Clean In Place (CIP)

Clean In Place (CIP)

The definition of on-site washing CIP in the 1990 edition of the Society of Dairy Technology (SDT) states: “Thorough cleaning of factory circuits or pipelines “Without dismantling or opening the equipment and without any manual involvement and automatically. This process includes washing and circulating cleaning solutions through the machine in automatic conditions.”

Necessity of on-site washing CIP in dairy and juice production lines

The Clean In Place (CIP) washing system has been used in health products such as food, beverages and pharmaceuticals for almost 50 years to clean a wide range of factory equipment. . CIP is a combination of chemicals, heat, and water to clean machinery, equipment, or internal piping without having to open parts.

In general, on-site washing CIP is a combination of mechanical and chemical systems used to reduce contamination of food processing equipment. After food processing, deposits of grease and food residue are formed in the internal pipelines, which the on-site washing system cleans and disinfects the contaminants of the internal surfaces without having to open the parts of the device.

Clean In Place is a process

In-App Washing Machine Applications

Maintaining a healthy environment is vital and undeniable for food, dairy and beverage factories. On-site washing (CIP) is the cleaning and disinfection of pipelines and food production equipment without the need to separate pipes and equipment. This system can be used for cleaning dishes, storage tanks , pipes, converters and homogenizer < Inside each plant, there are many processing lines, tanks, and areas that require CIP.

(CIP) pumps washing and disinfecting solutions through the piping of the same section to remove contaminants from all internal surfaces of the processing lines. On-site washing (CIP) was first used in food and pharmaceutical factories. One of the applications of on-site biotechnology (CIP) is sterilization in place (SIP) to prevent the growth of microorganisms, which is one of the important principles of environmental health.

The basic components of a CIP wash system are:

An on-site flushing system (CIP) usually consists of one or more tanks, on-site flushing pump, recirculation pump, metering pumps To measure chemical disinfectants, shell & tube heat exchanger for heating cleaning solutions, CIP supply and CIP return piping, valves valves, instrumentation including probes, pressure transmitters, etc., flow meters and a system or An automated control system is formed. Chemical feed equipment is also a requirement of an in-situ washing system.

Basic Concepts in a CIP Washing Machine

To select the type of CIP station to be installed in a food production plant, the plant’s economic capacity and size, the size and number of equipment to be cleaned, the number of disinfection operations and the risk of cross-contamination Potential by allergens should be considered. According to the above factors, there are four types of on-site washing CIP, which are explained separately depending on the type and application of each.

Fill-boil-and-dump cleaning

To clean the entire system with this method, the chemical tank must be large enough for the cleaning solution. In feather cleaning, welding and draining, after manual cleaning, the tank is filled with water and detergent is added. The cleaning solution is then heated by the heat exchangers in the CIP to boil. This method is used to clean pipes with a diameter of 5.7 cm or less. The advantage of this method is that it is simple and does not require additional plumbing or spraying machine to perform the process. Because no additional equipment is required, it requires less capital than other washing methods. This method requires a lot of time and energy to boil water and detergents. In this method, there is no recirculation of materials and the cleaning solution is completely drained, and since large amounts of water and detergent are used and emptied with just one wash, this method is considered a costly method. In cleaning process lines by filling, boiling and draining method, after manual cleaning, the tank is filled with water, then detergents are prepared. The cleaning solution is then heated to boiling. After washing, all detergents and water are drained.

single-path CIP systems

In this method, the tank is filled with detergent and then rinsed and drained with water. There is no re-circulation of materials and water in this method CIP space is not returned) and the cleaning solution is completely drained. Therefore, no contaminants are spread through other parts of the system, and this method, like the filling method, does not require a lot of capital to start up. The main disadvantage of this system is that the cleaning fluids are used only once and are drained at the end of the cycle.

Therefore, the current costs of energy, water and detergent and chemical disinfectants may be high and large amounts of chemical effluent may be generated. The method is also long because after each cycle, a new set of cleaning solution must be prepared. This cleaning method is recommended only for relatively small processing plants, very dirty processing equipment. This method is commonly used in the pharmaceutical industry.

