returns to 7.5. At this point, a small amount of 5.0% NaOH is added to the EO solution to increase the pH to 8.35. The solution is pumped through a flow path through the cell and the chlorine concentration and pH measured by the probe are recorded in the chamber. The CO2 is turned on again to inject CO2 into the mixing tee. The flow control of CO2 is not changed from the rate required to drop the pH from 7.5 to pH 6.1. When the pH is stable, the chlorine sensor value and pH are recorded.

[0094] The test was repeated a third time, wherein additional 5.0% NaOH solution was added to the EO solution to produce a pH of 9.35. CO2 was once again added to the mixing chamber without changing the flow rate. The concentration of chlorine measured by the chlorine probe was recorded for the original pH condition and the pH condition with CO2 addition.

[0095]

[0096] As a final test, the CO2 valve was opened so that its flow rate was approximately 1000 ml / min, with a pH of 8.35. Under these flow conditions, the pH dropped to 5.5, and the chlorine value was measured to be 44.0 ppm.

[0097] The results demonstrate the ability of the control system of the present invention to provide a target electrolytic solution having a desired pH and chlorine content suitable for CIP application purposes. As demonstrated, the control system does not require a feedback loop or other regulatory measures. Rather, an automatic control measure for providing a desired chlorine content in an electrolytic solution for CIP applications is provided in accordance with the present invention.

[0098] The invention being thus described, it will be obvious that the invention may be modified in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims.

[0099] The present invention includes the following technical solutions.

[0100] 1. A control system for use with an automated recirculation or once-through cleaning application utilizing an electrolytically generated chlorine oxyanion solution, the system comprising:

[0101] (a) an electrolytic solution;

[0102] (b) a first portion of the electrolytic solution connected in fluid communication with a chlorine sensor;

[0103] (c) a pH modifier connected in fluid communication with said first portion of the electrolytic solution to enable accurate measurement of a chlorine oxyanion concentration of about 10 ppm to about 1000 ppm; and

[0104] (d) Output to said cleaning application.

[0105] 2. A control system as described in item 1 above, wherein the electrolytic solution is used for cleaning or sanitizing food or beverage processing equipment.

[0106] 3. The control system of any one of items 1-2 above, wherein the electrolytic solution is used for cleaning or sanitizing textile or clothing processing equipment.

[0107] 4. A control system as described in any one of items 1-3 above, wherein the electrolytic solution is used to clean or sanitize plates, glasses, silverware or other food preparation and handling equipment in public institutions.

[0108] 5. The control system described in any one of items 1 to 4 above, wherein the electrolytic solution is any electrolytically generated chlorine oxyanion source.

[0109] 6. The control system of any one of items 1 to 5 above, wherein the chlorine oxyanion concentration is approximately 10 ppm to 200 ppm.

[0110] 7. The control system of any one of items 1 to 6 above, wherein the electrolytic solution has an initial pH of about 5 to about 11.

[0111] 8. The control system of any one of items 1-7 above, further comprising a flow control valve fluidically connected to the first portion of the electrolytic solution to provide the pH modifier.

[0112] 9. The control system of any one of items 1-8 above, wherein the pH modifier is added to the first portion of the electrolytic solution connected to the chlorine sensor at a fixed rate to adjust the pH of the first portion of the electrolytic solution to between about 5.5 and about 7.5.

[0113] 10. The control system according to any one of items 1 to 9 above, wherein the pH modifier is carbon dioxide gas.

[0114] 11. The control system according to any one of items 1 to 10 above, wherein the pH modifier is an alkaline pH buffer solution.

[0115] 12. The control system according to any one of items 1 to 11 above, wherein the pH modifier is an acidic pH buffer solution.

[0116] 13. The control system according to any one of items 1 to 12 above, wherein the pH modifier is a pH-neutral buffer solution.

[0117] 14. The control system of any one of items 1-13 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.75 pH units without adjusting the flow rate of the pH modifier or the electrolytic solution.

[0118] 15. The control system of any one of items 1-14 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.5 pH units without adjusting the flow rate of the pH modifier or the electrolytic solution.

[0119] 16. The control system of any one of items 1-15 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.25 pH units without adjusting the flow rate of the pH modifier or the electrolytic solution.

[0120] 17. The control system described in any one of items 1 to 16 above, further comprising an electrochemical cell capable of producing the electrolytic solution.

