Cleaning

In
Place

An Introduction
An Introduction
R.Hayano
R. Hayano

1
European Infant Formula Factory
Audit

7 Factories Audited

• 7 Factories found to have CIP

problems
• 5 T rule not respected

2
 Cleaning in Place

• Basic Concept
• What ?
• Why ?

• Where ?

• When ?

• How ?

• Applications in the Dairy

Industry
3
 Cleaning in
Place
Basic Concept
• What is
Historically,
CIP ? cleaning was done using manual tools such as brushes,
sponges and detergent.
Equipment had to be dismantled, people had to enter tanks to get to the
surfaces. ( COP )
Manual cleaning is still applied in our plants for special applications, such
as filling machines, Egron dry cleaning and outside cleaning of
equipment.

The introduction of high capacity and complex manufacturing processes

has led to the development of CIP (cleaning in place) techniques, now the
standard practice for our manufacturing processes.

4
 Cleaning in
Place
What is CIP ?
• CIP is a
For cleaning including steps such as pre-cleaning, rinsing and removal
procedure
of cleaning chemicals.
Consists of cleaning production lines in a closed circuit without
dismantling equipment or pipes

• What is Cleaning?
• Cleaning is the action to
remove Soil
The removal of soil, food residue, dirt, grease or other
objectionable matter from a surface by physico-chemical reaction
without, in any way, attacking the surface.

5
 Cleaning in
Place
Basic Concept

• So WHY do we need CIP ?

Safety :

Safe food for the consumer is one of the foundations

of the NQS.
Cleaning is a key element of the NQS

Quality products cannot be produced on dirty Equipme

6
CIP : Liquid Processing Hot Circuits Milk- and
Cream-
Standardiz
ation

S
t
e
a
m
C
o
n
d Separat Bacteria
or Removing
Machine

W
W

W
H

H
/
I
/
I
Cold Circuits HOMOG
Homogeni
ENISER

ser

Cooler
I
W

7
 Why CIP !

Cold Plant
• Removal of Protein soil and Milk Fats
• Reduce microbiological growth

Hot Plant
• Fouling in dairy plants is a serious problem which:

- Lowers the efficiency of heat transfer

- Increases the pressure drop through the plant

- Potentially endangers plant and process sterility

- Limits the operational time of the plant

8
 WHY CIP ?
CIPs systems have several advantages over the former manual cleaning.
 More consistent results : Accurate and rapid monitoring, repeatability

 Better plant usage : less downtime, fully automated processes

 Less manual work : No need to dismantle, less human errors

 Greater safety : Protection from heat and chemicals

 Cost savings : Better use of water, chemicals and energy

 Quality : Consistency in term of quality

CIP - key factor which play a vital role in the

manufacturing of consumer products

9
 Cleaning in
Place
Basic Concept
WHERE
:
CIP happens in two places :

CIP Station: Where the Chemicals are stored,

prepared and delivered to the user at the
correct concentration, temperature, flow rate
and for the correct time.

Users: Pipes, tanks an all equipment and surfaces

in direct contact with product.
Where soil or fouling deposition takes
place

10
 CIP Station

SINGLE USE STATION

OR
MULTI USE STATION ?

FOR OPERATING COST REASONS

MULTI USE STATION
SHOULD BE USED

11
 CIP Station : Reused
System Conductivi
ty
Flow Temperatur
e
Water

Group
A
Group B
Conductivit Conductivit
y y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Tem Temp Temp

p
Cond Cond

Level Lev Leve

Level l
el Pipe Cleaning 1
Circuit 1 (B1)
Circuit 2 (B2)

Tank 1
CIP
Tank 2

Technical Nitric
Acid
Caustic
Soda
Circuit 3 (B3)

Tank 3

Step Circuit 1 (A1)

Pipe Cleaning 2
Circuit 2 (A2)

12
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Conductivit
Group
Conductivit B
y y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Tem Tem Temp

p p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

CIP Tank 1

Tank Circuit Tank 2

With Acid Tank 3

Circuit B3 Pipe Cleaning 2

Recovered Water flush to Drain

13
 CIP Station Waiting for conductivity
Conductivity
Flow Temperatu
re
Water

Group
A

Conductivit Group
Conductivit B
y y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Tem Tem Temp

p p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit Emptying

Tank 3

With Acid
Pipe Cleaning 2

NaoH Washing Push to Sprayball

14
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Conductivit Group
Conductivit B
y y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Tem Tem Tem

p p p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit
Tank 3

With Acid
Pipe Cleaning 2

NaoH Circulation

15
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Conductivit
Group
Conductivit B
y y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Tem Tem Tem

p p p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit Emptying

Tank 3

With Acid
Pipe Cleaning 2

Recovered Water pushing NaOH

16
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Conductivit Group
Conductivit B
y y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Temp Tem Temp

p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit Emptying

Tank 3

With Acid
Pipe Cleaning 2

Acid pushing water

17
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Group
Conductivit
y
Conductivit B
y
Fresh Recovere Acid
d
NaoH
H20 Steam Steam
H20

