in-line optimization cleaning in place (cip)

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  • OptiCIP+: In-line monitoring, optimisationand control of cleaning in place

    A. J. van Asselt, D. Allersma, F. Smit, G. van Houwelingen and P. De

    AbstractThe current way of CIP cleaning is in most cases

    based on experience and often longer than strictly

    necessary due to the lack of reliable monitoring

    tools. Currently, NIZO food research is developing a

    real-time monitoring system, based on sensors and

    process simulation tools. This will ensure a further

    reduction of cleaning costs and an increase in

    production time.

    IntroductionCleaning in Place (CIP) is an important unit-

    operation that is commonly applied throughout the

    whole food industr y. In the dairy industry, CIP is

    applied daily for the major part of the equipment.

    This ensures a constant product quality, efficient

    heat transfer in heat exchangers and avoids possible

    growth of micro-organisms. It is clear that a high

    frequency of cleaning has a large impact on the

    availability of the processing equipment and on the

    environment (ennergy use, product loss) . If cleaning

    times can be reduced, production capacity will

    increase without additional investments. In

    addition, energy savings and reduced product loss

    can be obtained. An evaluation study in the industr y

    showed that CIP procedures are based on worst case

    scenarios and there is a potential for 30% saving in

    cleaning efficiency.

    An objective analysis is needed to evaluate whether

    reduction of cleaning time is possible without

    affecting product quality and safety.

    OptiCIP+In order to answer this need, NIZO food research has

    developed a model that is able to optimise the CIP

    procedure in a food factor y. By using that CIP model

    in combination with a model based process control

    system (Premic), a tool is available to monitor,

    optimise and control the CIP procedure. Optmisation

    of cleaning prcedures is carried out in three steps:

    1. Based on the actual production data, the type

    of product and the temperature difference the

    amount of fouling is calculated.

    2. After production, a database file is searched

    and depending on the degree of fouling , an

    initial CIP procedure is loaded into the system.

    3. During cleaning all CIP related data is linked

    with the production and product composition

    data and stored in a database file.

    By making use of the sensor values, the CIP

    procedure will continuously be optimized during

    cleaning. A schematic overview of OptiCIP+ and

    the different steps of the process is shown in Figure 2.

    ResultsOne of the first targets within this project was to

    find the right in-line sensor systems to monitor the

    fouling removal. The results of the fouling removal

    monitored by this in-line turbidity sensor and an

    off-line turbidity device are shown in Figure 3.

    Figure 3: Turbidity in-line versus off-line during


    The results show that the in-line measurement of

    turbidity is very well comparable with the off-line


    The in-line measurement of calcium is currently

    under investigation.

    Cost reductionApplication of OptiCIP+ can result in significant cost

    savings for the dairy industry. For a company with

    500 000 tons of milk processing preliminary

    calculations showed when the cleaning time is

    reduced by 25% and fouling is reduced by 5%, annual

    savings up to 200 000 can be possible. With regard

    to the environmental aspects 9000 GJ of energy can

    be saved and the product loss can be reduced by 550


    AcknowledgementThis work has been supported by the Dutch Dairy

    Association, Honeywell and the Netherlands Agency

    for Energy and Environment (SenterNovem).

    ConclusionNIZO food research has developed a system, called OptiCIP+, that makes it possibleto optimize the CIP procedure in-line.By using OptiCIP+ the food industry can achieve a significant cost reduction byshorter cleaning times and higher production capacities of up to 10-20%. Thesystem is currently being demonstrated in the dairy industry.

    Figure 2: Principle OptiCIP+

    Figure 1: Cleaning efficiency before and afteroptimisation based on fouling removal

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