[0121] 18. The control system of any one of items 1-17 above, further comprising a pH probe connected in fluid communication with the first portion of the electrolytic solution and the chlorine sensor.

[0122] 19. The control system of any one of items 1-18 above, further comprising a feedback control loop fluidically connected to the flow control device, the feedback control loop allowing the addition of additional electrolytic solution or water to the system to achieve a target set point.

[0123] 20. The control system of any one of items 1-19 above, further comprising a feedback control loop fluidically connected to the flow control device, the feedback control loop allowing the addition of additional pH modifier to the first portion of the electrolytic solution to achieve a pH between about 5.5 and 7.5.

[0124] 21. A control system for use in an automatic recirculation or once-through cleaning system utilizing an electrolytically generated chlorine oxyanion solution, the system comprising:

[0125] (a) an electrochemical cell for in situ generation of an electrolytic solution, wherein a first portion of the electrolytic solution is in fluid communication with a chlorine sensor;

[0126] (b) a source of carbon dioxide in fluid communication with said first portion of said electrolytic solution for pH change of said first portion of said electrolytic solution to enable accurate measurement of a concentration of chlorine oxyanions in the range of about 10 ppm to about 1000 ppm; and

[0127] (c) a system output for delivering an electrolytic solution to the cleaning system.

[0128] 22. A control system as described in item 21 above, wherein the system output delivers an electrolytic solution for cleaning or sanitizing food or beverage processing equipment.

[0129] 23. A control system as described in any of items 21-22 above, wherein the system output delivers an electrolytic solution for cleaning or sanitizing plates, glasses, silverware or other food preparation, handling and serving equipment in an institution.

[0130] 24. A control system as described in any of items 21-23 above, wherein the system output delivers an electrolytic solution for cleaning or sanitizing textile or garment processing equipment.

[0131] 25. The control system of any one of items 21-24 above, wherein the electrolytic solution has a chlorine content of approximately 10 ppm to approximately 200 ppm.

[0132] 26. The control system of any one of items 21-25 above, wherein the electrolytic solution has an initial pH of about 5 to about 11.

[0133] 27. The control system of any of items 21-26 above, wherein the first portion of the electrolytic solution is adjusted to a pH of about 5.5 to about 7.5.

[0134] 28. The control system of any one of items 21-27 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.75 pH units without adjusting the flow of the carbon dioxide or the electrolytic solution.

[0135] 29. The control system of any one of items 21-28 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.5 pH units without adjusting the flow of the carbon dioxide or the electrolytic solution.

[0136] 30. The control system of any one of items 21-29 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.25 pH units without adjusting the flow of the carbon dioxide or the electrolytic solution.

[0137] 31. The control system of any of items 21-30 above, wherein the carbon dioxide is provided at a fixed rate to adjust the pH of the first portion of the electrolytic solution to between about 5.5 and about 7.5.

[0138] 32. The control system of any one of items 21-31 above, further comprising a flow control valve fluidically connected to the first portion of the electrolytic solution to provide the carbon dioxide for pH change.

[0139] 33. The control system of any one of items 21-32 above, further comprising a pH probe connected in fluid communication with the first portion of the electrolytic solution and the chlorine sensor.

[0140] 34. A control system as described in any one of items 21-33 above, further comprising a feedback control loop connected in fluid communication with the flow control valve, the feedback control loop allowing additional electrolytic solution or water to be added to the system to achieve a target set point.

[0141] 35. A control system as described in any one of items 21-34 above, wherein the flow control valve can be operated to achieve a target concentration of oxychlorine species in the electrolytic solution used in the cleaning system.

[0142] 36. A control system for measuring the chlorine oxyanion concentration of an electrolytic solution used in an automatic recirculating or once-through cleaning system, the system comprising:

[0143] (a) a source of electrolyte solution concentrate and a source of dilution water for producing an electrolyte solution;

[0144] (b) a chlorine sensor connected in fluid communication with the first portion of the electrolytic solution;

[0145] (c) a pH modifier connected in fluid communication with the first portion of the electrolytic solution and capable of controlling the pH of the first portion of the electrolytic solution to between about 5.5 and 7.5 to enable accurate measurement of a chlorine oxyanion concentration of about 10 ppm to 1000 ppm; and

[0146] (d) a feedback loop mechanism activated based on the chlorine sensor measurement to adjust the chlorine oxyanion concentration in the electrolytic solution.

