Automated Caustic Cleaning Sequence and End of Run Sequence for a Keg Line.

The process piping of our customer’s Keg Filling Line is cleaned on a weekly basis with a caustic cleaning solution. The cleaning sequence was manually initiated by opening several valves by hand. This would allow the caustic solution to circulate through the process piping. The operators would allow the solution to circulate for a predetermined period of time and then close the valves and flush the piping with water for a predetermined period of time.

ABCO was called upon to automate this process. The advantages to automation of these procedures included:

* A reduction in the time required
* Consistent process step duration
* Improved repeatability and quality of cleaning
* Improved fail-safe protection of product integrity

ABCO made these improvements by installing automatic valves and linking them to an existing PLC. A new Wonderware screen was added to the line HMI to control the cleaning sequence. Additionally, ABCO added a conductivity probe to check for the presence of the caustic solution.

Now, when it is time to start the cleaning sequence, the operator clicks on a button on the HMI. All the appropriate valves open (the graphics representing the valves on the HMI change color as the valves change state) and the caustic solution is introduced into the system. The conductivity probe checks for the presence of the solution. Once it is detected, a timer starts. The solution then circulates for the preset amount of time and is then sent to drain as rinse water is introduced to the system. The probe then checks for the absence of the caustic solution and closes all valves when no more caustic is detected. Once complete, the HMI displays a "ready for production" message and regular production can resume.

ABCO worked with our customer’s schedule to complete this project with no loss of production time. Our engineers stayed onsite during the entire start up to provide training and troubleshooting support. Additionally, ABCO identified another area of the process (end of run) that could be automated easily while we were making the other changes. The identification of this area for improvement added additional value to the project with little additional cost to the customer, and no additional inconvenience.