Open place cleaning (OPC)

Challenge

To reduce water and energy used in the hygiene process in a savoury snack manufacturing plant

The plant used traditional industrial chemicals for cleaning and hygiene, following a standard five step process during these operations.

Our industries

The solution

The Ozo Innovations team ran a pilot trial on a potato crisp line and was able to demonstrate that a three step process using eloclear was able to match or better the efficacy of the plant’s current cleaning operations. Following this work, the team went on to run trials across the full factory estate, covering a range of potato crisp and savoury extruded snack products. In all areas of the site tested, the trials achieved the same or improved efficacy as the current hygiene operations, meeting all validation standards for microbiological pathogens and allergens.

As cleaning and disinfection occurs in the same cycle and effective rinsing can be achieved with significantly less water, the use of eloclear saves time, water and energy.

 Results

  • All food safety validation requirements passed
  • >30% reduction in hygiene cycle time – increased line capacity
  • >70% reduction in water consumption
  • >80% reduction in energy that was needed for hot water production
  • Safer – removed need to handle and dilute harsh chemical concentrates

The site Technical Manager stated the trials “highlighted significant water savings, reduced wastewater treatment needs, and successful visual cleanliness, microbial and allergen swab results.”