Cleaning-In-Place (CIP) and Sterilization-In-Place (SIP) are systems designed for automatic cleaning and disinfecting without major disassembly and assembly work. Additionally, a well designed CIP system (employing double seat valve (block and bleed) technology and a bit of process integration) will enable you to clean one part of the plant while other areas continue to produce product. Furthermore, a modern CIP system will not only save money in terms of higher plant utilization but also due to significant savings in CIP liquid (by recycling cleaning solutions), water (the system is designed to use the optimum quantity of water) and man-hours.
GEA Liquid Processing 3-tank CIP (Cleaning-In-Place) System utilizing double-seat valve technology (here Tuchenhagen valves have been used)
The cleaning can be carried out with automated or manual systems and is a reliable and repeatable process that meets the stringent hygiene regulations demanded by the food, dairy, biotechnology and pharmaceutical industries. Other benefits of a well designed CIP plant includes: operator safety (operators are not required to enter tanks and vessels to clean them and potent cleaning materials do not need to be handled by operators), and downtime (if any) between product runs / product changeover is minimized. The technology of CIP (Cleaning-In-Place) and SIP (Sterilization-In-Place) is obviously important to many industries including food, dairy, beverage, nutraceutical, biotechnology, pharmaceutical, cosmetic, health and personal care industries in which the processing must take place in a hygienic or aseptic environment. GEA Liquid Processing installations are designed in such a way that optimal cleaning is ensured. We can even provide a complete CIP (Cleaning-In-Place) and SIP (Sterilization-In-Place) validation protocols for USDA 3A, FDA cGMP and/or ASME BPE installations. Depending on the existing automation infrastructure and/or the customer preference a central or decentralized system, (or a combination of the two) are installed and integrated into plantwide operation.
Cleaning in CIP processes
The sanitary aspects of producing food and beverage products are of extreme importance. Plants must meet high hygienic standards to avoid a product's degradation and contamination during operation, and plant cleaning must be carried out quickly and thoroughly. The cleaning requirements are best met with Cleaning-in-Place (CIP) systems. CIP systems offer fast, efficient and reliable cleaning of all types of process plant. It's a method which cleans complete items of plant equipment or pipelines circuits without dismantling the equipment.
CIP systems are divided in differents operations : 1- Flushing in order to eliminate residues 2- Alkaline cleaning operation : alkaline detergents dissolve fat and proteins, and cleaning where harder deposits have occured 3- Intermediate water rinse 4- Acidic cleaning operation : for neutralising the caustic remaining on the surfaces of the plant. The acidic detergents remove mineral deposits in the equipment (especially warm areas like in the pasteurizer) 5- Final water rinse : Cold water purges out the residual acid solution CIP is a closed system where recirculating cleaning solution is applied (often with nozzles) that cleans, rinses and sanitises equipment. The CIP system is usually automatically controlled and the cleaning sequences are given the optimum timing for efficient cleaning of all parts of the plants. Differents types of Cleaning-in-Place systems exist :
Single pass system : New cleaning solution is introduced to the plant to be cleaned and then disposed to drain. In most cases, a single pass system would start with a prerinse to remove as much soiling as possible. The detergent clean and a final rinse would follow this.
Recirculation system : The cleaning solution is made up in an external tank then introduced to the plant to be cleaned. It is recirculated and topped up as required until the cleaning cycle is complete. When the detergent clean is complete it is then normal to carry out a final rinse. Recirculation systems use less water and cleaning detergents but require greater capital outlay and in some circumstances may be unsuitable due to cross contamination from one process to another.
