cip technologies - kendall 2017-08-04آ  cip vs. cop clean-in-place (cip) an automated system for...

Download CIP Technologies - Kendall 2017-08-04آ  CIP vs. COP Clean-In-Place (CIP) An automated system for cleaning

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  • CIP Technologies

    August 1st, 2017

  • sanimatic.com

    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 piping o Remove residue with chemical o 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)

    T A C T

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

    Chemistry Action

    Temperature Time

    ime ction hemical/Concentration emperature

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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 Sequence STEP STEP

    DESCRIPTION TIME (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 Sequence STEP STEP

    DESCRIPTION TIME (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

  • sanimatic.com

    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.

  • sanimatic.com

    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

  • sanimatic.com

    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

    RO WFI

    Drain

    Target Tank

    ChemDrain Drain Drain

    VERIFY SUPPLY FLOW RATE

    VERIFY RETURN FLOW

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    HOLD FOR RETURN TEMP

     Recirculated Wash

    HOLD FOR CHEMICAL

    CONCENTRATION

    Steam

    RO WFI

    Drain

    Target Tank

    ChemDrain Drain Drain

    VERIFY SUPPLY FLOW RATE VERIFY

    RETURN FLOW

    Hot RO Water Solution Wash2

  • sanimatic.com

    Rinse CIP Tank

     Rinse tank/WFI through spray ball

    4

    Steam

    RO WFI

    Drain

    Target Tank

    ChemDrain Drain Drain

  • sanimatic.com

     Post-Rinse To Drain

    Steam

    RO WFI

    Drain

    Target Tank

    ChemDrain Drain Drain

    VERIFY SUPPLY FLOW RATE VERIFY RETURN

    FLOW

    Hot RO Post-Rinse5

  • sanimatic.com

    Rinse CIP Tank

     Rinse tank/WFI through spray ball

    8

    Steam

    RO WFI

    Drain

    Target Tank

    ChemDrain Drain Drain

  • sanimatic.com

     Post-Rinse To Drain

    Steam

    RO WFI

    Drain

    Target Tank

    ChemDrain Drain Drain

    VERIFY SUPPLY FLOW RATE VERIFY

    RETURN FLOW

    Hot WFI Post-Rinse to Drain12

  • sanimatic.com

    Air Blow Supply Line13

    Steam

    RO WFI

    Drain

    Target Tank

    ChemDrain Drain Drain

  • sanimatic.com

    Food & Beverage 3-Tank CIP System

  • sanimatic.com

    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 Solution Return 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

  • sanimatic.com

    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

  • sanimatic.com

    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

  • sanimatic.com

    Questions

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    CIP Technologies CIP vs. COP Critical Cleaning Parameters (TACT) Clean-In-Place (CIP) Slide Number 5 Slide Number 6 CIP Applications CIP of Process Tanks Slide Number 9 CIP of Process Lines 5 Feet Per Second Cleaning Chart Apply Cleaning Solutions