Single-use CIP systems

Disposable systems are known for their smaller volume of detergent solutions, which automatically adjust the concentration and temperature of detergents. Disposable washing system has a tank, pipes, centrifugal pumps, valves, direct steam injection device (direct heating of detergent solutions), heating coil in the tank. Or an external heat exchanger (indirect heating of detergent solutions) requires several dosing pumps to automatically feed the cleaning chemicals. These systems use the solution with the lowest possible resistance only once and discharge it into the sewage. At the end of each cycle, the tank must have sufficient capacity to clean the equipment and process pipes, inlet and outlet paths for a clean environment. It is short and the material wastage due to the washing process is low.

Similarly, the use of cleaning solutions (and cleaning chemicals) can be minimized and the amount of effluent reduced. Occasionally, an additional water tank is installed to retrieve the last wash water, where the recovered water is temporarily stored and can be used as a pre-wash in the next clean cycle. Small disposable CIP systems are simple in terms of simple design, inexpensive in terms of initial investment, and very practical in terms of performance.

A CIP system Re-Use systems CIP

This system consists of an alkali tank, an acid tank, a water recovery tank (for example, to recover the last wash water of a previous cleaning cycle, which for the next clean cycle again As water is used before rinsing), and is a tank containing water for final rinsing. All tanks are connected by piping and the valves are equipped with multi-capacity CIP supply and return pumps.

All tanks display alkaline or acidic cleaning chemicals by means of measuring pumps. All chemicals are injected linearly in one cycle. The preparation cycle is a very efficient system, especially when the alkaline and acidic CIP tanks are long. For large CIP stations, each tank (alkaline, acid and water tanks) is equipped with its own preparation cycle. The contents of each CIP tank are mixed by circulating through the supply pump and CIP recirculation.

After returning to the CIP system, the solution can go to one of the CIP tanks or be directed to drain. Reuse of CIP systems is generally planned, wasting a small portion of the solution at the end of each cleaning cycle to continuously remove the contaminated solution from the system. After that, clean water is added to bring the solution tank to a normal level. A detergent solution that becomes less contaminated during re-spinning through process equipment that undergoes a cleaning step can therefore be used repeatedly. This is especially useful in processing plants where parts of the process equipment are not severely contaminated and in cases where the water before rinsing manages to remove a high percentage of particles during the initial wash.

A typical CIP system consists of an alkaline reservoir, an acid reservoir, a water recovery tank, and a final wash tank, all connected by piping and having multi-valve valves equipped with a CIP source and return.

Detergent chemicals are fed into the tank by a pump. The contents of each CIP tank are mixed by rotating over the corresponding CIP tank by means of a recirculation pump and at the same time it is heated while passing through the heat exchanger. At sufficient strength and temperature, all are controlled by conductivity and temperature sensors, the spin valve closes, and the cleaning solution flows into the CIP supply line.

Cleaning can be conducted using gravity (if possible) or via a quick return pump to the CIP system. The solutions are recovered to the appropriate tanks or directed for evacuation. At that moment, the CIP tank rotation valve closes and the CIP supply valve opens, allowing the cleaning solution to pass through the filter, eventually flowing into the CIP supply line.

The filter may be of the self-cleaning type, which discharges the accumulated waste whenever there is a pressure drop on the machine. The CIP supply line is connected to the spray equipment in the process and piping equipment that needs to be cleaned.

The dry operation of the feed pump, which can damage the pump, is controlled by a sensor. Maximum recovery of alkaline or acidic detergent solutions is possible only after rinsing. The recycling of solutions is controlled by a sensor. When the sensor detects that the conductivity of a solution is higher than the preset target value, the CIP solution returns to the corresponding detergent tank. In the next washing step, the cleaning solution is cleaned with water.

As a result, the conductivity signal is reduced. A valve directs the wash water to the drain to be drained. However, after reaching the predetermined minimum conductivity, which indicates the complete removal of acid or caustic substances from the system, the intermediate or final rinsing is stopped. Usually the whole CIP process is automated and allows the CIP system to stop regularly at certain stages.

Types of washing machines in place and explanation of each

The design of CIP systems varies greatly depending on the application, factory standards, industry, and so on. These systems can be portable or fixed. On-site washing system as single tank, double tank or multi tank; Disposable, reusable as well as designed for multi-circuit capabilities. Each plan seeks to minimize cycle time, reduce chemical consumption, reduce water and utility costs, and improve worker safety.

