cip (clean in place) - burkert-usa.com 8175 ultrasonic level transmitter is ideal for cip...

CIP (Clean in Place)

Definition, Application, Implementation

What is CIP?

Definition: Automatic, reproducable, and reliable delivery of

cleaning solutions, rinse & wash water, to and through process

equipment and piping with limited or no dissasembly

Burkert Built CIP Skid IPPE 2014

Key Objectives of CIP

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1. Maximize Sterility — to avoid cross-contamination between

product changes

2. Minimize CIP time — to help speed up time-to-market and

reduce impact on plant production (downtime reduction)

3. Optimize thermal efficiency — to avoid unnecessary heat

loss and reduce energy requirements.

4. Minimize water usage

5. Validate process – Help process meet

cleanliness objectives

Why do we need CIP?


- In the Pharmaceutical field batch manufacturing is

commonplace

- A sanitary process is mandatory for many products

- Through the introduction of high pressure water, chemicals, etc.

CIP is able to maintain sanitary conditions between batches

-Typical Pharmaceutical residues include: Proteins, Lipids,

Sugars, Salts, Nucleic Acids, Viable Organisms, and Endotoxins

- CIP allows for reliable cleaning with minimal downtime due to

the lack of a need to disassemble critical parts of the process

The CIP Process


1. Pre-Rinse - Mechanical Removal of Media

2. Detergent - Cleaning of Remaining Soil - Caustic, Acid or Both

3. Intermediate Rinse 4. Sterilant/ Disinfectant Chlorine Dioxide, Hypochlorite, Iodophor, Acid Anionic, Quaternary Ammonium, Hydrogen Peroxide, PAA (Peroxyacetic Acid)

5. Final Rinse - Wash Residual Detergent/Soil

Operating Conditions of CIP


Control is critical in CIP applications

Must monitor/control:

1. Flow Rate -> Velocity is critical, generally 5ft/second and

higher for pharma applications.

- Generally between 10-160 GPM

2. Temperature -> Can range from 120-175 F based on system

requirements

3. Cleaning Times -> Cleaning cycle must be completed within a

specific time frame to ensure sanitary conditions

4. Concentration of Cleaning Chemicals -> pH and Conductivity

testing are popular methods of monitoring chemical

concentration

Detergents: Acidic vs. Caustic


Acidic

- Effective at removing inorganic Scale

- Not Affected by Water Hardness

- Not affected by the presence of CO2

- Concentration easily

monitored/controlled by conductivity

meters

- Better for Low soil environments

- More expensive

Caustic

- Effective at removing Organic Scale

- Affected by Water Hardness

- Carbonized by the presence of CO2

- Also controlled easily by conductivity

meters

- More effective in high soil environments

- Cost Effective

CIP 100


• Steris CIP 100 is a common alkaline based detergent used in

pharmaceutical CIP

• It is a blend of potassium peroxide, an advanced surfactant

system and other performance enhancing ingredients that

provide multiple cleaning mechanisms

• Flexible due to its application in a wide variety of

pharmaceutical residues

• Reduces water consumption and cleaning time due to

its low foaming characteristics

CIP Designs

Two main types of CIP design include:

1. Single Use

1. Primarily skid based/ modular design

2. Small footprint with high level of adaptability

3. Lower Capital cost but higher chemical costs

2. Recovery

1. Primarily centralized design with focus on water and

chemical cost savings

2. Recirculates water and chemicals to minimize waste

3. Ideal for locations with limited access to water


Single Tank


Multi Tank


Single Use vs. Recovery

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• Recovery CIP – High Capital Cost

– Large Space Req.

– Higher Contamination Risk

– Low Loss

• Low Water Use

• Low Energy Use

• Low Effluent Vols.

– Suitable for high frequency CIP applications

• Single Use CIP

– Low Capital Cost

– Small Space Req.

– Low Contamination Risk

– Total Loss

• High Water Use

• High Energy Use

• High Effluent Vols.

– Typical for Pharma

application

Burkert Application


Where does Burkert fit in?

1. Components

1. Standard

2. Custom (Block Body)

2. Systems Build (Fabrication)

3. Refurbishment

Type 2103 ELEMENT Diaphragm Valve for

ON/OFF


The Type 2103 ELEMENT series valve is among the most popular

valves for CIP application

- The SS wrapping makes the 2103 suitable for rugged wash-

down environments. (IP65/67/NEMA4X)

- The design of this valve allows for high flow. Ideal for the

requirements of CIP applications

- This valve is also ideal for hygienic applications due to its zero

dead volume/Self Draining design

- Our Advanced PTFE/EPDM diaphragm material is popular for

use in pharmaceutical CIP (Due to high deltaT)

