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Preventing & Cleaning Orbeseal Residue in CIP
GEA Farm Technologies
GEA Farm Technologies – The right choice.
2010 Wisconsin Dairy Field Representative Conference
Keith L. Engel
Preventing & Cleaning Orbeseal Residue in CIP Wash Systems
•We must first understand:
•Why do dairy producers use
GEA Farm Technologies – The right choice.2
Orbeseal?
65% of clinical environmental mastitis cases 65% of clinical environmental mastitis cases found at calving had the same pathogen found at calving had the same pathogen
isolated during the dry periodisolated during the dry periodBradley et al, NMC ‘99
Infections are often acquired Infections are often acquired during the dry periodduring the dry period
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Cows with environmental pathogens isolatedCows with environmental pathogens isolated
at dry off were at dry off were 4.5 times4.5 times more likely to havemore likely to have
a new clinical case in their next lactationa new clinical case in their next lactation
Courtesy of Pam Ruegg
3
Natural Teat SealingNatural Teat Sealing
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Courtesy of Pfizer
4
Why the dry period problems Why the dry period problems –– Keratin Plug Formation?Keratin Plug Formation?
• Almost half of all teats remained open during the first week of dry off*
100
Teats open in dry period
nn Over 23% remain open six weeks after dry Over 23% remain open six weeks after dry off.off.
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% s
till
open
Weeks in the dry period
Dry off 1 2 3 4 5 6
100
90
80
70
60
50
40
30
20
10
0
off.off.
*Dingwell, R.T., et al. 2002. Association of cow and quarter-level factors at dry off and new intramammary infections in the dry period. Kansas State University Dairy Day.
*Dingwell, R.T., et al. 2002.
Kansas State University Courtesy of Pfizer
5
“Orbeseal”“Orbeseal”
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Courtesy of Pfizer
6
• The Orbeseal Group showed statistical significance over the Control Group by improving three economic parameters as follows:
Results of Regression AnalysisResults of Regression Analysis
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economic parameters as follows:
•• 20%20% improvement in incidence of new infections at calving.
•• 26%26% improvement in clinical mastitis between dry off and 60 days in milk.
•• 19%19% improvement* in somatic cell count at 6-8 days in milk.
Courtesy of Pfizer
7
Economic resultsEconomic results
• Differences in the timing and frequency of the first cow case of mastitis led to an improvement in the milk available for sale prediction in the treatment group over the control group ranging from 1,418 to 7,084 Kg milk per 100 cows, with an average for all herds of 4,237 kg (9341 #s).
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• The cost benefit calculation for all three herds gave a mean benefit per cow of $ 5.38 for Orbeseal use. For herds A and C, the benefit was $10.77 and $13.84 per cow.
• With this kind of profit on the table dairy producers are going to continue to use Orbeseal.
Courtesy of Pfizer
8
• Prevention is key.
• Proper training of milkers on administration and removal.
• Make sure that the CIP wash system is optimized and maintained.
• Always make sure the 6 requirements of CIP cleaning are me on the washing system.
• Proper slug velocity and a water flow through units is key.
Keeping Orbeseal off Milk Contact surfaces
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• Always use a milk filter for washing and milking.
• There are products to help maintain the system, but they are not shock treatments for removal of Orbeseal.
• Sometimes manual cleaning of meters and receivers is necessary when the above has failed. It is important to use foam brushes or sponges with a manual cleaner with a lot of surfactant so that you do not scratch equipment causing future problems.
In order prevent Orbeseal residues in CIP wash systems, milk harvesters must first understand:
GEA Farm Technologies – The right choice.10
Courtesy of Pfizer
Proper administration of Orbeseal at Dry Off
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Courtesy of Pfizer
Proper Removal of Orbeseal at Freshening
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Training and re-training of milkers on stripping fresh cows treated
With Orbeseal should be done to remove it optimally.Courtesy of Pfizer
Picture taken in a fresh cow group just beforemilker unit attachment.
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Observation of CIP Procedures
• Evaluate if CIP procedures are being followed correctly.
• Always consider the 6 requirements of cleaning when troubleshooting any build-up.
• Check temperature monitoring devices.• Measure chemical concentrations • Record temperature of the water returning to the
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• Record temperature of the water returning to the wash sink at the beginning and end of each cycle
• Complete a sketch of the CIP system and flow circuit to document conditions for future reference and consultation
Time
Temperature
Water Volume
Requirements for C.I.P. Cleaning
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Water Volume
Chemical Balance
Velocity
Drainage
15
Adequate chemical levels, drainage, and temperatures.
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C.I.P. Wash Cycles
Pre – Wash Rinse
q No chemicalq Circulate and divertq Starting temperature: 95 – 110°F (35-43°C)
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q Starting temperature: 95 – 110°F (35-43°C)
Purpose:
Ł Removes some soil load - Up to 98%
Ł Warm the equipment surface
17
C.I.P. Wash Cycles
Wash Cycle
q Chlorinated alkaline cleanerq Circulate 8-10 minutes (Make sure to have a minimum of 20 “GOOD SLUGS” in wash cycle!)q Starting temperature: 160°F (70°C)
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q Starting temperature: 160°F (70°C)q Discharge temperature: 120°F (50°C)q Wash solution pH: 10 – 11.5 (minimum)
q Active alkalinity: 250 – 350 ppm (minimum) Higher
depending system size & run time.)
q Active chlorine: 75 – 100 ppm (minimum)
Purpose: Ł Removes Milk Fat, Protein and Minerals.
