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CIP Systems 22003 05 02 2013 GB tcm11-7665 PDF
CIP Systems 22003 05 02 2013 GB tcm11-7665 PDF
Process Plant
White Paper
CIP and Sanitation of Process Plant
TABLE OF CONTENTS
INTRODUCTION TO SPX PURGING OF PRODUCT FROM
FLOW TECHNOLOGY - - - - - - - - - - - 4 THE PROCESS PLANT - - - - - - - - - - 10
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CIP and Sanitation of Process Plant
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CIP and Sanitation of Process Plant
Cleaning and sanitisation of process plant is one of the most Although CIP systems are usually fully automated, the process
critical aspects of food processing to ensure the health and is often a combination of manual actions and automatic
safety of the consumer. Proper cleaning is essential for the sequencing. This applies especially to operations within a
production of high quality food products especially those with process plant where different types and/or concentrations
extended shelf life. of cleaning chemicals are utilised. For example, a membrane
filtration system with polymeric membranes would be damaged
Cleaning-in-Place (CIP) is now a very common practice in
if exposed to sodium hydroxide and nitric acid solutions routinely
many dairy, processed food, beverage and brewery plant
used in most centralised CIP operations.
replacing manual strip down, cleaning and rebuilding of
process systems. The primary commercial advantage is In the most simple application, CIP solutions can be used once
a substantial reduction in the time that the plant is out of (single-use CIP) and then discarded to drain, but this is very
production and the ability to utilise more aggressive cleaning expensive in cleaning chemicals, water use and effluent costs.
chemicals in a contained environment which cannot be safely Such operation is not environmentally friendly and can only be
handled with manual cleaning. justified if it is essential to apply a single use system to prevent
microbiological cross-contamination of different areas of the
The definition of CIP is given in the 1990 edition of the Society
process plant. It is more usual to recover cleaning solutions in
of Dairy Technology manual “CIP: Cleaning in Place” as:
a recovery tank and restore the original concentration of the
“The cleaning of complete items of plant or pipeline circuits cleaning fluid, and then to re-use the recovered solution. Such
without dismantling or opening of the equipment, and with systems will need to be monitored for the build-up of residual
little or no manual involvement on the part of the operator. The soils and the cleaning chemicals replenished as necessary.
process involves the jetting or spraying of surfaces or circulation
In some situations, membrane filtration technology can be used
of cleaning solutions through the plant under conditions of
to filter soil from cleaning solutions to enable a further extension
increased turbulence and flow velocity.”
of useful life.
CIP is not simply the provision of a CIP bulk unit but the
Although not always recognised as such, CIP is a methodology
integrated process and hygienic design of the complete
to remove product residues from a process plant. It is not a
process. A CIP system will consist of vessels for preparation
means of eliminating micro-organisms from the system. This is
and storage of cleaning chemicals, pumps and valves for
the role of the post CIP sanitisation or sterilisation process using
circulation of the CIP chemicals throughout the plant,
either chemical sanitisers or the application of heat to destroy
instrumentation to monitor the cleaning process and vessels
micro-organisms.
to recover the chemicals.
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CIP and Sanitation of Process Plant
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CIP and Sanitation of Process Plant
Sharp Sharp
corner with corner
crevice Smooth product
contact surface
Radiussed corner
Welding seams in
corners
Fig. 1: Angles and corners of process plant should be well radiussed to facilitate cleaning (Hasting, 2008)
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CIP and Sanitation of Process Plant
Water soluble deposits include: • Contamination is not visible under good lighting conditions
with the surface wet or dry
• Sugars and some salts
• The surface does not give a greasy feeling to clean fingers
when they are rubbed on to the surface
Alkali soluble deposits include:
• No objectionable odour is apparent
• Fats • A new white facial tissue wiped several times over the surface
• Proteins shows no discolouration
Acid soluble deposits include: • The surface is completely wetted when water is draining from it
• No sign of fluorescence is detectable when the surface is
• Calcium salts inspected with a long wave ultraviolet light
• Organic solvent soluble deposits • After sanitising the surface it will not cause re-infection of the
• Mineral Oils product coming into contact with it
Soils can be simple or highly complex mixtures depending on A commonly applied test is to determine the presence of
the food product that is being processed. The soil can be made micro-organisms in the final flush water, but in this respect, it is
more difficult to remove by the application of excessive heat important to realise that micro-organisms will usually always be
treatment. This is why the temperature difference between the present in mains and bore hole water supplies. The total count
heating medium and the product should be kept to a minimum of potable water should not exceed 100 cfu/ml (colony forming
in the case of highly fouling materials such as UHT milk - ideally units) with the absence of coliforms and E.coli in 100ml.
no more than 1º or 2ºC.
