Aplicação do dmaic na redução do uso de produtos químicos nos processos de limpeza em linhas frias

Abstract

In the dairy industry, the CIP (Cleaning In Place) system plays a central role in the internal cleaning of pipelines, tanks, and equipment, allowing for the removal of residues without the need to disassemble production systems. This study aims to apply the DMAIC methodology to reduce the consumption of chemical products in Cleaning In Place (CIP) processes in cold lines of a dairy industry. The addressed problem relates to the high consumption of caustic soda and nitric acid, which represented approximately 47% of the fixed costs of the manufacturing sector. The methodology applied included the use of tools such as the Ishikawa Diagram, 5W2H, and performance indicator analysis. Through the disciplined application of the Define, Measure, Analyze, Improve, and Control phases, it was possible to identify root causes related to sealing failures, uncalibrated sensors, and inadequacies in thermal processes. The actions implemented involved the replacement of chemical products with a multifunctional formulation, improvements in equipment maintenance, and the standardization of cleaning procedures. As a result, there was a 34% reduction in caustic soda consumption and a 42% reduction in acid consumption, with an annual savings estimated at approximately R$ 302,000. The project demonstrated the effectiveness of the DMAIC methodology in promoting operational, financial, and environmental gains, and reinforced the importance of process management and continuous improvement in the food industry.