CIP circuits can be designed to

(1) Disposable and drain the cleaning solution directly after the CIP cycle is completed.

(2) Evacuate the reuse or multipurpose system.

Multipurpose CIP systems are often designed and built for final rinsing water and rinsing solutions for later use. In multi-purpose systems, all or some of the cleaning solutions are saved to minimize the use of chemicals.

Single Tank

The cleaning solution is circulated once or again and then rinsed. This device has a simple and flexible operation and takes up less space.

Multi-reservoir CIP systems

Two-Tank & Multi-Tank Two-Tank & amp; Multi-Tank

Allows washing and rinsing solution to be reused. This device is very cost-effective for saving water. Supply and recirculation options reduce the washing cycle time and improve efficiency, and on the other hand, reduce water and sewage costs.

There are three main reasons to use the CIP system:

1- A CIP system is much more reliable than any other cleaning method due to its fully automatic nature.

2- CIP reduces labor and factory costs because the time required for cleaning is reduced and the production capacity of the factory is increased. The volume of water and solvents for cleaning is also significantly reduced.

3- CIP on-site washing has resulted in significant safety improvements as factory personnel are forced to open equipment, enter dangerous vessels, and engage in hazardous activities such as hand scraping and They are not high pressure explosions. CIP also greatly reduces the potential for personnel to be exposed to cleaning chemicals.

Advantages of CIP in-place washing system

Minimizes errors:

Automatic cleaning reduces the likelihood of human error that could affect a product quality.

Keeps employees safe:

By pouring cleaning solutions into the system, the amount of contact with chemicals in personnel is reduced.

More production time:

Because less production time is wasted on cleaning, more time is spent making the product.

Product quality:

Guaranteed and repeatable cleaning means product quality and stability. Less pollution means better product quality and more trust in the brand.

Save more:

Repeatable cycle is controlled by the operator and thus water and energy consumption is reduced.

Dual Operating CIP operating systems Dual Operating

Clears two CIP-enabled environments simultaneously. This device saves significant space and cost in two separate units.

Material of important washing components in place and importance of each

The CIP process usually involves rinsing with alkaline substances, followed by acid washing and then disinfection. Stainless steel is the most common material for making food equipment in the food industry. Nitric acid, along with other acids or surfactants, is the most commonly used acid in industry.

How to use the washing machine in place

The on-site washing process varies depending on the type of processing of each food, such as paste, beverage or dairy products. On-site cleaning usually consists of five steps with washing time and circulation of water and solution depending on the length of the pipe and equipment cleaned.

Step 1: Pre-rinse before washing

The purpose of this step is to remove as many particles as possible, which is the step before alkaline washing. At this stage, the removal of organic fats, carbohydrates or protein particles is done with hot water.

Step 2: Caustic Wash (140 ° – 185 ° F) Caustic Wash – (140 ° – 185 ° F)

At this stage, alkaline rinsing with formulated solutions is performed at a temperature between (70-80 ° C). Since the initial cleaning step requires a relatively long contact time, recirculation of the cleaning solution is essential for economic performance.

Step 3: Intermediate Rinse

After rinsing with alkaline solutions, rinsing with water is usually done at room temperature. This step is for further rinsing of alkaline detergents.

Step 4: Final Rinse Wash

This step involves rinsing with acidic solutions that dissolve the acid at room temperature or hot (55-80 ° C). Washing with neutralizing acid neutralizes and removes residual alkali. Alkaline cleaners are formed on equipment that is not easily removed by simple rinsing with water. Acid washing also removes mineral deposits.

Step 5: Disinfect Sanitizing Rinse

After rinsing with water or rinsing with disinfectant, which is used to apply an antibacterial agent on all cleaned surfaces. After washing, it is sometimes heated to dry the equipment faster.

On-site washing (CIP) system cleans, rinses and disinfects equipment through the same product piping route to remove food particles from all interior surfaces. .

Washing Disinfectant Operators typically automatically control CIP cleaning of production facilities. Advantage: The temperature, duration and sequence of the environment to be cleaned are automatically adjusted.