It is therefore necessary to analyse the flush water for any
Only practical experience can determine how long a plant can increase in micro-organisms during passage through the plant.
be run before it has to be cleaned, and how long the cleaning
regime will need to be. A more recent technique is the use of ATP (adenosine tri-
phosphate) sensors. ATP is a natural component and is the
If plants are allowed to run for too long it may not be possible to chemical in which energy is stored in all living cells such as
clean without dismantling. This applies especially if the flow path bacteria. ATP is also present in food soils.
becomes substantially blocked.
In the presence of luciferase (an enzyme derived from the
Any plant involving heat treatment must be carefully monitored firefly), the substrate luciferin, oxygen and magnesium ions, ATP
to identify when cleaning is required. Fouling is directly related is catalysed to ADP (adenosine di-phosphate) with the release
to the temperatures applied. of light. The quantity of light released is a direct measure of the
Dryness or ageing can influence the stability of the soil and its concentration of ATP. There are several commercial suppliers
effective removal by cleaning chemicals. of ATP sensing kits, which can detect very low levels of residual
bacteria after CIP and sanitisation.
The complexity of some soils can be illustrated by soils found in
a dairy plant: A very effective technique to determine residual soil within
a complex plant component such as a valve or pump is to
• Milk remaining in a pipeline
recirculate a solution of potassium permanganate through
• Air-dried films of milk
the component, whereupon it will react with any soil to form
• Heat-precipitated milk constituents (protein and milkstone)
manganese dioxide. The permanganate is flushed out with
• Fat
water and replaced with a solution of hydrogen peroxide, and
• Hard water salts
the inlet and outlet to the component sealed. The manganese
• Miscellaneous foreign matter
dioxide within the soil acts as a catalyst for the decomposition
The situation becomes even more complex in a milk UHT plant of hydrogen peroxide to water and oxygen. The production of
as protein will be the predominant soil at temperatures of up oxygen can be measured using a pressure gauge installed in the
to 115ºC whilst mineral deposits will prevail as the temperature line.
increases further.
The cleanliness of the surfaces of individual items of process
Each type of soil will need a specific regime for removal. equipment can also be assessed using swab tests where a
pre-determined surface area is wiped with a sterilised swab and
then incubated to detect micro-organisms.
A S S E S S M E N T O F C L E A N I N G E F F I C I E N CY
After CIP, the product contact surfaces must be free from Finally, the EHEDG has developed a very demanding CIP test to
residual film or soil so that they do not contaminate food validate the hygienic design of individual plant components prior
products subsequently coming in contact with them. to release on to the market.
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CIP and Sanitation of Process Plant
CIP design criteria minutes. Typically 100 ppm at 25ºC for two minutes is adequate
for pre-cleaned surfaces.
Not only is it essential that the equipment is properly cleaned, Great care is needed should there be any aluminium, copper or
it is also fundamental that the product is protected from any bronze product contact surfaces in the line. This should not be
possibility of contamination by CIP solutions. the case, however, in a modern process plant. Such materials are
commonplace in older brewery process units. Caustic soda is
Plant is cleaned by the combination of dissolving the soil or
corrosive to aluminium whilst acids will attack copper and bronze.
removing it by scouring of the surfaces. Before cleaning any
product in the plant must be reclaimed.
C I R C U L AT I O N T I M E
After cleaning the plant must be sanitised (removal of any
The period of circulation depends on the degree of fouling
pathogenic organisms but not necessarily all micro-organisms).
and the type of equipment being cleaned. Typically 20 mins of
A system of maintaining a physical break between a product line caustic circulation is required for pipework and vessels.
and a CIP line must be adopted at all times in order to eliminate
Pasteurisers and UHT plants which suffer from higher levels of
the possibility of chemical contamination of the product.
fouling may require up to 40 mins of caustic circulation. Acid
circulation is normally 10 mins.