Type 2103 Forged

Type 2100 angle seat for ON/OFF


The type 2100 angle seat valve can be used for rinse water or

detergent control

- High flow rates and cycle life

- Flow optimized body in stainless steel

- Deliverable with flow direction below or above seat

- Clean design for optimal use in hygienic environment

- Suitable for steam up to 10 bar (145.03 psi) and 365°F

Type 8691 ELEMENT On/Off Control Top


The Type 8691 ELEMENT Control Top is easily combined with the

Type 2103 Diaphragm valve

- IP65/67 Wash Down Resistant

- Integrated Pilot solenoids for decentralized control

- Visual position indication

- Internal air routing/ durable 316 SS housing allows for better

wash-down protection

- Integrated air filter helps keep the actuator free from outside

contaminants

- Contactless/ inductive stroke measurement allows

for longer life span

Type 2300 Angle Seat Valve for Control


- High Cycle Life

- IP65/67 Washdown

- Clean design and look

- Compatible with 8692 and 8693 control tops

- Internal air routing from control tops

- Comes is class IV and Class VI shut off

Type 8692 Electro Pneumatic Positioner


The type 8692/8694 Positioners Provide Decentralized control of

process valves

8692

- IP 67 Rated Wash-down environment

- Local backlit display

- Internal built in pilot valves with Integrated air supply filter to protect actuator

- Profibus or DeviceNet communication protocols

- Digital or Analog output options

- Built in X tune option for quick setup

- Integrated check valve to protect internals

Type 8692

Type 8693 Positioner with PID Control


They type 8693 Positioner borrows from the 8692’s functionality

and adds full PID control

- Able to fully manage a control loop without PLC assistance

- Hygienic design IP65/67 wash-down rated

- Full graphical display for local viewing

- Profibus or DeviceNet communication options

- Local setpoint programming (if desired)

Type 8170/8175 Ultrasonic Level Transmitter


Type 8175 Ultrasonic Level Transmitter is ideal for CIP application.

- Its contactless design allows for sanitary monitoring of

wash/rinse and detergent tanks

- Able to monitor both open and closed tanks. Up to 10m

- Ideal for filling applications due to its continuous monitoring and

feedback procedures

- Available with compact mounted transmitter or remote mount

options

Type 8176 Ultrasonic Transmitter


The Type 8176 is the ELEMENT series successor to the 8175

- The primary difference is display size / lack of remote mount

option

- 8176 is also more suitable for solids

- Measurement of up to 5m liquid/ 2m solids

Type 8045 Insertion Flow Magmeter


The Type 8045 Insertion Flow Magmeter is commonly used in CIP

applications.

- Designed for liquids with a conductivity of >20 µS/cm

- Provides 4-20 mA output (Pulse and Relay)

- Version w/ Stainless Steel sensor is ideal for high pressure/ high

heat CIP applications

-SS version also provides good chemical

resistance

- FDA approved

Type 8311 Pressure Transmitter/ Switch


Ideal for measuring process pressure

- Good for CIP applications due to heat resistance.

- Easily combined with 8693 Control Top to establish control loop

- Local programmable switching points

- 4-20 mA output to PLC

- Continuous or ON/OFF application

Type 8222 Conductivity Meter


The Type 8222 Is Burkert's ELEMENT series conductivity meter

- HMI can be removed to program multiple meters

- Suitable for pH and ORP as well as conductivity

- NEMA 4X wash-down protection

- Backlit 2 Line Display

- Measuring Range of 0.05 µS/cm – 10mS/cm

Type 8619


- Burkert’s 8619 is compatible with most flow, PH/O.R.P. and

conductivity sensors, directly connected (4-20 mA)

- Analog and digital input

- Basic transmitter/controller with hardware extension (up to 6

slots), and selectable software extensions

- Data logging

- Ideal device for measurement and control

8644 AIRLINE Manifolds


Process Automation of Burkert's Valves can be achieved with the

8644 AIRLINE System

- Compact Combination of Fieldbus, Pilot Valves, and I/O

Modules

- Fully compatible with: Phoenix, Wago, Rockwell, and Siemens

Systems

- Added panel flexibility with AIRLINE quick option

Implementation


Where do we go from here?

- Burkert currently bases the majority of its business on component sales

- Continue to look for fabrication partnerships. i.e ―JBT‖

- Continue to look for opportunities to refurbish end users CIP skids.

Retrofitting them with Burkert Valves and Instrumentation. (i.e Biogen)

We make ideas flow.

Thanks!

Luke LaPlant & Taylor McKusick

Bürkert Fluid Control Systems

2915 Whitehall Park Drive

Charlotte, NC 28270

Tel.: 800-325-1405

www.burkert-usa.com

cip (clean in place) - burkert-usa.com 8175 ultrasonic level transmitter is ideal for cip...

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