System Cleaners supplied one of the world’s leading poultry processing companies with an automatic (OPC) open plant cleaning system in order to optimise production efficiency and hygiene in their primary processing facilities. The following is their case study on it.
The three main objectives were:
- Reduction in cleaning time
- Better cleaning result
- Reduction in cleaning staff
Processing 1,000,000 chickens per day:
20 hours of processing and a flow of 1,000,000 chickens each day creates a very busy workday demanding an efficient (OPC) open plant cleaning solution to facilitate smooth operations and keep the processing equipment and other surfaces clean.
The cleaning of the processing equipment is comprised of three cycles in between production sequences and one main cycle at the end of the day. The secondary cleaning cycles are of limited duration, and the challenge was to ensure a consistent, high quality cleaning result within the timeframe available with as little cleaning staff as possible.
Extensive optimisation of cleaning cycle:
System Cleaners installed automatic solutions on the spin chillers, deboners and eviscerators. All of them were customised to ensure complete coverage of all surfaces on each machine.
This poultry processing automatic cleaning solution comprised of:
- Multiple nozzle systems consisting of fixed and oscillating nozzle bars with flat jet nozzles
- Rotating nozzles
- Booster stations and chemical pump stations supplying automatic satellites and nozzle systems with water and chemicals
- PLC controller running the pre-programmed cleaning programs utilising segment valves
In terms of the objectives of this optimisation, the installation of automatic solutions in the processing plants was a success. Regarding cleaning time, it resulted in a reduction of 35-50% depending on the equipment type. *
In the matter of staff, the outcome was a reduction in staff of 60-85% depending on the equipment type.
As to the cleaning result, installing automatic solutions resulted in a more effective and consistent cleaning within the time available.
23B specialise in the design and manufacture of custom wash down and fluid transfer systems for a range of industries. These include Food and Beverage Production, Agriculture, Utilities, Material Handling & Processing, Marine and many more.
We are an official distributor for System Cleaners in the UK and Ireland.
If you would like to know more about this project or our products and services, please get in touch:
T: +44 28 9261 7515
E: info@23bsolutions.com
*Initial manual knock-down of the processing equipment remains necessary to get rid of the biggest chunks of waste before commencing the automatic cleaning processes. The time occupied by the manual process is included in the final reduction calculation.