[0147] 37. The control system described in item 36 above, wherein the source of electrolytic solution concentrate and dilution water used to produce the electrolytic solution is an electrolytic cell.

[0148] 38. The control system of any one of items 36-37 above, wherein the source of electrolytic solution concentrate is a storage container.

[0149] 39. The control system of any one of items 36-38 above, wherein the electrolytic solution has an initial pH of about 5 to about 11.

[0150] 40. The control system of any one of items 36-39 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.75 pH units without adjusting the flow of the pH modifier or the electrolytic solution.

[0151] 41. The control system of any one of items 36-40 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.5 pH units without adjusting the flow rate of the pH modifier or the electrolytic solution.

[0152] 42. The control system of any one of items 36-41 above, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.25 pH units without adjusting the flow of the pH modifier or the electrolytic solution.

[0153] 43. The control system of any one of items 36-42 above, wherein the pH modifier is a source of carbon dioxide gas and is provided at a fixed rate to adjust the pH of the first portion of the electrolytic solution.

[0154] 44. The control system of any one of items 36-43 above, further comprising a pH probe connected in fluid communication with the first portion of the electrolytic solution and the chlorine sensor.

[0155] 45. The control system of any one of items 36-44 above, further comprising a feedback control loop connected in fluid communication with the flow control valve, the feedback control loop allowing the addition of additional electrolytic solution, electrolytic solution concentrate or dilution water.

[0156] 46. ​​A control system as described in any of items 36-45 above, wherein the flow control valve is operated to achieve a target concentration of oxychlorine species in the electrolytic solution used in the cleaning system.

[0157] 47. The control system of any one of items 36-46 above, further comprising a feedback control loop connected in communication with a loop control, wherein the loop control is triggered by the chlorine oxyanion concentration.

[0158] 48. A method for using electrolytically generated chlorine oxyanions in an automated recirculation or once-through cleaning system for cleaning or sanitization, the method comprising:

[0159] (a) obtaining an electrolytic solution by the control system described in item 36 above; and

[0160] (b) applying the electrolytic solution to the cleaning system.

[0161] 49. The CIP cleaning or sanitizing method of item 48 above, further comprising generating on-site an electrolytic solution to be used as the electrolytic solution.

[0162] 50. The CIP cleaning or sanitizing method of any one of items 48-49 above, wherein the electrolytic solution is any electrolytically generated chlorine oxyanion source.

[0163] 51. The CIP cleaning or sanitizing method of any one of items 48-50 above, further comprising diluting the electrolytic solution with a water source.

[0164] 52. The CIP cleaning or sanitizing method of any one of items 48-51 above, further comprising rinsing the cleaning system after contact with the electrolytic solution.

[0165] 53. A method of antimicrobial treatment using electrolytically generated chlorine oxyanions in an automated recirculating or once-through cleaning system, the method comprising:

[0166] (a) diluting the electrolytic concentrate in water to produce an electrolytic solution, wherein the concentration of chlorine oxyanions in the electrolytic solution is measured by the control system described in item 36 above; and

[0167] (b) applying the electrolytic solution to the cleaning system in need of antimicrobial treatment.

[0168] 54. The method for antimicrobial treatment described in item 53 above, wherein the electrolytic solution has a pH range of about 5 to about 11.

[0169] 55. The method for antimicrobial treatment as described in any one of items 53-54 above, wherein the control system maintains the pH of the measured portion of the electrolytic solution within the pH range of less than or equal to 0.75 pH units without adjusting the flow rate of the pH modifier or the electrolytic solution.

[0170] 56. The method for antimicrobial treatment as described in any one of items 53-55 above, wherein the control system maintains the pH of the measured portion of the electrolytic solution within the pH range of less than or equal to 0.5 pH units without adjusting the flow rate of the pH modifier or the electrolytic solution.

[0171] 57. The method for antimicrobial treatment of any one of items 53-56 above, wherein the control system maintains the pH of the measured portion of the electrolytic solution within the pH range of less than or equal to 0.25 pH units without adjusting the flow rate of the pH modifier or the electrolytic solution.

[0172] 58. The method of antimicrobial treatment of any one of items 53-57 above, wherein the pH modifier is provided at a fixed rate to adjust the pH of the measured portion of the electrolytic solution.

[0173] 59. The method for antimicrobial treatment according to any one of items 53 to 58 above, wherein the pH modifier is a carbon dioxide gas source.