C H O I C E O F C H E M I CA L S
The choice of chemicals is governed by the materials of
O P E R AT I N G T E M P E R AT U R E S
construction of the plant. As mentioned previously, the most
Contrary to popular belief, the higher the temperature the poorer
common material of construction is austenitic stainless steels,
the soil removal with an optimum at 50°C. In practice, caustic is
which are very resistant to most cleaning solutions (with the
usually circulated at higher temperatures in order to improve the
exception of high-chloride solutions).
sanitising effect.
In the food industry, the most common form of fouling is the
deposition of proteins. These are nearly always removed by hot
FLOW VE LOCITY
alkali (caustic soda) assisted by wetting agents that break up
Process plant should always be cleaned under turbulent flow
the protein into water soluble units. Typically 2% caustic soda
conditions. The efficiency of cleaning under laminar flow
will be used at temperatures of up to 85ºC. For highly fouled
conditions, i.e. <1.4 m/s, is not sufficient. For this reason, flow
surfaces of up to 4% can be applied.
velocities in the region of 1.5 to 2.1 m/s are usually applied.
Milkstone and calcium deposits are easily removed by the use
The use of a high velocity also improves cleaning efficiency in
of a dilute mineral acid. Nitric acid is the most common although
small dead legs, for example at instrumentation or sample valves.
phosphoric acid can also be used. Typically 0.5% nitric acid at
temperatures up to 50ºC is used. Above this temperature, heat It has been generally considered that flow velocities in excess
exchanger gaskets can be adversely affected. Hydrochloric or of 2.1 m/s are not beneficial, but recent work indicates that the
sulphuric acids should never be used. application of even higher flow velocities can enable a beneficial
reduction in cleaning chemicals.
Apart from basic caustic soda and nitric acid, special
formulations have been developed by detergent manufacturers
containing added components such as sequestrants. A typical S E L E C T I O N O F S P R AY D E V I C E S
sequestering application is the solubilisation of calcium and Scouring and wetting of the surfaces inside tanks and vessels
magnesium salts using EDTA (ethylenediaminetetra-acetic acid) is achieved by the use of spray devices. Simple spray balls are
to prevent precipitation by alkaline detergents. the most commonly used. The holes are positioned to provide
maximum impingement in areas of high fouling. These devices
Acid should never be used ahead of the alkaline clean when run at relatively low pressures (1 to 2 bar).
removing milk deposits. Acid will cause the precipitation of
protein with the result that it is more difficult to subsequently Rotating jet devices must be used for vessels with a high degree
remove. of fouling or with large diameters (>3m). These operate at
higher pressures (5 bar).
Sanitation is achieved by the use of hot water, hypochlorite or
one of the peroxide based sterilants such as Oxonia P4. Vessels with top mounted agitators must always be fitted with
two spray balls to overcome shadows cast by the agitator shaft
If hypochlorite (sodium) is used for sanitising the strength and blades. A similar consideration often exists for tank vents
should not exceed 150ppm free chlorine, the temperature be where a small spray ball may need to be positioned at the vent
kept below 40ºC, and the circulation time kept below twenty to improve CIP.
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CIP and Sanitation of Process Plant
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CIP and Sanitation of Process Plant
prohibits any dilution with water) or used for animal feeding. In • Do not mix large diameter with small diameter line cleans.
the case of drinking milk, SPX has developed reverse osmosis • Always ensure that every component in the line receives a
membrane technology to concentrate the milk solids back to the turbulent flow rate even if this means other components see a
original level. The recovered milk can then be blended with fresh higher rate. For example a plate heat exchanger in a pipeline
milk for production of products such as cheese or yoghurt. circuit may require a flow rate higher than 2.1m/s in the line.
• Avoid very long line cleans.
