NAME : REMOKENG FAITH

SURNAME : TSHAKALISA

REG NO : R195967W

PROGRAMME : FOOD SCIENCE AND TECHNOLOGY

COURSE AND COURSE CODE : SANITATION AND LEGLISLATION

TOPIC: CLEANING IN PLACE OF A MILK PASTEURIZER

SUMMARY
This practical was all about learning and understanding the principles of cleaning
in palace (CIP) system of a diary plant specifically that of a milk pasteurizer in
order to maintain process environment to ensure product quality and purity.
Process was done with the aid of pipelines and valves installed so as to perform
programmed opening and closing operation in order to regulate circulation of
fluids (di ionized water, high concentration of caustic soda, nitric acid and hypo
chlorites) in the inner surface of pipelined, vessels, filters, process equipment
without tearing the equipment apart. After CIP level of soil reduces back to the
level they were before use.
INTRODUCTION
The arrangement of cleaning equipment in contact with products is an essential
part of food manufacturers are always obliged to maintain high hygienic standard.

Circulatory Cleaning In Place (CIP) systems were adopted by many manufacturing

companies. CIP is defined as the cleaning of complete item of plant or pipeline
circuit without dismantling or opening the equipment and with little or no manual
involvement on the part of the operator. The process includes movement of
cleaning solutions through the plant under conditions of increased turbulence and
flow velocity. Even though some details of the cleaning may differ in each plant
the main steps of CIP process are similar. These are removal of loose soils with
water, removal of fine soils using detergents, rinsing and sanitization.(Bremer P.J.
Seale R.B)

Food soil is defined as the unwanted matter on food-contact surfaces it can be

visible or invisible. The minerals from water residue and residues from cleaning
chemicals contribute to films left on surfaces. Microbiological biofilms also
contribute to the soil buildup on surfaces. Soils vary in composition and many
detergents are used to remove all types. Many complex food soil films contain
combinations of food components, surface oil or dust, insoluble cleaner
components, and insoluble hard-water salts.

Dairy processing plant use CIP because the raw materials and major products are
liquid and the processing equipment are amenable to a CIP approach. Milk
contains proteins, fats, lactose, minerals that have the ability to have contact with
the surface of the operating equipment and CIP functions in high performance in
the elimination of all residua contamination.(Dairy Practice Council)

The detergents used in CIP system can be alkali or acid detergents or both. The
most commonly used alkali detergents are Sodium Hydroxide, Potassium
Hydroxide and the acid detergents include Hydrochloric Acid, Nitric Acid. Alkali
detergents Alkaline cleaners are those that have a pH higher than 7. They are
commonly used in the dairy industry because they dissolve organic compounds.
Disinfectants used in the food processing industry include oxidizing agents such as
hypochlorite, hydrogen peroxide, ozone and per acetic acid. Denaturing agents
like alcohol-based products and non-oxidizing and surface tension diminishing
agents and enzyme-based products are also used. Sanitizers based on per oxygen
can eliminate spores but they are corrosive at high temperature and
concentrations. Depending on the processing practice and load of soiling on the
process equipment, the cleaning solutions may be used for single cycle or
recycled and reused for multi-use. In multiple use, cleaning solutions are drained
after a many cleaning cycles circulating chemicals and water without taking the
equipment apart.( Moerman et al., 2013)

The CIP system has advantages and disadvantages. The advantages include
minimum labor , minimized cleaning time, improved hygiene, difficult to clean
areas can be accessed, it maintains high plant production, there is improved
safety since its automated and there is optimization of the use of detergent
water. The disadvantage include the installation and cleaning programs should be
carried out by qualified people and that pressure or flow rate of cleaning
chemicals through the system should be measured; must be reviewed routinely to
ensure that these elements are applied consistently and continuously. (Moerman
et al., 2013)

OBJECTIONS
 to clean up a milk pasteurizer using Cleaning in palace method
 to avoid cross contamination between product change
 to minimize water usage
 to achieve high level hygiene and disinfection for the pasteurization
process
 to find out how effective CIP is in a dairy processing plant

MATERIALS
 Water
 Detergents
  Sanitizers

PROCEDURE
STEP 1: PRE-RINSE

The pre-rinse cycle, wets the interior surface of the lines and tanks and removes
most of the remaining residue. It also dissolves sugars and partially melts fats.
There is use of potable plant water, de-ionized water (DI), water that has been
processed through reverse osmosis (RO), or reuse the final rinse solution from the
previous cleaning sequence. A Turbidity Sensor may be used to verify that the
pre-rinse effectively removes all solids. Water is run through the sterilizers at 60
degrees Celsius so as to remove the solid soils. This is done for 30 minutes.

