All of the data mentioned below are based on the information submitted by one of our clients.
- FOREWORD :
To clean the inner surface of conduction piping of any residual at a bottling or canning plant, pressurized carbon dioxide gas, germfree air or clean water is used, but the efficiency of recovering residual has remained at comparatively low levels.
We have tried a rubber-made PUSHKUN running inside the piping and has succeeded in raising recovery efficiency to a very satisfactory level.
- OUTLINES OF THE PUSHKUN SYSTEM :
We adopted the PUSHKUN System developed by OEG Co., Ltd. headquartered in Osaka, which had already been in use at some food and beverage packers, where such sticky items a jam, condensed milk and yogurt are transported through the pipe. It made some modification of the System to enhance its sanitary and operational conditions.
- Mechanical function of the System :
It is made up of three principal sections an extruder PUSHKUN, a "Starter Pipe Section: which drives out the PUSHKUN and a "Catcher Pipe Section" :which receives the Pushkun and lets pass residual for recovery. The System is provided with a compressor to pressurize germfree air or carbon dioxide gas as driving force and a PUSHKUN detector.
- PUSHKUN :
Out of two types of Pushkuns, namely WH Type and WK Type, WWH Type was adopted at our works for the sake of air tightness. In both types, the diameter of the Shield Advance is designed to be a little larger than the inner diameter of the piping to keep the passage of PUSHKUN airtight.
- STARTER PIPE SECTION
- CATCHER PIPE SECTION
- PUSHKUN Detecter :
1, A magnet built in PUSHKUN is detected by the Cylindrical Switch, and the position of PUSHKUN is signaled by flashing and buzzing.
2, OPERATION METHODS OF THE SYSTEM
Specific operation methods at (One of our client's Works). were stated in the Report.
- INSTALLATION OF SYRUP RECOVERY SYSTEM AND ITS EVALUATION :
- Installation Data (for a Pipeline between the Transfer Pump in the Syrup Storage Room and the Service Tank in the Canning Room).
|Piping Inner Diameter||l-l/2" (IDF)|
|Total Length||160 meters|
|Number of Elbow||16|
|Number of Fitting||78|
|Inner Volume of Piping ||158 liters|
- Results :
a) Residual water recovered by PUSHKUN at the startupª@2 Liters
b) Residual syrup recovered by PUSHKUN on terminal runª@30 Liters
c) Residual syrup upon the passing of PUSHKUNª@2 Liters
d) Syrup discarded in the course of conventional cleaning system becauseª@5 Liters
If the piping is cleaned with water by PUSHKUN before startup, a total of 35 liters of syrup, or (b) + (d) as above, can be recovered in good condition.
- Meritorious results obtained by the PUSHKUN System :
- Recovery of residual syrup :
Compared with a recovery rate at 77 percent of residual syrup against the whole inner volume of the piping, the PUSHKUN System has raised the rate to 99 percent.
Outlays at works in setting up the System have been recovered by boosted production and savings in cost within four months.
- Saving in operation time :
In the conventional methods, lead time for startup took about ten minutes, but the PUSHKUN Cleaning System cut it to about two minutes. However, a little more care and time are needed to have PUSHKUN cleaned, stored, mounted and dismounted in good order. For a plant to be newly established, investment for water treatment can be reduced, as the PUSHKUN System can reduce BOD factors.
- ANY INFLUENCES BY THE PUSHKUN SYSTEM ON PRODUCT :
Thorough going tests and inspections have been conducted at works to see if a round of cleaning work by PUSHKUN would have affected quality, look and taste of product to be packed in the subsequent round. The prove that the System has not produced any adverse effects on bacterial contamination, degrading in taste, color tone and brightness of such products. (Various types of beverages, such as Coca-Cola, Fanta Grade, Aquarius Lemon, were used of the tests)
- PARTICULAR CARES TO BE TAKEN IN INTRODUCING THE PUSHKUN SYSTEM :
Every section of the piping must dimensionally fit well to the specific type and size of PUSHKUN to be used. The piping circuit must be independent of any others, if any, in the same plant, so that the pressure of germfree air, carbon dioxide gas and the driving force for PUSHKUN can be always stabilized.