A 1 million/day drinking milk plant can generate 25 to 35,000
• Where possible clean tanks individually and not in pairs.
litres of white water per day equivalent to some 10,000 litres
• Do not try to clean equipment that is not designed for CIP (for
normal milk. The value of this white water over a year can be as
example cheese vats and tanks with lift off lids).
high as £900,000 per annum, easily justifying the installation of
A CIP cycle is generally made up of a combination of the
a reverse osmosis recovery system.
following steps:
With other dairy products, it is often possible to blend a small
• Initial purge to recover product, either into product tanks or to
proportion of recovered diluted product with the next batch of
a product recovery system.
raw feed.
• First rinse using recovered water (from final flush of previous
CIP cycle) to remove gross soil.
R E-US E OF CLEAN I NG SOLUTION S • Caustic wash with or without recovery to remove residual
It is common practice and economically prudent to re-use both adhering debris.
caustic soda and acid solutions. Where high degrees of fouling • Intermediate rinse to clear caustic from the system.
are encountered (for example in milk pasteurisers), it is not • Acid wash with or without recovery to remove mineral scale.
always practical to recover the solutions. • Final rinse to clear any remaining chemicals from the system.
To minimise water usage, final rinse water is usually recovered • Sanitation using heat or chemical sanitiser to destroy any
and used as the first rinse of the next clean. After a certain residual organisms.
number of cleans (approx. 100) it is advisable to dispose of the Additional special operations that may be included are:
solutions due to a build-up of solids in the chemical solutions. • Warm pre-rinse prior to initial rinse to remove fats from pipe
Alternatively, SPX has also developed membrane systems to walls
actively filter the soil from cleaning solutions to enable effective • A two stage caustic wash in the case of heavily fouled
re-use. equipment - the first wash is routed to drain whilst the second
wash is recovered and re-used.
If it is mandatory that no contamination occurs between batches,
• Intermediate cleans while maintaining sterility in the case of
single use systems must be used.
a UHT plant where the production run length is compromised
It is not practical to re-use sanitising solutions such as by fouling to an extent that a high delta T is required at the
hypochlorite or oxonia due to a short active life. heat transfer surfaces to maintain production temperatures.
A high delta T can lead to a runaway situation where deposit
forms at an exponential rate.
C I P CYC L E S
At the end of each CIP cycle the unit should automatically dose
Every CIP circuit will have its own unique sequence of
fresh cleaning chemical into the bulk tanks to make up for that
operations and cycle times. The different types of clean in
lost during the clean.
an automated operation will usually include the following
operations: Each day a service cycle should be run to check the
concentrations, then dose to achieve the correct strength, and to
• Caustic wash
warm up the bulk tanks.
• Full clean (with acid)
• Hot rinse Service cycles should also be available for dumping the caustic/
• Cold clean acid tank and making up fresh solutions..
• Intermediate clean
An example of typical dairy pipework clean is as follows:
• Pulse cleans (not recommended)
• Snake cleans • N
ormal daily clean:
Useful guidelines for the design of the CIP operation are: - Product recovery using fresh purge water
- Initial rinse (3 to 5 mins) using recovered water to drain
• Do not mix line cleans with tank cleans.
- Caustic wash at 75ºC (10 to 20 mins) with recovery
• Size the cleaning rate for the largest pipe diameter in the
- Final rinse (3 to 5 mins), fresh water to recovery tank
circuit.
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CIP and Sanitation of Process Plant
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CIP and Sanitation of Process Plant
S TA N D A R D A P V C I P U N I T S A P V C I P M I D I SYS T E M
Apart from the installation of large bulk units and/or ed CIP units The CIP MIDI is intended for small to medium CIP applications,
during initial plant design, SPX also manufactures a range of and will cater for the following capacities and sizes, up to a
standard skid-mounted CIP modules for cleaning of individual maximum of two CIP circuits per CIP set.
process units. These systems are ideal for upgrading of CIP
systems to reduce bottlenecks and enable the plant to go back on
BA S I C S P E C I F I CAT I O N S
commercial production.
