Preventing & Cleaning Orbeseal Residuex at calving had the same pathogen ... Courtesy of Pfizer 4....

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

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

Natural Teat SealingNatural Teat Sealing

Courtesy of Pfizer

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*

Teats open in dry period

nn Over 23% remain open six weeks after dry Over 23% remain open six weeks after dry off.off.

Weeks in the dry period

Dry off 1 2 3 4 5 6

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

“Orbeseal”“Orbeseal”

Courtesy of Pfizer

• The Orbeseal Group showed statistical significance over the Control Group by improving three economic parameters as follows:

Results of Regression AnalysisResults of Regression Analysis

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

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).

• 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

• 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

• 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:

Courtesy of Pfizer

Proper administration of Orbeseal at Dry Off

Courtesy of Pfizer

Proper Removal of Orbeseal at Freshening

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.

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

• 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

Temperature

Water Volume

Requirements for C.I.P. Cleaning

Water Volume

Chemical Balance

Velocity

Drainage

Adequate chemical levels, drainage, and temperatures.

C.I.P. Wash Cycles

Pre – Wash Rinse

q No chemicalq Circulate and divertq Starting temperature: 95 – 110°F (35-43°C)

q Starting temperature: 95 – 110°F (35-43°C)

Purpose:

Ł Removes some soil load - Up to 98%

Ł Warm the equipment surface

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)

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.

C.I.P. Wash Cycles

Acid Rinse

q Acid Rinseq Circulate 5 minutesq Starting temperature: 95 – 110°F (35-43°C)

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

C.I.P. Wash Cycles

Sanitize Cycle

q Sanitizer (EPA registered product)q Run cycle 30 minutes before milkingq Circulation time: 5 minutes

q Circulation time: 5 minutesq Starting temperature: 95 – 100°F (35-38°C)q Active chlorine: 100 – 200 ppm (optimum)

Purpose:Ł Kill bacteria

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

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.

Most Common Causes of C.I.P. Cleaning Problems

Water Temperature

Mechanics

Optimize Washing – Slug size & Speed

0% 5% 10% 15% 20% 25% 30% 35% 40% 45%

Milking Hygiene

DetergentDosage/rate

Water Quality

Temperature

• 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

– Too Small• Improper Volume may not allow slug to travel through the system

• Components will not clean

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

Gals per unit 7

Receiver size 1 gal/unit

Slug speed 30 ft/sec

Air injector Milk line only

Make sure you have even flow of wash solutionthrough all units.

“Blow By”

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

One vertical division on graph equals one second

Travel Distance divided by time equals feet/meters per second

• 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

• 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.

ID of Build-up Using NMC Troubleshooting Procedures

Location Color TextureAcid

SolubleDetergent Soluble

Chlorine Soluble

Receiver White tacky No No No

Neck of

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

• 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

• 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.

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!

Thank-you!

GEA Farm Technologies

Thank-you!

Keith L. EngelGEA WestfaliaSurge

Keith.Engel@geagroup.com

Preventing & Cleaning Orbeseal Residuex at calving had the same pathogen ... Courtesy of Pfizer 4....

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