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A Guide to Clean In Place (CIP)

Clean-in-place (CIP) technology offers significant advantages to manufacturing facilities, from

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efficient and reliable cleaning of process equipment and piping at lower cost to improved product
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quality. This summary highlights the important factors in CIP technology, identifying several
designs of CIP systems and discussing the basic operation of the units. The controls incorporated
into CIP systems are critically important, being required to provide a variety of cycle times,
temperatures, composition and concentration of cleaning solutions. The clean-in-place systems
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may include current recycling and regeneration technologies, in order to reduce operating costs
and control the cost of waste disposal.
A&B Process Systems has over 30 years of experience in the design, fabrication, installation and

start-up of CIP systems for the chemical, pharmaceutical, bio-pharmaceutical, dairy, food and
other processing industries. The company offers a seminar that focuses upon many aspects of this
technology. Through the seminar A&B Process Systems is able to provide practical knowledge
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that is of immediate use, knowledge that has been gained from those years of experience working
with the clean-in-place technology.
Introduction

The development of clean-in-place (CIP) technology, i.e., the automatic, reproducible and
reliable delivery of cleaning solutions, rinse and wash water to and through process equipment
and process piping, has improved both product quality and plant hygiene. Furthermore, the
ability to clean a processing system, incorporating tanks, pumps, valves, filters, heat exchange
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units and process piping, without the need to disassemble all or part of that system, significantly
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reduces cleaning costs and minimizes the handling of chemicals to provide a safer environment
for plant personnel. These systems may be integrated into existing processing systems, but more
importantly, clean-in-place technology should be included in the design of any new process
system, to be simultaneously incorporated with the design of the process flows, the controls and
automation.
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Clean-in-place technology may be applied to any equipment in which contact by a liquid can

be achieved by way of spraying or recirculation of water and aqueous cleaning solutions under
pressures ranging from 25 to 80 psig. Prior to cleaning a process system, it is economically
beneficial to many processing industries to recover the residual product. Several approaches may
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be used, e.g., evacuation, “water flush,” “airblow” or “pipe pigging.” This latter term describes
the propelling of a flexible, elastomer projectile through the piping system. The pig is usually
driven by air, nitrogen, water or a cleaning solution. This technique reduces downtime between
product runs or when formulations are changed and recovery of the product is economically
significant.

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Designs of CIP systems

There are several designs of CIP systems. The “single-pass” and the “recirculating”
configurations are often utilized in the processing industries, since both require minimal
capital investment, typically have a small footprint and are flexible, in that the unit can readily
adjust to a range of cleaning protocols. However, the cost for the chemicals, water and steam
and for disposal of the wastewater are higher than for other designs.

The dairy and food industries have consistently favored a “re-use design,” which provides
for the recycling of the water and possible regeneration of the cleaning chemicals. These CIP
systems have a larger footprint than “single pass” systems and there is a greater risk of cross-
contamination during operation. The “re-use” systems also lack flexibility, in that a single
temperature and a single concentration of cleaning solution is used for whole process system,
unless additional vessels are included in the CIP unit.

The pharmaceutical and bio-pharmaceutical industries prefer to use a multi-tank configuration,

with independent, stainless steel tanks being used to hold water of different quality, e.g.,
deionized water (DI), hot or cold water for injection (WFI) and water from reverse osmosis units
(RO). These multi-tank systems are operated as if they were single-use systems, the tanks being
drained between subsequent programs to minimize cross-contamination.

A single-use, eductor assisted CIP unit, which reduces the consumption of water and
chemicals, was developed primarily for use in the dairy and food processing industries, but has
recently found application for selected pharmaceutical processes. This system is capable of
circulating small volumes of water at relatively high rates.

How does a CIP system operate?

The operation of the CIP system requires the control of several conditions, i.e., the fluid flow
rates and velocities, temperatures, cleaning times and the concentrations of the cleaning
chemicals (detergents, caustic soda). Fluid velocities in the process piping are typically
approximately 5 feet per second, although some systems in the pharmaceutical and bio-
pharmaceutical industries use higher velocities. In the case of tanks, the rates of flow of either
water or cleaning solution are largely determined by the size of the tank, as well as the number
and the properties of the spray devices. These flow rates usually range from 10 to 160 gallons
per minute.
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Spray devices come in a variety of designs. The traditional spray ball is commonly used and
provides directional streams of water or cleaning solution from small, static nozzles. Rotational
devices provide spherical spray patterns and direct impingement spray devices introduce high
pressure streams at low flows, rotating through 360˚ The impingement spray devices represent
an alternative to the removal of soils or deposits by cascading water or cleaning solution that
cascade down the sidewalls of the tanks or vessels.
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may be added using peristaltic, pneumatic diaphragm and or more precise metering pumps.

The temperature of the CIP process may vary from 135 to 175˚F and control is usually critical.
The necessary heat transfer demands are met either by incorporating heat exchangers (plate-
and-frame or shell-and-tube) into the CIP system, or by direct injection of steam. Chemicals
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Concentrations of the cleaning solutions are monitored and controlled by the measurement of the

pH or electrical conductivity of the solution.