STEP 2: CAUSTIC WASH

Caustic washes and soften fats and proteins, making them easier to remove. It is
also known as caustic soda, sodium hydroxide ( NaOH). The alkali used is caustic
washes have a very high pH in a concentration range of 0.5-2.0%.Concentrations
as high as 4% may be used for highly soiled surfaces. Caustic is typically used as
the main detergent in most CIP wash cycle. Caustic was applied at 80-900C. The
soda ran for 30 minutes to ensure maximum cleaning takes place.

STEP 3: INTERMEDIATE RINSE

Fresh water flushes out residual traces of detergent remaining from the caustic
wash. Level Transmitters and Probes monitor tank levels of wash and rinse tanks.
Flow Transmitters ensured optimum flow for spray devices to precisely control
wash and rinse steps. Conductivity Transmitters ensured chemical levels are
hitting predetermined set point.

STEP 4: ACID WASH

Acid detergents circulation in CIP procedures for pasteurization is included to

remove encrusted protein and salts from the surfaces of heat treatment
equipment and the flow rate must be greater than 1.5 m/sec to achieve the
mechanical force necessary to prevent biofilm build-up. (Wirtanen and Salo,
2003). The most common acids found in dairy cleaning are the inorganic acids,
such as phosphoric acid and nitric acid, and the organic acids, such as citric acid.
Other mineral acids that may be used from time to time are hydrochloric acid and
sulphuric acid. (Tamime, 2008). Following an alkaline wash, an acid detergent
wash is applied in order to remove any traces of alkaline product from equipment
surfaces. It enhances draining and drying of pipelines and provide bacteriostatic
conditions that delay the growth of organisms that may be found in the water
supply. It will also help in removing mineral deposits such as hard water stone,
beer stone, calcium oxalate, or milk stone. The most common acid detergent is
nitric acid, which is generally used at a concentration of 0.5– 1.0 per cent under
either ambient or heated conditions (55–800C) for 5 to 20 minutes (Bremer and
Seale, 2010).

STEP . SANITIZING RINSE

Step was required to help kill microorganisms before starting the next production
run. Various hypochlorite solutions were used as sanitizers in many CIP cycles.
The active ingredient in a sanitizing rinse is chlorine.

STEP 5: FINAL RINSE

The final rinse water may be recovered and re used as the pre-rinse solution for
the next cleaning cycle. The residual heat and chemicals it retains from the final
rinse will help make the next pre-rinse more effective and economical.

STEP 6 : DRYING

Drying(at is commonly blown in the process line through the CIP spray devices or
via separate supply ports. Fully automated control of cleaning programs is
preferable to manual control and should include variables of rinse, drain and
recirculation times, temperatures, detergent concentration, flow-rate, etc. all
monitored and governed via either instrumentation or engineering design.
RESULTS

Step Reason

Pre-rinse Remove soluble soils like sugar

and melted fat
alkali circulation Causes dissolution of organic siols
like denatured proteins.
Hydrolysis of fat and oils
rinse Removes alkali detergent and
dissolved soils
Acid circulation Removal of minerals and other
inorganic soils present
rinse Removes acid detergent and
dissolves
sanitization Kills microbiological organisms
drying Removes excess water in the
pasteurizer