18
C.I.P. Wash Cycles
Acid Rinse
q Acid Rinseq Circulate 5 minutesq Starting temperature: 95 – 110°F (35-43°C)
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q Starting temperature: 95 – 110°F (35-43°C) q Acid solution pH: 2.5 – 3 (optimum)
Purpose:Ł Removes chlorine/detergent residues
Ł Remove minerals
Ł Inhibits bacteria growth
Ł Increase chemical activity
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C.I.P. Wash Cycles
Sanitize Cycle
q Sanitizer (EPA registered product)q Run cycle 30 minutes before milkingq Circulation time: 5 minutes
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q Circulation time: 5 minutesq Starting temperature: 95 – 100°F (35-38°C)q Active chlorine: 100 – 200 ppm (optimum)
Purpose:Ł Kill bacteria
20
C.I.P. CleaningRequirements
TimeTimeTimeTime
C.I.P. Cleaning Cycles
PrePrePrePre----Wash RinseWash RinseWash RinseWash Rinse
Detergents -Basic
Ingredients
• Alkalinity
emulsifies fats.
C.I.P. Wash Cycles
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TimeTimeTimeTime
TemperatureTemperatureTemperatureTemperature
VolumeVolumeVolumeVolume
ChemicalChemicalChemicalChemicalBalanceBalanceBalanceBalance
VelocityVelocityVelocityVelocity
DrainageDrainageDrainageDrainage
Wash CycleWash CycleWash CycleWash Cycle
Acid RinseAcid RinseAcid RinseAcid Rinse
Sanitize CycleSanitize CycleSanitize CycleSanitize Cycle
• Chlorine
peptizes
Proteins.
• Sequestration
Agents tie up
Solids and
carry them out.
21
Most Common Causes of C.I.P. Cleaning Problems
Water Temperature
Mechanics
Optimize Washing – Slug size & Speed
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0% 5% 10% 15% 20% 25% 30% 35% 40% 45%
Milking Hygiene
DetergentDosage/rate
Water Quality
Temperature
22
• Slug Volume and Size– Too Large
• Increases use of chemical and water
• Improper volume may admit unwanted air into the system through the wash tank
• Causes the Milk Receiver to Flood
– Too Small
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– Too Small• Improper Volume may not allow slug to travel through the system
• Components will not clean
23
Slug setup Single slug
Slugs per cycle 30
Slugs per minute (range) 3-6
Min slug size for 3" 4 gal or 1/4 rec
Setup Specifications
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Min slug size for 3" 4 gal or 1/4 rec
Min slug size for 4" 12 gal or 1/4 rec
Gals per unit 7
Receiver size 1 gal/unit
Slug speed 30 ft/sec
Air injector Milk line only
24
Make sure you have even flow of wash solutionthrough all units.
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“Blow By”
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Vacuum Levels Equal on both channels
80 feet (24 Meters) divided by 2.75 seconds equals 29 feet/second (8.8 Meters)
2.75 sec
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One vertical division on graph equals one second
Travel Distance divided by time equals feet/meters per second
28
• 1) Do not assume that it is always Orbeseal just because the film is white.
• 2) Always observe whether the 6 requirements of cleaning are being met.
• Time
• Temperature
• Water Volume
• Chemical Balance
Identification
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• Chemical Balance
• Velocity
• Drainage
• 3) Use identification chart and perform chemical test to help in your identification.
• 4) Know what Orbeseal feels like right out of the tube.
GEA Farm Technologies – The right choice.30
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ID of Build-up Using NMC Troubleshooting Procedures
Location Color TextureAcid
SolubleDetergent Soluble
Chlorine Soluble
Receiver White tacky No No No
Neck of
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Neck of Receiver
Yellow/White Slimy No Yes Yes
Receiver Gasket
Yellow/White Slimy No Yes Yes
Gaskets by Milk Pump
Yellow Slimy No Yes Yes
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• Prevention is key.
• Proper training of milkers on administration and removal.
• Make sure that the CIP wash system is optimized and maintained.
• Always make sure the 6 requirements of CIP cleaning are me on the washing system.
• Proper slug velocity and a water flow through units is key.
Keeping Orbeseal off Milk Contact surfaces
GEA Farm Technologies – The right choice.48
• Always use a milk filter for washing and milking.
• There are products to help maintain the system, but they are not shock treatments for removal of Orbeseal.
• Sometimes manual cleaning of meters and receivers is necessary when the above has failed. It is important to use foam brushes or sponges with a manual cleaner with a lot of surfactant so that you do not scratch equipment causing future problems.
GEA Farm Technologies – The right choice.49
If you have to manually clean Orbeseal, do not use anything abrasive.
Foam paint brushes work great for meters and a foam car wash sponge for receivers with a high surfactant manual cleaner.
Thank-you for your time!
GEA Farm Technologies – The right choice.50
Thank-you!
GEA Farm Technologies
GEA Farm Technologies – The right choice.
Thank-you!
Keith L. EngelGEA WestfaliaSurge