The CIP process involves a sequence of cycles that includes an initial and final drain step, a pre-

rinse, wash and post-rinse. The duration of the rinse and wash cycles vary from 5 minutes to 1
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hour. In the pharmaceutical, bio-pharmaceutical, dairy and food industries, the CIP process may
include a “sanitize” cycle to reduce the levels of bacterial contamination. This cycle necessarily
uses aqueous solutions of strong oxidants such as hydrogen peroxide, ozone, chlorine dioxide
and other chlorine-containing compounds.
When a “sanitize” cycle is included, thorough final rinse cycles are required to avoid corrosion
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of the stainless steel tanks, vessels and process piping, due to the presence of traces of the strong
oxidant, particularly the chlorine containing compounds or chloride ions. In order to efficiently
drain process equipment and process piping, the system should be designed and installed to
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either allow the fluids to flow out under gravity or be pitched to drain points. It is also very
The pre-rinse uses recycled water to flush out loosely adhering particulat es and soil. This water is

important to avoid sections of the piping and equipment in which fluid flow is restricted. Split
flow designs also adversely affect the flow of solution through a piping system. Any problem
areas should be identified and the piping modified or an appropriate cleaning method developed.
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often flows directly to the drains as it leaves the CIP system. The wash cycle may use more than

one chemical, depending upon the degree of fouling and nature of the deposits in the process
equipment and piping. The post-rinse cycle provides the final flush for the system. The effluent
from this final cycle may be discharged to the drains, directed to a solution recovery tank or to
a pre-rinse tank, as has been described earlier. The effluent may flow to the drain or recovery
points under gravity, but some CIP systems include return pumps or eductor devices.
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How important is the control system to the operation of the CIP unit?

The importance of the controls incorporated into the CIP system cannot be overstated. It is
necessary to include a variety of instruments and devices, i.e., resistors that are dependent upon
temperature, pH probes, conductivity meters, flowmeters, timers, level sensors and alarms. Fully
automated control must provide for variable times for rinse and drain cycles and for recirculation
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of the various solutions. The system must also have the capability to change the temperature,
flowrates, composition and concentration of the cleaning solutions. The main control unit is
usually based upon PLC equipment, often as multiple panels to service operator stations and for
valve and I/O termination. The process control system is critical to controlling or minimizing
hydraulic shock, a common problem in CIP units. The proper sequencing or “pulsing” is required
to clean the valves, lip seals, o-rings and valve seats. A correctly designed and installed control
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at A&B works with the design engineers and the customer to ensure that this objective is realized

system may eliminate the problem of hydraulic shock, leading to lower maintenance costs and
longer component life. A&B Process Systems has recognized the importance of providing user-
friendly controls and instrumentation with any CIP system. The Automation and Controls group
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and that the proper level of operator training is provided.

What is meant by “process validation?”

Process validation is an important aspect of a properly managed CIP system. Three questions
should be asked of the operating CIP unit;
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Is the CIP system working as intended?

Has the CIP process cleaned/ sterilized to the level required?
Have residual chemicals been removed from the process equipment and process piping?
The answer to question (a) is provided by the array of instruments in the CIP system. The probes,

devices and meters monitor fluid flows, times, temperatures and concentrations of the cleaning
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solutions and the data obtained establishes that the system is, or is not, working as intended.
The answers to questions (b) and (c) are obtained from analysis of the effluents, using such
techniques as TOC (total organic carbon) analyses, atomic absorption, HPLC (High Pressure
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Liquid Chromatography) and GC (Gas Chromatography). Efficient cleaning of the tanks in the
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process system requires that the interior surfaces be totally covered by the sprays introduced
through the spray devices. The surface coverage is determined by the “Riboflavin Validation”
process, a visual analysis based upon the response of the organic compound to ultra-violet light.
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Are other factors or components significant to CIP processes?

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common arrays being triangular or radial. The incorporation of “proximity sensors” into th ese

An important component of the CIP system is the transfer panel. This is actually a “routing
station,” which controls the distribution of the various fluid streams. Today’s transfer panels are
the result of continued modification and development of the “flow-verters” or “cleaning hook-
up stations” used for solution distribution in early CIP systems. There are several geometric
configurations used for the ports in the design of the transfer panel, the simplest and most
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designs has become an industry standard, the sensors interfacing with the process control system,

as well as providing verification of the connections to the transfer panel for product and operator
safety.
The utilization of chemicals, water and energy is an important consideration in CIP systems.
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Manufacturing facilities are concerned with controlling consumption of the chemicals and water
to reduce the cost of operation and waste disposal and to maintain compliance with respect to
the environmental regulations. In CIP processes large volumes of the solutions are brought into
contact with the contaminated surfaces and economic operation often requires recycling and re-
use of the rinse water, wash water and chemicals in the cleaning solutions.
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In the design, fabrication and installation of clean-in-place systems, the engineers at A&B
Process Systems emphasize the advantages of incorporating current recycling and regeneration
technologies, particularly those approved by the USDA and FDA. The company offers a tutorial
that focuses upon the critical aspects of water management. A&B will also complete a water
audit at a customer’s plant to identify opportunities for recycling and re-use of chemicals and
water.

How can one learn more about this technology?

A&B Process Systems has over 30 years of experience in the design, fabrication and installation
of process equipment, including CIP systems. The company is renowned for its’ expertise in the
fabrication and installation of stainless steel equipment and the stainless steels are the materials
of choice for CIP systems. A&B offers a technical seminar that focuses upon many aspects of
the CIP technology and draws upon the years of experience to present practical and immediately
useful information. The seminar provides details of system design, system operation, system
components – the tanks, valves, pumps, spray devices, heat exchangers, transfer panels – and the
interconnecting piping. In addition topics such as electropolishing and welding methodology are
discussed.
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