Tem Temp Temp

p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit
Tank 3

With Acid
Pipe Cleaning 2

Acid circulation

18
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Conductivit Group
Conductivit B
y y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Tem Tem Tem

p p p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit Emptying

Tank 3

With Acid
Pipe Cleaning 2

Fresh Water pushing acid

19
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Group
Conductivit Conductivit B
y y
Fresh Recovere Acid
d
NaoH
H20 Steam Steam
H20

Tem Temp Tem

p p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit
Tank 3

With Acid
Pipe Cleaning 2

Fresh Water rinse to recovered water tank

20
 CIP Station
Conductivity
Flow Temperatu
re
Water

Group
A

Group
Conductivit Conductivit
y B
y
Fresh Recovere Acid
d
Nao
H
H20 Steam Steam
H20

Temp Temp Tem

p
Cond Cond

Level Leve
Level Level
l
Pipe Cleaning 1

Tank 1
CIP
Tank 2

Tank Circuit
Tank 3

With Acid
Pipe Cleaning 2

CIP Program Finished

21
 Circuit
Logistics
CIP Logistics with 2 Group System
Allocation of CIP programs: Production Plan
Grp-A:Pipe cleaning of reception Line 1 5 10 15 20 24 Hrs
Plant Item
Pipe cleaning of PROD-Line1
Line 1
Pipe cleaning of filling AF1 Line 2

Tank cleaning tank T1 AN-Line

Tank T 1
Tank cleaning tank T2 Tank T 2
Tank cleaning tank T3 PROD-Line 1
Tank T 3
Tank cleaning tank T4
Tank T 4
PROD-Line 2
Tank T 5
Grp-B:Pipe cleaning of reception Line 2
Tank T 6
Pipe cleaning of production line AN-Line AF 1

Pipe cleaning of filling PROD-Line 2 AF 2

Pipe cleaning of filling AF2

Tank cleaning tank T5 Grp A
Grp B
Tank cleaning tank T6

22
BASIC RULES 5 T
• TITRATION
• Chemical concentration

• TURBULENCE
• Flow velocity

• TEMPERATURE
• of cleaning solution

• TIME
• Duration of cleaning

• TECHNOLOGY
• Design of equipment

23
 5T
Rules
CIP
T T T TT T
I U E II E
T R M M
M C
R B P EE H
A U E N
T L R O
I E A L
O N T O
N C U G
E R Y
E
1.5% 1.5m/s ~70°C ~15min Design

24
 5T
Rules
CIP
T T T T
I U E E
T R M C
R B P H
A U E N
T L R O
I E A L
O N T O
N C U G
E R Y

M
E
E
1.5% 1.5m/s ~70°C ~15min T Design

25
1st T : Titration
• Concentration of Chemical Solutions
• Alkaline 0.5* to 2 %
• Acid 1.0 to 2 %

•
Chemical Solutions
• ~ 2/3rd of Total operational cost
of CIP.
• Concentration has to be adjusted
periodically.

26
Degree of Solubility of Soil
Deposits
• The principal constituents of the
deposits from milk products have
different degrees of solubility in
cleaning solutions.
Constituents Water Alkali Solution Acid Solution
Lactose Good Poor Poor
Fat Poor Good Medium
Proteins Poor Good Medium
Mineral Salts Medium Medium Good

27
2nd T :
Turbulence
Mechanical Energy generated by
Pump

Pressure Energy

Dissipated in form of Friction &

Turbulence
28
2nd T :
Turbulence
• Flow Velocity inside Pipe >1.5 m/s.
CIP Flowrate (min) v Pipe diameter

50

40 VV =
= 1.5
1.5
m/s
m/s
30
m3/hr

20

10

0
1.5" 2" 2.5" 3" 4"
Pipe diameter

29
2nd T :
Turbulence
• CIP Flow for Vertical Tanks : Range < 20m3
Low Viscocity applications

25 -- 30
25 30 litre
litre // min
min
per metre
per metre circumference
circumference
eg. If
eg. If VV =
= 6m3
6m3 (c
(c =~5.65m)
=~5.65m)
H=
D = 1.8m CIP Flowrate
Flowrate =
= 8.500
8.500 -- 10.000
10.000
2.4m CIP
lph
lph

30
2nd T :
Turbulence
• CIP Flow for Vertical Tanks : Range > 20m3
Low Viscocity applications

~30 -- 50
~30 50 litre
litre // min
min
per meter
per meter ofof
circumference
circumference
H
D = 3.5m =10 eg. If
eg. If VV == 100m3
100m3 (c
(c =~11
=~11 m)
m)
m
CIP Flowrate
CIP Flowrate = = 30.000
30.000 --
35.000 lph
35.000 lph

31
 3rd T :
Temperature
• Lower Temperature reduces the efficiency of
cleaning.

