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note date october 28 2005 to project project syncro from cc michael nelson jojo briones kevin katajamaki martin victor tim framer armando melendez paul warnecke gavin constantine nestlé oit member currently assigned to franklin park subject report on dry steam cleaning trials ­ franklin park ­ oct 2005 introduction the purpose of this trial was to explore the capabilities of vapor cleaning in chocolate confectionery factories the trial was focussed on the dq line in franklin park factory this line is on of our most challenging lines specifically during the humid summer days currently it takes 5 team members and the time ranges from 8hrs thru 14hrs this team faces typical problems with cleaning as seen in confectionery plants worldwide such as · difficult access · no drains so water application have to be at a minimum even though we require water to remove must of the substance · complicated surfaces · time consuming manual cleaning methods · greasy chocolate residue that accumulates on all parts of the line summary of trials and results the vapor cleaner was found to clean chocolate residue effectively off the following items moulding plant frames internals and structures ­ e.g backing off area section electrical parts plastic buckets rollers and berings motor housings pumps checker plate flooring steps

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safety grip flooring `feet and wall/floor joints of plants and machinery screw threads and heads nuts bolts and brackets information about the cleaning technique the trials were carried out using a dss 18 kw portable steam cleaner which was supplied on loan by dry syeam systems further information can be found on their website a www.blue-steam.com the model used was a 480v machine which complied fully with the nestle electrical safety regulations with a 30ma rcd device fitted to the plug and restricted length braided cable maximum length 30 feet although an 110v model would have been the preferred option for the factory to comply with standard power supply the 480v model has the benefit of significantly faster heating time and higher steam pressure 160 psi therefore giving more effective cleaning the implication for the factory of using this model is that a network of 480v power sockets is required to cover the areas to be cleaned a variety of nozzles brushes and hose extensions are supplied with the steam cleaner to cover most applications 19.5 kw portable vapor cleaner health and safety requirements although steam is heated to temperatures up to 260°f it quickly loses heat to become safe to the touch within approximately 2-3 inches after exiting the spray nozzle wearing of gloves was required as a safety precaution and the wearing of goggles is recommended for tasks where the operator is working close to the surface to be cleaned because of the risk of splashes of residue.

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trial details the steam cleaner was used to clean a number of types of equipment in each case the clean was successful as illustrated by the `before and after photos below for flat areas such as floors and steps it was most effective to use the steam alone first to remove ingrained residue followed by an air hose to remove any excess moisture much of the moisture generated during the cleaning operation evaporates but there is a residual amount of moisture left on the surface on complex surfaces e.g internals of moulding any residual moisture must be removed with a dry disposable cloth either during the clean or immediately afterwards restrictions of the method it is important not to use the steam cleaner in areas where moisture and removed residue will be driven into holes hollow sections or areas with any access to remove them this is the main restriction on the use of this method and areas must be carefully evaluated before cleaning by this method the other restriction to be considered is the use of steam cleaning on mild steel surfaces ­ it is likely that this could cause rusting if there are no dry propetly of the surface but we most rember the amount of water use is very little in the same way that cleaning with water would photos illustrating areas cleaned before steam clean after steam clean hard-imbedded candy 4 week build up after a 25 second application used a wire brush attachment

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on the second level about 3 feet away from the platform very difficult to reach after a 10 seconds application 5min:40sec to clean manually after a 32 seconds application before after

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trial was done on the bag maker this took about 2min 40sec to clean removed all traces of product.

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before areas like this can be missed during cleaning after 12second application before after

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time study the speed of clean using steam compared to the current manual method was tested in four areas these areas were the floors our bucket elevators metal detector and our super sack station currently these are our bottleneck areas when it comes to cleaning before super sack area bucket elev 52 buckets metal detector floor inside view of super sack

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to achieve this standard of clean a thorough deep manual clean of this equipment had previously been carried out on soiled equipment using only scrapers brushes and hoses steam cleaning was also carried out on soiled equipment the major time reductions were performed by a trained dry steam associate and not by a franklin park associate these times indicated below are all potential times due to the fact that these times need to be verified with one of our team members actually using the dry steam machine super sack metal detector floor only the inside done manual clean 5min.10 sec per 2 hrs 37 min 1hrs.20 min 47 minuets bucket x2 people 1 person 1 person lots of water total time unable to reach unable to had to be 4hrs.30min all areas clean properly applied plus product still left lots of we had to use a in the area product still scraper lots of water left area had to be used extremely to remove hard to reach product dry steam 1min.12sec per 27 minutes 12 minutes 6 minutes cleaning bucket x 1 person for the same removed build very little to no total time around area using up that was water a one step 1hr2min current there for some process we cleaned all attachments time area 52 buckets will manufacture was extremely during the demo an attachment to clean clean this area time should be cut in 1/2 · equipment bucket elev 52 during extreme heavily soiled conditions these times would increase by 70 for the manual cleaning.

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before after team member 5min 10 sec per bucket after xtreme mach 1min 12sec per bucket machine backside of buckets cleaned by dry steam machine great detailed cleaning

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area under metal detector belt usually goes un cleaned currently very difficult to reach several weeks build up before inside super sack after xtreme clean machine

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12 minutes to clean conclusions this demonstration was a huge success this is the type of equipment that can have a tremendous effect on the way we clean my time study shows a potential 83 reduction in cleaning times plus a more detailed clean.

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stage two below are some potential savings if we are able to validate these numbers with two more trial runs having our own team members perform the trial study currently this department is cleaned by 5 team members at an average salary of $18 an hour not including over time or benefits with two vapor units this entire department can be cleaned in 5 hours with only two team members a cost savings about $25,960 if you subtract the cost of the unit 11,500 in the first year we would net $2960 this number was calculated at straight time no benefits and a 48-work weeks 4 weeks for shut down were removed this is a very rough calculation steam cleaning is an effective cleaning method for these types of problems and it is likely that there are many other potential applications within our confectionery factories confectionery next steps bring the equipment back in for another two demos in the next two demos our team members will actually run the machine and i ll conduct the time trial we will have martin victor from qa to verify the cleanliness a representative from the maintenance group to verify that this process won t warp our buckets or potentially harm any of our equipment the ie manager will be on hand to verify all times conduct a trial in the baby ruth kitchen on the rafters and ceilings if the above test goes well rent two units for one month and conduct more evaluations and in different departments initial tests to be carried out on portable in-line conveyor belt cleaning using steam ­ by early 2006 feasibility of in-line chain cleaning using steam to be assessed ­ feasibility by end 2005 3401 mount prospect road franklin park il

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