Spray Bar Rinse SystemSpray Bar Rinse System

ClearWater Tech, LLC.

Garlic Processing - Bakersfield, CA

The Company

- Located in Bakersfield, CA

- In business over 20 years

- Serves large companies as a food ingredient supplier

- Also serves prisons, schools, restaurant chains, etc.

Garlic processing

The Company - products

– Whole peeled garlic

– Private-label garlic purees

– Jalapeno pepper products

Garlic processing

• Spray bar rinse of whole peeled garlic– Goals: 1. Reduction of aerobic plate counts

(APCs) from in the 100,000s to the 10,000s. 2. Reduce lactic acid bacteria (spoilage) and mold.

– 100-125 ppm solution of sodium hypochlorite

– Still in place as back-up for ozone system

Previous system-Sodium hypochlorite spray bar

Spray bar rinse system

• Sodium hypo was pitting stainless steel rollers and other exposed stainless steel

• Maintenance costs - High TDS from sodium hypo was plugging spray bars, corroding the feed pump and plumbing

• Sodium hypo was adding to issues in the wastewater pond– Pond is directly over source water aquifer

Challenges presented by Sodium hypo system

• Air scrubbing (carbon) required– Odor from 100-125 ppm sodium hypo– Sodium hypo reacting with organics, causing strong ammonia odor

• Long term cost - $3,000/year in sodium hypo. With maintenance, system was costing

$500 - $600/month• Potential for sodium hypo residual on product

Challenges presented

• Ozone system installed in March of 2002 on garlic spray bar rinse system

• Installed in single pass configuration @ 13 gpm– Maintains a dissolved ozone level of 1.3

ppm– Capable of up to 5.0 ppm dissolved ozone

The solution - ozone

• Skid-mounted, pre-plumbed and pre-wired• Includes the following components:

– 20 gram/hour, variable output CD ozone generator– Stainless steel contact vessel– Fully integrated dissolved ozone monitor– Full instrumentation

The ozone systemHdo3-11 skid mount ozone delivery system

- If placed outdoors

- Requires protection from wind, rain, dust, moisture, and impacts.

Hdo3 system - on the job

• The plant’s source water comes from a deep well on the property

• Source water is fed directly to the HDO3 system

• HDO3 puts 1.3 ppm dissolved ozone into water, which is fed directly to the spray bar– Water fed @ 13gpm @ 20 psi– Spray heads increased in size to accommodate lower psi of ozone system

The Ozone System

• 4-20 mA signal from integrated dissolved ozone monitor controls output of ozone generator

• System also includes a 10 gpm wash down wand

• Ambient ozone monitor installed to insure safety of workers

the ozone system

Conveyor system and ambient ozone monitor

• 20-30% reduction in APCs from chlorine system

• Check approx. twice/month

• Anything below 10,000 is acceptable

Ozone system results

• Reduced maintenance costs– Pitting of stainless steel rollers eliminated– Spray bar plugging (from high TDS of sodium

hypo) & corrosion eliminated. Saves $500-$600/month in materials & maintenance costs

– Air scrubbing system shut down completely, saving approx. $150/month in operating & maintenance costs

Ozone system results

• Wastewater from spray bar system now has <1 ppm sodium hypo

• No potential for chemical residual on product

Ozone system results

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Other System BenefitsOther System Benefits

• Reliability - The company reports more consistent sanitation results with reduced system maintanence requirements.

• Marketing

- Easier to get product certified “organic” using ozone- Food safety is an important issue and ozone helps - both in employee safety (chemical handling) and food quality (reduced spoilage)

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Other Plant ApplicationsOther Plant Applications

• Plans to use the ozone system for equipment washdown & hard surface cleaning (10 gpm spray wand is in place)

• Considering ozone for spray bar rinse in jalapeno processing line and garlic puree processing

• Disinfection of process water

• Mobile Wash down• Wall mounted low flow systems• Spray Bar• CIP System• Flume• Surface Sanitizer• Equipment Wash down

Other systems available