Analisis Faktor Pembentukan Fouling pada Proses Sterilisasi Susu UHT Full Cream PT XYZ

Abstract

AKHMAD ANDY RIYANTORO. Analisis Faktor Pembentukan Fouling pada Proses Sterilisasi Susu UHT Full Cream PT XYZ. Dibimbing oleh PROF. DR. NUGRAHA EDHI SUYATMA, S.T.P., D.E.A. dan FERY NURDIN FERDIYAN, S.SI.

Fouling pada unit sterilisasi Shell and Tube (S&T) merupakan salah satu permasalahan dalam produksi susu UHT karena meningkatkan hambatan perpindahan panas yang ditandai oleh kenaikan nilai ?T serta meningkatkan frekuensi pelaksanaan Cleaning in Place (CIP). Penelitian ini bertujuan menganalisis faktor-faktor yang berkontribusi terhadap pembentukan fouling pada proses sterilisasi susu UHT full cream di PT XYZ sebagai dasar penyusunan tindakan pengendalian sesuai kondisi operasional perusahaan. Penelitian menggunakan pendekatan Plan–Do–Check–Act (PDCA). Tahap Plan dilakukan melalui identifikasi faktor pembentukan fouling menggunakan diagram Ishikawa. Tahap Do meliputi analisis data operasional, pengujian kadar abu pada deposit fouling, simulasi efektivitas CIP skala laboratorium, serta pengujian laboratorium menggunakan fresh milk untuk menganalisis pengaruh suhu dan waktu pemanasan terhadap pembentukan agregat protein. Tahap Check dilakukan menggunakan scoring, diagram Pareto, dan why–why analysis, sedangkan tahap Act menghasilkan usulan tindakan pengendalian fouling. Hasil penelitian menunjukkan bahwa peningkatan ?T merupakan indikator operasional perkembangan fouling akibat akumulasi deposit pada permukaan heat exchanger. Hasil karakterisasi deposit menunjukkan kadar abu sebesar 79,95% yang mengindikasikan bahwa deposit didominasi oleh komponen mineral (fouling tipe B). Faktor prioritas yang berkontribusi terhadap pembentukan fouling meliputi karakteristik susu, penggunaan bahan tambahan, suhu dan waktu final mixing, serta tipe heat exchanger. Hasil karakterisasi deposit digunakan sebagai bukti pendukung untuk menjelaskan mekanisme pembentukan fouling, sedangkan rekomendasi pengendalian difokuskan pada pengendalian karakteristik bahan, formulasi produk, serta parameter proses sesuai dengan kondisi operasional PT XYZ.

Kata kunci: fouling, PDCA, Shell and Tube, sterilisasi UHT, susu UHT full cream

AKHMAD ANDY RIYANTORO. Analysis of Factors Contributing to Fouling Formation during the Sterilization Process of Full Cream UHT Milk at PT XYZ. Supervised by PROF. DR. NUGRAHA EDHI SUYATMA, S.T.P., D.E.A. and FERY NURDIN FERDIYAN, S.SI.

Fouling in Shell and Tube (S&T) sterilization units is one of the major challenges in UHT milk production because it increases heat transfer resistance, as indicated by an increase in the temperature difference (?T), and leads to more frequent Cleaning in Place (CIP) operations. This study aimed to analyze the factors contributing to fouling formation during the sterilization process of full cream UHT milk at PT XYZ as a basis for developing fouling control measures that are compatible with the company's operating conditions. The study employed the Plan–Do–Check–Act (PDCA) approach. The Plan stage involved identifying the factors contributing to fouling formation using the Ishikawa diagram. The Do stage included operational data analysis, ash content determination of fouling deposits, laboratory-scale simulation of CIP effectiveness, and laboratory experiments using fresh milk to evaluate the effects of heating temperature and holding time on protein aggregate formation. The Check stage employed scoring, Pareto analysis, and why–why analysis, while the Act stage generated proposed fouling control measures. The results showed that an increase in ?T serves as an operational indicator of fouling progression caused by deposit accumulation on the heat exchanger surface. Deposit characterization revealed an ash content of 79.95%, indicating that the deposits were predominantly composed of mineral components (Type B fouling). The priority factors contributing to fouling formation were milk characteristics, the use of additives, final mixing temperature and holding time, and the type of heat exchanger. Deposit characterization was used as supporting evidence to explain the fouling formation mechanism, while the proposed control measures focused on controlling raw material characteristics, product formulation, and process parameters in accordance with the operating conditions at PT XYZ.

Keywords: fouling, PDCA, Shell and Tube, UHT full cream milk, UHT sterilization