Dosage of disinfectants for on-site washing

The main application of the on-site washing system (CIP) is primarily to remove contamination. Contamination refers to food deposited in the walls of internal pipes that should not be present in clean equipment. Food deposits cause stains and unpleasant odors and help the growth of bacteria such as E Coli or yeast spores and other microorganisms. The time required to remove the contamination is at least 15 minutes using a suitable chemical (strength of the chemical product) at a temperature of 50 to 75 degrees Celsius. Temperatures above 75 ° C have no advantage in removing contaminants.

Detergents

Chemicals commonly used to remove particles include sodium hydroxide or caustic soda, phosphoric and nitric acids, and sodium hypochlorite. Hypochlorite (Hypo) and Peracetic Acid.

sodium hydroxide

Sodium hydroxide (NaOH) is the most common and aggressive detergent used in the CIP in-washing system. It is commonly used in concentrations of 1 to 5% for plate and tube heat exchangers and other highly contaminated surfaces. The active ingredient in caustic soda is OH ions. Hydroxyl ions, which make up the bulk of the cleaning fluid, are rapidly transferred to the solid-liquid interface at the biofilm surface. The high pH of the solution repels the protonation of the functional groups in the proteins, leaving a net negative charge. These negative charges cause the protein to be excreted and clarified. Alkaline washing is designed to remove organic matter such as proteins. Nitric acid, along with other acids or surfactants, is the most commonly used acid in industry. Acid washing removes traces of alkali on surfaces and removes alkali remaining on the surface. Bacteriostatic conditions resulting from acidic washing delay the growth of any remaining microorganisms. The third important part of CIP is disinfection. Some common disinfectants include ammonium compounds, anionic acids, iodophores, chlorine-based compounds, and peroxyacetic acid / hydrogen peroxide.

In order to increase the efficiency of the alkaline washing step, other compounds can be added to the basic alkali material. It has been shown that the addition of oxidants and complexing agents can increase the yield by a factor of ten compared to 0.25% pure sodium hydroxide. For example, sodium hypochlorite is added to alkaline solutions to increase the removal of fat and protein contaminants, and chelating agents can be used in systems where the water problem is severe. These chemical solutions are called caustic mixtures and have been shown in laboratory studies to improve the removal of dairy biofilms from stainless steel. One-step CIP additives are also available that can be added to caustic and caustic mixtures to increase CIP performance.

Phosphoric and Nitric acids

Acid detergents are used to remove scale minerals left on the interior surfaces of equipment after exposure to caustic detergents. Increase acidic detergents by removing any trace of alkaline product from the surface of drainage and drying equipment and provide bacteriostatic conditions that delay the growth of organisms that can be found in the water source. The acid phase requires temperature-sensitive compounds to be effective. The most common acidic detergent used in the dairy industry is nitric acid. A major concern about the use of acid was its corrosive effect on stainless steel. However, it is now well established that low concentrations of nitric acid are not corrosive to type 304 stainless steel and can typically be used for long periods. Like caustic chemicals, acidic detergents can be used as O formulated compounds that contain surfactants that improve properties, wet the surface, penetrate particles and clean them.

Sodium Hypochlorite (Hypo

One of the advantages of using sodium hypochlorite (Hypo) in the on-site washing system CIP is its very low cost. It is primarily used for disinfection because of its poor ability to remove particles. The active ingredient in Hypo is chlorine (bleach). These materials in high concentrations can corrode stainless steel and are harmful to the health of personnel. These substances can pollute the environment if not washed properly, and if mixed with acid, they produce chlorine gas, which is toxic and dangerous.

Peric acid (PAA) is a mixture of acetic acid and hydrogen peroxide. It is a strong oxidant with a higher oxidation capacity than sodium hypochlorite and chlorine dioxide and is comparable to the oxidative capacity of ozone. In the higher concentration range (three and a half to five percent ozone in one oxygen) ozone has a strong antimicrobial potential with oxidative degradation. PAA at 75 mg / L of 10 cells / ml

When does the production line need a CIP washing machine

Hygiene of equipment in an industrial factory is done by automatic and manual methods. The growth of factories makes it less accessible to the internal equipment of the machines, which makes manual operations completely impossible. The so-called cleaning in local systems, known as CIP, allows cleaning without disassembly, so in addition to the use of detergents and disinfectants at higher concentrations and temperatures, as well as the recovery of cleaning solutions, Shortens the time required. Automation of these systems also allows for safe and reproducible results and cost-effective optimization of the process.