DISCUSSION
The aim of the practical was to evaluate the effectiveness of (CIP) Cleaning in
place system of a milk pasteurizer. The effectiveness of cleaning is measured by
factors such as concentration of the detergent solution, temperature of the
detergent solution, mechanical effect on the cleaned surfaces, duration of
cleaning (time). Chemical concentration of the cleaning agent can affect
effectiveness of CIP system. A concentrated cleaning solution will clean a dirty
surface much better than a dilute one due to the increased surface binding
capacity. The type of chemical being applied will affect how the soil is removed
from the surface. The results in the cleaning process rely heavily on the amount of
time spent, the longer the time, the more the effect the process. This means more
time is taken to break down the soils in the milk pasteurizer. Increased
temperature, speeds up soil suspension and makes a chemical solution more
effective. Heat breaks up fat and grease by decreasing the viscosity of the fat thus
assisting in their removal, however caution should be taken in using high
temperatures to avoid harming certain surfaces Giving a solution contact time;
allows solution to bring soil into suspension for easy removal, re-hydrates dried
on soil and allows chemicals time to do their job. However the time can be
shortened by adjusting some of the factors in the formulations. (Dairy Practice
Council ,1993). According to Gracia and Diaz (2011) desired results occur when
optimal chemical reaction and mechanical action takes place. Agitation can help
break up soils, increase wash efficiency and reduce wash time. Too much
mechanical action can result in damaged surfaces, resulting in higher equipment
and maintenance expenses. During the ware washing process, agitation typically
occurs first with pre-scraping to remove stubborn food deposits. A specific
amount of pressure is required to affect the response rate. The merits of CIP
systems include a reduction of cleaning time and automatic cycles to ensure every
item are cleaned every time. In a closed system CIP process with no human
contact, higher temperatures and stronger detergents can be used for circulation
and many times more cleaning fluid per unit time and per unit area under
conditions of increased turbulence and flow velocity can be applied. Fluid can be
distributed more evenly, or more solution can be applied to highly soiled areas
while less-soiled areas can be treated less aggressively. Because the physical
integrity of the process equipment is maintained during CIP, recontamination is
less likely. The overall result is less product rejections. The relevant data
generated during CIP operations are a useful source for the operator to make any
changes in the washing program cycle. The benefits of automated CIP include
ease of operation, higher quality and control, higher worker safety due to fewer
manual operations, availability of event logs for traceability, quality assurance,
troubleshooting, removal of human factor errors, lower labor costs, and savings
of water and energy. CIP systems reduce the exposure of the operating personnel
to hazardous atmospheres and cleaning conditions such as high temperatures,
and aggressive cleaning agents and disinfectants. The use of ladders or temporary
supports for dangerous vessel entry and the risk of falls on slippery internal
surfaces are also eliminated. However, CIP systems have disadvantages which
include less suitable to remove insoluble heavy soils and inflexibility. In these
areas, the application of CIP is limited to vacuum thawing chambers, pumping and
brine circulation lines, pre-blend/batch silos, and edible and inedible fat-
rendering systems. Investment costs for implementing CIP in a new facility or
retrofitting an existing plant are considerably high, especially because most CIP
systems are custom designed. The complexity of the hardware and software to
control and monitor the CIP process further increases capital expenditure.
According to Troller (1993) the effectiveness of cleaning in place of a milk
pasteurizer can be monitored by a specific or nonspecific analytical method.
Specific methods that detect the individual ingredients of cleaning solutions are
ion selective electrode (ISE), high performance liquid chromatography (HPLC), thin
layer chromatography (TLC), flame photometry, and ultraviolet spectroscope.

CONCUSION
The Cleaning in Place (CIP) application is an еffеctivе way of cleaning machinery,
vessels or pipes without dismantling the plant. Modern technology implemented
in food processing methods and microbiological food safety standards have led to
reduced, but not completely eliminated, likelihood of diseases that are associated
with food and the occurrence of food product defects in industrialized countries.

REFERENCES
1. Bremer, P. J. and Seale, R. B. 2010. Clean-in-Place (CIP). Encyclopedia of
Industrial Biotechnology: Bioprocess, Bioseparation, and Cell Technology.
pp 1–8
2. Dairy Practice Council. 1993. Guidelines for cleaning and sanitizing in fluid
milk processing plant
3. Gracia, M and Diaz, M. 2011. Cleaning in place. Comprehensive Biotechnol.
2:983- 997
4. . Moerman, F., Rizoulières, P., & Majoor, F. A. (2013). Cleaning in place (CIP)
in food processing. Hygiene in Food Processing: Principles and Practice:
Second Edition, 305–383.
5. Tamime, A.Y. 2008. Cleaning in place- dairy foods and beverage operations.
Blackwell Science Ltd, Oxford, pp 2-8
6. Troller, J. A. 1993. Sanitation in food processing . Academic press, San
Diego. Pp 30- 286
7. Wirtanen G. and Salo S. 2003, Disinfection in food processing, Efficacy
testing of disinfectants. Rev. Env. Science Biotechnol. 2: 293–306.00