As with every system, CIP systems show some advantages and disadvantages : Advantages : - Reduced labor (minimise cleaning time) Disadvantages : - Installation : the optimisation of cleaning programmes should be carried out by qualified people
- Improved hygiene (automated systems clean and sanitise more effectively and consistently than manual cleaning) - Maintenance : pressure or flow rate of cleaning chemicals through the system should be measured; must be reviewed routinely to ensure - Conservation of cleaning solution that these elements are applied consistently and continuously - Improved equipment and storage utilisation - Improved safety - Maintain high plant production availability - Optimisation of the use of detergent and water - Difficult to access areas can be cleaned Applications : CIP has been used in dairies and breweries for many years but has been adapted in other plants because of equipments and installation costs and the difficulty of cleaning certain processing equipment. So CIP could be used for : - liquid filling, especially in the dairy industry - dairy products - cooked meat
- short shelf-life, chilled food - finished salads - conveyor systems for unpacked product - meat slicers - ice-cream production post-pasteurisation - cook-in sauce lines - cook-chill production - sandwich manufacture - pastry production - dust control units and silos (infestation risks)
Matrix piping utilizing mix-proof valves (double-seat valves) - typically used in modern CIP (Cleaning-In-Place) system.
Technical Data and considerations
flow velocity: normally up to up to 3 m/s flow rate: normally up to 140 m³/h and 10 bar number of tanks: depending on the required detergent an disinfectant volumes - this number rarely exceeds 8 tanks per system volume of the tanks: depending on the effective volume needed for cleaning the pipes, tanks, etc... number of CIP circuits: depending on plant areas to be cleaned and the required availability
whatever you need: ask us, we will help you for the most suitable and economic solution common cleaning media: caustic, acid, disinfectant, return water, fresh water standard of cleaning required? the available cleaning time? the type of cleaning medium? whether recycled detergent can be used?
For further information about our CIP (Cleaning-In-Place) capabilities please access these pages:
Cleaning In Place Nozzle Cleaning in Place of Spray Drying Plants cGMP Standard Single Use CIP / WIP System Standard Single Use CIP/WIP System (pdf) Cleaning In Place (CIP) CIP & SIP Enabled Homogenizers Cleaning In Place Components CIP (Clean in Place) caustic recovery CIP Process Time Optimization of Dairy Evaporators Wash Off Line (WOL) for the Courtoy MODUL™ tablet press CIP - Cleaning-in-Place of Spray Drying Plants (pdf).
Note: CIP (cleaning-in-place) covers a variety of areas but its main purpose is to remove solids and bacteria from tanks, vessels, and pipework in the food, dairy, beverage, nutraceutical, pharmaceutical, and biotechnology processing industries. Mixproof Valves
Matrix piping utilizing Tuchenhagen mix-proof valves (double-seat valves) - the photo shows an integrated CIP (Cleaning-In-Place) distribution valve cluster in a large brewery.
Hygienic mixproof process valves are an essential part of sanitary flow processing. Mixproof valves are used for mixproof separation of incompatible media at flow path intersections within the pipe system. In the closed position of the valve (non-actuated position) always two seals are located between the pipes. If one of the seals fails, leakage may drain via the therefore provided leakage outlet without intermixing with the product being in the second pipe.
Pneumatically operated mixproof valves can be either double-seated or single-seated. The double-seated mixproof valve has two independent seals separating the two liquids and the drainage chamber. The chamber is open to atmosphere to ensure full mixproof safety in case either of the seal failure. When a double-seated mixproof valve is activated, the chamber between the upper and lower body is closed and then the valve opens to connect the upper and lower pipelines. During cleaning one of the plugs lifts, or an external CIP line is connected to the leakage chamber. Some valves can be connected to an external cleaning source for cleaning those parts of the plugs which have been in contact with the product. The single-seated mixproof valve has one seat and two seals on the same plug. The area between the two seals is open to atmosphere. Small shut-off vales valves seal the leakage drain chamber before the single-seated mixproof valve is activated and an external CIP line is connected to the drainage line by the small shut-off valves.
Rendering of a GEA Process Engineering (GEA Liquid Processing) matrix-piped CIP system. Matrix piping utilizes mix-proof valve technology to enable simultaneous functions of process (liquid product transfers, etc.) and CIP/SIP (cleaning-inplace / sterilization-in-place) in a totally contained in a hard-piped and it is fully automated, making each operation robust and reliable. Integrated in targeted applications, this technology will increase efficiency as well as the asset utilization, improve conditions for personnel and product safety and minimize manual interventions.
Matrix piping with GEA Tuchenhagen PMO mix-proof valves for Grade A dairy processes. The valve matrix shown here is wired for field bus