cip technologies - kendall group · 2017-08-04 · cip vs. cop clean-in-place (cip) an automated...
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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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