• Sanitary, reclaim CIP, multi-compartment horizontal tank (alkali,
Three standard ranges are available: acid )
• Rinse water by direct supply
• APV MINI - basic single use skid-mounted system with optional
• One circuit or two circuits
water rinse and product recovery tanks
• Five standard volumetric sizes, (1,000, 1,500, 2,000, 3,000 and
• APV MIDI - multiple use skid-mounted system
4,000 litres)
• APV MAXI - multiple use system with multiple circuits and
• Three standard circulation rates, (8,000, 12,500, 20,000 lph)
tanks custom built on application
• Frame mounted equipment and panel (Stainless Steel)
• Free-standing horizontal multi-compartment tank
A P V C I P M I N I SYS T E M
• CIP Solution heating in-tank by APV ParaTube, Stainless Steel
The CIP MINI is is a single-use system with a choice of tank sizes
shell and tube, 12°C per pass
and is designed for efficient cleaning of pipeline systems, tanks
• Stainless steel steam control (Samson) w/float trap (Sarco FT
and processing plants.
series)
• Pneumatic, single-seat rising stem sanitary valves std.
BA S I C S P E C I F I CAT I O N • Control tops w/dual feedbacks and solenoids on APV valves
• Sanitary, single use CIP w/o recovery, single tank and pilot air sv’s on service valves
• Four standard volumetric sizes, (400, 600, 850 and 1,250 • EHEDG APV process equipment (valves, pumps and fittings)
litres) • EHEDG sanitary Endress & Hauser Instrumentation
• Four standard circulation rates, (8,000, 12,500, 20,000 and (temperature and level)
36,000 lph) • CIP supply flow transmitter (magnetic)
• Frame mounted tank, equipment and panel (Stainless Steel) • AC variable speed drive (Danfoss or Allen-Bradley Powerflex)
• CIP Solution heating by APV ParaTube, Stainless Steel shell on CIP supply pump
and tube, 12°C per pass • CIP return conductivity transmitter
• Stainless Steel steam control (Samson) w/float trap (Sarco FT • CIP return flow switch
series) • Std. IP65 Stainless Steel, high and low voltage panel
• Single chemical delivery system (pump, injector and valves) • Integral, IP65 panel mounted - Siemens Simatic S7-315-2 PN/
• Pneumatic, single-seat rising stem sanitary valves std. DP Siemens MP277 10” HMI panel, mounted in the door of the
• Control tops w/dual feedbacks and solenoids on APV valves control panel
and pilot air sv’s on service valves • Std. three-step CIP (prerinse, alkali circulation, postrinse, acid
• CIP supply temperature transmitter circulation, postrinse)
• CIP return temperature transmitter • IEC electrical std. (230/460V, 3-Phase, 50 Hertz)
• EHEDG APV process equipment (valves, pumps and fittings)
• EHEDG sanitary Endress & Hauser Instrumentation
(temperature and level)
• Std. IP65 Stainless Steel, high and low voltage panel
• Integral, IP65 panel mounted - Siemens Simatic S7-315-2 PN/
DP Siemens MP277 10" HMI panel , mounted in the door of
the control panel
• Std. three-step CIP (prerinse, alkali circulation and postrinse)
• IEC Electrical Std. (230/460V, 3-Phase, 50 Hertz)
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CIP and Sanitation of Process Plant
E Q U I P M E N T S I Z I N G ( P R O D U CT I O N CA PA C I T I E S )
C I P M I N I S I Z I N G I N F O R M AT I O N
D I SCHARG E &
F LOW R AT E TA N K S I Z E TA N K D R O P
R ETU R N
MOD E L
LPH G PM (US) LITR E S G A L LO N S ( U S ) O.D. I NCH E S O.D. I NCH E S
P R O D U CT I O N CA PAC I T I E S
C I P M I N I WA S H I N G D U T Y S E C T I O N
P I P E L I N E WA S H ( 2 M / S ) TA N K WA S H * *
MOD E L
MAX. PI PE D IA. (I N) MAX. PI PE LE NGTH (M) TA N K S I Z E ( L ) TA N K S I Z E ( G A L L O N S U S )
* * I N D I CAT I V E O N LY - S I Z I N G S H O U L D B E B A S E D O N S P E C I F I C TA N K S P R AY D E V I C E R E Q U I R E M E N T
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CIP and Sanitation of Process Plant
E Q U I P M E N T S I Z I N G ( P R O D U CT I O N CA PAC I T I E S )
C I P M I N I S I Z I N G I N F O R M AT I O N
TA N K S I Z E
PU M P D I SCHARG E
F LOW R AT E ON E CI P CI RCU IT T WO C I P C I R C U I T S
S U CTI ON & R ETU R N
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CIP and Sanitation of Process Plant
AU TO M AT I O N O F C I P SYS T E M S
All CIP systems should be automated to some degree. The level
will depend on the sophistication of the complete plant.