[0174] 60. The method of antimicrobial treatment as described in any one of items 53 to 59 above, further comprising a pH probe connected in fluid communication with the measured portion of the electrolytic solution and the chlorine sensor.

[0175] 61. The method of antimicrobial treatment described in any of items 53-60 above, which also includes a feedback control loop mechanism connected to the flow control valve fluid, which allows recirculation or addition of electrolytic solution to obtain a target chlorine oxyanion concentration for use in the cleaning system.

[0176] 62. The method of antimicrobial treatment as described in any one of items 53-61 above, which also includes a feedback control loop mechanism connected to the loop control, wherein the loop control is triggered by the chlorine oxyanion concentration.

[0177] 63. The method for antimicrobial treatment as described in any one of items 53-62 above, further comprising generating an electrolytic solution in situ by an electrolytic cell.

[0178] 64. The method of antimicrobial treatment of any one of items 53-63 above, wherein the cleaning system is selected from food or beverage processing equipment, textile or clothing processing equipment, a plurality of plates, glasses, silverware and other food preparation, processing or service equipment, and combinations thereof.

Claims

1. A control system for use in an automatic recirculation or once-through cleaning application utilizing an electrolytically generated chlorine oxyanion solution, the control system comprising: (a) a sensing cell including a pH sensor and a chlorine sensor; (b) an electrochemical cell for in situ generation of an electrolytic solution, wherein a first portion of the electrolytic solution is in fluid communication with a chlorine sensor in the sensing cell; (c) a source of carbon dioxide gas in fluid communication with the first portion of the electrolytic solution for pH change of the first portion of the electrolytic solution to maintain the pH of the first portion of the electrolytic solution stable at 5.5-7.5, thereby enabling accurate measurement of chlorine oxyanion concentrations of 10 ppm-1000 ppm, wherein the chlorine oxyanions include hypochlorite, chlorite, chlorate and perchlorate; (d) at least one flow control valve fluidly connected to the first portion of the electrolytic solution to provide the electrolytic solution from the electrochemical cell, water and / or carbon dioxide gas from the carbon dioxide gas source for the pH change; (e) a feedback control loop connected in fluid communication with the flow control valve to allow the addition of additional electrolytic solution, water and / or carbon dioxide gas to the first portion of the electrolytic solution of the control system to obtain a target chlorine oxyanion concentration in the first portion of the electrolytic solution of the control system; (f) a system output for delivering a second portion of the electrolytic solution to the cleaning system; wherein the control system is capable of producing an electrolytic solution having 10 ppm to 1000 ppm of chlorine oxyanions; Wherein the control system does not require continuous adjustment of the flow rate of the solution or other chemical additives, resulting in the stable pH range of the first portion of the electrolytic solution connected in fluid communication with the chlorine sensor.

2. The control system of claim 1, wherein the system output delivers an electrolytic solution for cleaning or sanitizing food or beverage processing equipment.

3. The control system of claim 1, wherein the system output delivers an electrolytic solution for cleaning or sanitizing food preparation equipment, processing equipment, or serving equipment.

4. The control system of claim 3, wherein the system output delivers an electrolytic solution for cleaning or sanitizing dishes.

5. The control system of claim 1, wherein the system output delivers an electrolytic solution for cleaning or sanitizing textile or garment processing equipment.

6. The control system of any one of claims 1-2, wherein the electrolytic solution has a chlorine content of 10 ppm-200 ppm.

7. The control system of any one of claims 1-2, wherein the electrolytic solution has an initial pH of 5-11.

8. The control system of any one of claims 1-2, wherein the first portion of the electrolytic solution is adjusted to a pH of 5.5-6.

5.

9. The control system of claim 8, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.75 pH units without adjusting the flow of the carbon dioxide gas or the electrolytic solution.

10. The control system of claim 8, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.5 pH units without adjusting the flow of the carbon dioxide gas or the electrolytic solution.

11. The control system of claim 8, wherein the control system maintains the pH of the first portion of the electrolytic solution within the pH range of less than or equal to 0.25 pH units without adjusting the flow of the carbon dioxide gas or the electrolytic solution.

12. The control system of any one of claims 1-2, wherein the carbon dioxide gas is provided at a fixed rate to adjust the pH of the first portion of the electrolytic solution to between 5.5 and 7.

5.

13. The control system of any one of claims 1-2, further comprising a pH sensor connected in fluid communication with the first portion of electrolytic solution and the chlorine sensor.

