CIP Technologies

August 1st, 2017

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CIP vs. COP

Clean-In-Place (CIP)

An automated system for cleaning processing equipment in place without disassembly.o Spray clean vessels and pressure/flow clean pipingo Remove residue with chemicalo Little manual intervention

Clean-Out-of-Place (COP)

COP is required to clean process items that are unable to be cleaned in place and must be disassembled to achieve a complete clean.

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Critical Cleaning Parameters (TACT)

TACT

Effective cleaning is a combination of both Physical and Chemicalprocesses. When one parameter is decreased the other parameters must compensate.

Chemistry Action

TemperatureTime

imectionhemical/Concentrationemperature

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Clean-In-Place (CIP)

Advantages

Highly reproducible, especially if automated

May provide utility savings over manual processes

Disadvantages

Requires high initial investment

Requires extensive engineering of the process and CIP system to ensure cleanability

Cannot be applied to all processes

An automated procedure in which the process equipment is cleaned without disassembly by circulation of cleaning solutions along the process flow path.

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Typical CIP Cleaning SequenceSTEP STEP

DESCRIPTIONTIME(min)

TEMP( F⁰ )

% CHEM.CONCEN.

FLOW(gpm)

1 Pre-Rinse 2 50-100 none 43

2 Alkaline Wash 20 145 2 43

3 Rinse 2 50-100 none 43

4 Acid Wash-optional 15 145 1 43

5 Rinse 5 50-100 none 43

6 Sanitizer Rinse 5 50-100 150-400 ppm 43

7 Airblow to drain 4 none none NA

Food Plant Cleaning Sequence Example

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Typical CIP Cleaning SequenceSTEP STEP

DESCRIPTIONTIME(min)

TEMP( F⁰ )

% CHEM.CONCEN.

FLOW(gpm)

1 Pre-Rinse 2 50-100 none 43

2 Alkaline Wash 20 145 2 43

3 Rinse 2 50-100 none 43

4 Acid Wash-optional 15 145 1 43

5 Rinse 5 50-100 none 43

6 Sanitizer Rinse 5 50-100 150-400 ppm 43

7 Airblow to drain 4 none none NA

Pharma Plant Cleaning Sequence Example

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CIP Applications

Process equipment Product Tanks & Lines Mixers & Blenders Bioreactors & Fermenters Coating Equipment Spiral Freezers Centrifuges

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CIP of Process Tanks

Cascade water down interior surfaces

Spray devices installed in tank

All tank interior surfaces must be wetted

Tank must be evacuated at rate greater than supplied to avoid pooling in tank

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Riboflavin Testing Procedures Set-up Dye Specification and Application Procedure Rinsing Procedure Inspection and Acceptance Rejection Documentation Post Test Procedure Spray device Test Form

How do you verify that your spray devices are covering 100% of the surface area to be cleaned?

Spray Ball Coverage Verification

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CIP of Process Lines

Pump solution through lines with sufficient velocity to create turbulent flow.

Target velocity > than 5 ft/second

If you do not wet the surface it will not be cleaned

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5 Feet Per Second Cleaning Chart

Tube Diameter Flow rate needed to achieve 5 FPS

0.5” 1.7 gpm

0.75” 4.8 gpm

1.0” 9.4 gpm

1.5” 24 gpm

2.0” 43 gpm

2.5” 70 gpm

3.0” 102 gpm

4.0” 180 gpm

6.0” 420 gpm

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Apply Cleaning Solutions: Once-Through or Recirculate

Once-Through CIP

Cleaning solution is introduced into process from CIP system and not recirculated.

Typical for rinses.

Recirculated

Cleaning solution is introduced into process from CIP system and returned to the CIP and back to the process multiple times.

Typical for chemical washes.

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Apply Cleaning Solutions: Once-Through or Recirculate

Recirculated

Cleaning solution is introduced into process from CIP system and returned to the CIP and back to the process multiple times

Return pump or other means used to return solutions

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Single Use of CIP Solutions

New cleaning solutions are made with new for each recipe

Applied to all cleaning steps

Pre-Rinses

Alkali Washes

Acid Washes

Final Rinses

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Re-Use of CIP Solutions

Cleaning Solutions are used multiple times for different CIP circuits

When is Re-use common?

Alkali Wash Solutions

Acid Wash Solutions

Final Rinses – saved for use as next pre-rinse

Sanitizer Rinses - Europe

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1 Cold RO Water Pre-Rinse to Drain

Steam

ROWFI

Drain

Target Tank

ChemDrainDrain Drain

VERIFY SUPPLY FLOW RATE

VERIFY RETURN FLOW

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HOLD FOR RETURN TEMP

Recirculated Wash

HOLD FOR CHEMICAL

CONCENTRATION

Steam

ROWFI

Drain

Target Tank

ChemDrainDrain Drain

VERIFY SUPPLY FLOW RATE VERIFY

RETURN FLOW

Hot RO Water Solution Wash2

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Rinse CIP Tank

Rinse tank/WFI through spray ball

4

Steam

ROWFI

Drain

Target Tank

ChemDrainDrain Drain

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Post-Rinse To Drain

Steam

ROWFI

Drain

Target Tank

ChemDrainDrain Drain

VERIFY SUPPLY FLOW RATE VERIFY

RETURN FLOW

Hot RO Post-Rinse5

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Rinse CIP Tank

Rinse tank/WFI through spray ball

8

Steam

ROWFI

Drain

Target Tank

ChemDrainDrain Drain

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Post-Rinse To Drain

Steam

ROWFI

Drain

Target Tank

ChemDrainDrain Drain

VERIFY SUPPLY FLOW RATE VERIFY

RETURN FLOW

Hot WFI Post-Rinse to Drain12

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Air Blow Supply Line13

Steam

ROWFI

Drain

Target Tank

ChemDrainDrain Drain

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Food & Beverage 3-Tank CIP System

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1. Pre-rinse to Drain

Food & Beverage 3-Tank CIP System

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4. Detergent Wash Recirculation–Hold for Temperature and Chemistry

Hold for Temperature

Verify Supply Flow

Hold for Conductivity

Food & Beverage 3-Tank CIP System

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Verify Supply Flow

6b. Post-rinse SolutionReturn to Rinse Recovery Tank Until Full

Food & Beverage 3-Tank CIP System

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Verify Supply Flow

8. Sanitize Rinse to Drain

Food & Beverage 3-Tank CIP System

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9. Air Blow and Pump Back to Drain

Food & Beverage 3-Tank CIP System

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1-Tank

All solutions made up in a common tank

Tank is cleaned through sprayball before changing solution types

Time should be allowed for repeated filling and cleaning of tank

2-Tank

1st Tank- chem wash solutions

2nd tank used for final rinse.

Optional -Both tanks cleaned through sprayballs

Faster than a 1-tank. Final rinse tank filling begins at start of cycle

3-Tank

1st Tank- Saved chem wash solutions

2nd tank- Saved final rinse used for pre-rinse,

3rd tank -cold or hot final rinse.

Optional- tanks cleaned through sprayballs

Faster than a 2-tank system

Configurations

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Portable CIP Systems

CIP system brought to the cleaning application

Eliminates the need for permanent piping

Utility connections required at each point of use

Low water usage – no long supply and return line

Requires more time for setup

Suitable for large and small scale applications

Identical cleaning performance to Fixed Place systems

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Stationary CIP Systems

Typically installed in a utility space

Utilities are only required in one location

Supply and return piping are permanently installed

Reduced setup time over portable systems

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Questions

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