Booster Composition for Fermentation Cleaning Under Variable Alkalinity
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Solution Overview
Problem
Fermentation equipment cleaning processes are inefficient due to the conversion of sodium hydroxide into less effective sodium carbonate and sodium bicarbonate by residual carbon dioxide, necessitating excessive use and increased costs.
Innovation Solution
A booster composition comprising surfactants, polymers, and chelating agents is introduced into a separate circuit of the CIP system that includes the fermentation tank, allowing alkali metal hydroxide to maintain effectiveness by reacting with carbon dioxide and forming alkali metal carbonate or bicarbonate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excess sodium hydroxide is added to overcome carbon dioxide conversion, then cleaning effectiveness is maintained, but material consumption and cost increase
Solution Approach 1:
The CIP system is divided into separate circuits: a first circuit that does not contact fermentation tanks and a second circuit that does. The booster composition is added only to the second circuit, segmenting the system to apply enhanced cleaning chemistry only where carbon dioxide conversion occurs, thereby reducing overall sodium hydroxide consumption while maintaining effectiveness in critical areas
Solution Approach 2:
A booster composition containing surfactants, polymers, and chelating agents is introduced as an intermediary substance into the second circuit. This intermediary enhances the cleaning action of the alkali metal hydroxide solution, allowing effective cleaning at lower concentrations of sodium hydroxide by compensating for the conversion to carbonate and bicarbonate
2Reliability
If high concentrations of sodium hydroxide are used, then cleaning power is maintained despite carbon dioxide reaction, but operational efficiency decreases
Solution Approach 1:
The invention changes the chemical parameters of the cleaning solution by adding a booster composition with surfactants, polymers, and chelating agents to the second circuit. This modifies the cleaning mechanism to work effectively at lower alkali concentrations, improving operational efficiency while maintaining cleaning power through enhanced chemical action rather than relying on high sodium hydroxide concentrations
3Reliability
If sodium hydroxide converts to carbonate and bicarbonate, then cleaning effectiveness decreases, but adding more sodium hydroxide increases cost
Solution Approach 1:
The booster composition is added continuously to the second circuit throughout the CIP process, ensuring that the cleaning action remains effective despite the continuous conversion of sodium hydroxide to carbonate and bicarbonate. The booster composition maintains useful cleaning action throughout the process without requiring continuous addition of excess sodium hydroxide
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The booster composition enhances cleaning efficiency in fermentation tanks with variable alkalinity, reducing the need for excessive sodium hydroxide use and maintaining effective cleaning power, while being compatible with food and feed additives.
Implementation Method 1
the alkali metal hydroxide that is circulated through the fermentation tank reacts with carbon dioxide or carbonic acid in the fermentation tank to form alkali metal carbonate or alkali metal bicarbonate
Implementation Method 2
The booster composition includes at least one of a surfactant, a polymer, and a chelating agent
Implementation Method 3
The booster composition includes at least one of a surfactant, a polymer, and a chelating agent
Data Source
AI summary
Certain booster compositions and methods of using the booster compositions to clean fermentation equipment are disclosed. The booster compositions are useful in environments with variable, changing, unstable, or limited alkalinity sources found within fermentation equipment.