14. The control system of any one of claims 1-2, wherein the feedback control loop adds additional electrolytic solution to the control system to achieve the target set point for the chlorine oxyanion concentration.

15. The control system of claim 14, wherein the second portion of the electrolytic solution used in the cleaning system has a chlorine oxyanion concentration of 10 ppm to 200 ppm.

16. A method for using electrolytically generated chlorine oxyanions in an automated recirculation or once-through cleaning system for cleaning or sanitization, the method comprising: (a) generating an electrolytic solution using a control system as described in any one of claims 1 to 15; as well as (b) applying a second portion of the electrolytic solution to the cleaning system.

17. The method of claim 16, wherein the electrolytic solution is generated on-site as an electrolytic solution concentrate source.

18. The method of claim 17, wherein the source of electrolytic solution concentrate is any electrolytically generated source of chlorine oxyanions.

19. The method of claim 17, further comprising diluting the source of electrolyte solution concentrate with a source of water.

20. The method of any of claims 16-17, further comprising rinsing the cleaning system after contacting with the second portion of the electrolytic solution.

21. A method of antimicrobial treatment using electrolytically generated chlorine oxyanions in an automated recirculating or once-through cleaning system, the method comprising: (a) measuring the concentration of chlorine oxyanions in the electrolytic solution using a control system, wherein the control system comprises: (i) a sensing cell including a pH sensor and a chlorine sensor; (ii) a source of electrolyte solution concentrate and a source of dilution water for producing an electrolyte solution, wherein a first portion of the electrolyte solution is in fluid communication with a chlorine sensor in the sensing cell; (iii) a source of carbon dioxide gas in fluid communication with the first portion of the electrolytic solution for pH change of the first portion of the electrolytic solution to maintain the pH of the first portion of the electrolytic solution stable at 5.5-7.5, thereby enabling accurate measurement of chlorine oxyanion concentrations of 10 ppm-1000 ppm, wherein the chlorine oxyanions include hypochlorite, chlorite, chlorate and perchlorate; (iv) at least one flow control valve fluidly connected to the first portion of the electrolytic solution to provide the electrolytic solution, water and / or carbon dioxide gas from the carbon dioxide gas source for the pH change; (v) a feedback control loop connected in fluid communication with the flow control valve to allow the addition of additional electrolytic solution, water and / or carbon dioxide gas to the first portion of the electrolytic solution of the control system to obtain a target chlorine oxyanion concentration from the first portion of the electrolytic solution of the control system; (vi) a system output for delivering a second portion of the electrolytic solution to the cleaning system, wherein the control system is capable of producing an electrolytic solution having 10 ppm to 1000 ppm of chlorine oxyanions; wherein said control system does not require continuous adjustment of the flow rate of said solution or other chemical additives, resulting in said stable pH range for a first portion of said electrolytic solution coupled in fluid communication with said chlorine sensor; and (b) applying the electrolytic solution to the cleaning system requiring antimicrobial treatment.

22. The method of antimicrobial treatment as claimed in claim 21, wherein the electrolytic solution has a pH range in the range of 5-11.

23. The method of antimicrobial treatment of any one of claims 21-22, wherein the control system maintains the pH of the measured portion of the electrolytic solution within the pH range of less than or equal to 0.75 pH units without adjusting the flow of the carbon dioxide gas or the electrolytic solution.

24. The method of antimicrobial treatment of any one of claims 21-22, wherein the control system maintains the pH of the measured portion of the electrolytic solution within the pH range of less than or equal to 0.5 pH units without adjusting the flow of the carbon dioxide gas or the electrolytic solution.

25. The method of antimicrobial treatment of any one of claims 21-22, wherein the control system maintains the pH of the measured portion of the electrolytic solution within the pH range of less than or equal to 0.25 pH units without adjusting the flow of the carbon dioxide gas or the electrolytic solution.

26. The method of antimicrobial treatment of any one of claims 21-22, wherein the carbon dioxide gas is provided at a fixed rate to adjust the pH of the measured portion of the electrolytic solution.

27. The method of antimicrobial treatment of any one of claims 21-22, wherein the control system further comprises a pH sensor connected in fluid communication with the measured portion of the electrolytic solution and the chlorine sensor.

28. The method of antimicrobial treatment of any one of claims 21-22, wherein the control system further comprises a feedback control loop mechanism connected in communication with a loop control, wherein the loop control is triggered by the chlorine oxyanion concentration.

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