Time for Equivalent Cleaning results

with constant Velocity &
Concentration and varied temperature

Verfahrenstechnik der Bundesanstalt Fur Milchforschung Kiel

32
 4th T : Time
• Average 15 minutes per phase as
starting parameter

• Diffusion of Chemicals
• Chemical reaction
• Swelling effect
• Weakening of the fouling adhesion
forces to the wall
Confirm CIP effectiveness by Visual Inspection

33
 5th T :
Technology
• CIP is part of the Process and conceived at the
very conceptual stage.
• The whole production installation is conceived
for
• No dead ends longer than 2D.
• Cleaning of all the internal product contact surfaces.
• Safe separation between CIP and Product.
• Ensuring minimum flow velocity in pipes.
• Selection of Equipment.
• CIP Technology is a DISCIPLINE which demands
detailed Engineering.

34
 Safe Separation CIP -
• Product
Manual Systems
• Semi Automatic
• Hook Up Plates & single seat valves
• Automatic systems
• Leakproof valves
• Applications

Selection based on :
Automation Level, Complexity, Cost,
Labour optimization, Hygiene level,
Operational Flexibility, Ease of expansion.

35
 Safe Separation : Manual
systems

Physically impossible to Manual connections

connect tank to CIP inlet Simple systems only
during production
eg. 1 inlet 1 outlet + CIP

Valves
Manual or Auto

36
 Hook Up Plates : Do’s
8 Port :
Buffer Tanks or Silos with Separate product
Rule : inlet / outlet
CIP feed & return for Tank circuit
Product Connect Horizontal
Auxiliary Loop for CIP of pipe circuits
CIP Connect Sloping
4 Port :
CIP inlet / outlet for closed circuit
Process circuit or pipe circuit

Product in/out Tank 1 6 Port :

T1 Tanks or Silos with 1 product inlet
CIP feed & return for Tank circuit
Product in/out Tank 2 CIP Loop for pipe circuit
T2

Rule :
CIP Return

CIP Auxiliary
Always CIP in Series never parallel

37
Hook Up Plates : Dont’s

Caution :

CIP Possible to have tank connected to CIP

Supply supply line during production.
Leaking CIP valve = product contamination

38
Safe Separation : Automatic
Systems

39
 Cleaning in Place

• Applications in the Dairy

Industry
• Silos

• PHE

• UHT

• Evaporator

40
 Silo
s
• Open Circuit
• Spray Balls
• Under the Top Ceiling of

Silo
• On Air Vent
CIP Return

• On Agitator

• Separate CIP Circuit from CIP Supply

Piping network.
• Self Priming Pump
• Ventilation
• Critical as risk of

Collapsing
under vacuum.
41
PHE
•CIP Flow rate requires special attention
• Low velocity in the product side ~ 0,2 m/s
• According to arrangement of Plates

• Depending on Fouling the flow rate must be

increased
• How to increase flow rate of CIP through PHE?
• Dedicated CIP circuit only for PHE

• Recirculation by installing
additional pump
25 m3/h CIP Flow rate - 50 m3/h
2525
m3m
/h3/h
25 m3/h

50 m3/h 50 m/h

25 m3/h
25 m /h
3

42
UHT
Plant Water

HL
Measuring Tank

Water
UHT Plant LL

HL

Chemical Dosing

GUARANTEE INPUT TO COMPLY WITH 5T LAW REQUIREMENT

43
Evaluation of CIP
Efficiency
Important !!!!!
• By Regular Visual
Inspection
• By analysis of Organic
and Mineral Residues
• Microbiological
analyses in the last
rinse water
• UV
• Bioluminescence - ATP

44
STERILISATION
• CIP destroy 95% of micro-organisms
• Sterilisation is not part of CIP
• Chemical sterilisation needs
• Concentration
• Temperature (dependant on chemical)
• Contact time
• Perfect CIP of all parts of the system
• Thermal sterilisation requires
• Temperature
• Time
• Correct equipment design

45
99% Clean
is still
1% Dirty
46