• PLC controller on the bulk unit only operating the unit valves,
conductivity switches to monitor chemical, temperature control
and the timing sequences.
• No interface with the process plant.
C I P A N A LYS I S A N D O P T I M I S AT I O N
The efficiency of a cleaning cycle is of the utmost importance,
but the cost should be kept as low as possible in terms of
cleaning chemicals and production downtime. SPX has
developed a comprehensive CIP analysis and optimisation tool
called “CIP Expert” to help food processors minimise costs and
maximise productivity.
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CIP and Sanitation of Process Plant
In all cases the protection of the product from CIP fluids is In between each valve seat is a leakage chamber that routes
paramount. directly to atmosphere. Thus in the event of either valve leaking
product or CIP fluid will seek the path of lowest resistance to
The systems available are:
drain. Leakage can be visually detected and corrected.
• "Key Piece" systems
The main benefits of the APV Delta 3+ valve are detailed below.
• Selector panels with swing bends
Special 3A approved double seat valves are available for the
• Selector panels with checked swing bends
North American market.
• Single seat valve arrangements (double, single or no feed back)
• Double seat valve arrangements (with or without pulsing units).
These systems all provide for a physical break in the pipework WAT E R H A M M E R
between product and CIP thus ensuring that no contamination A common fault in a CIP system is water hammer which can
can take place. be engineered out by careful design. Transient shocks up to
20 bar are possible through water hammer with the result that
An alternative system based upon pressure balance to reduce instruments, pipe supports, diaphragms and the pipework itself
CIP contamination of product is NOT recommended. can all be damaged.
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CIP and Sanitation of Process Plant
F E AT U R E S B E N E FITS
M I X - P R O O F O P E R AT I O N A N D
S A F E S E PA R AT I O N O F T W O
T W O I N D E P E N D E N T S E AT DI FFE R E NT M E DIA.
S E A L I N G A R R A N G E M E N TS R E LIAB LE P R O D U CTI O N – N O
A N D L E A K A G E CAV I T Y W I T H R ISK OF M IXE D FLU I DS.
D I S C H A R G E TO AT M O S P H E R E . P O S S I B L E TO S E E W H E N S E A L S
AR E LEAKI NG – R E DUCI NG
P R O D U C T LO S S .
WAT E R H A M M E R S A F E I N
O P E N A N D C LO S E D P O S I T I O N ,
R E M OVI N G R I S K O F M E D IA
B A L A N C E D U P P E R A N D LOW E R M IXI NG.
VA LV E S H A F TS . S M O OT H O P E N I N G A N D
C LO S I N G O F VA LV E
R E G A R D L E S S O F F LO W
D I R E CTI O N.
L A R G E S E PA R AT I O N CAV I T Y N O P R E S S U R E I S B U I LT U P
D R A I N A G E P O R T. AV O I D I N G M I X E D M E D I A .
E H E D G C E R T I F I CAT E . M E E TS I N D U ST RY STA N D A R D S .
CLEANAB I LITY
E N S U R E S U P P E R A N D LO W E R
S E AT S E A L S , S H A F T S E A L S
A N D S H A F T S U R FA C E S A R E
C L E A N E D E L I M I N AT I N G
I N N OVAT I V E , U N I Q U E
B A CT E R I O LO G I CA L G R OW T H
COM PR E H E NSIVE CLEAN I NG
POSSI B I LITI ES.
PROCESS OF ALL WETTE D
MOR E COM PR E H E NSIVE
S U R FA C E S .
CLEAN I NG THAN ANY
C O M P E T I TO R A N D A B OV E
E H E D G T E ST R E Q U I R E M E N T S .
A U N IQU E SE LLI NG POI NT!
A S STA N D A R D I N T E R N A L
I M P R OV E S C L E A N A B I L I T Y
S U R FA C E S E L E C T R O - P O L I S H E D
D U R I N G C I P CYC L E .
TO < 0 . 8 Μ M .
S E PA R AT I O N CAV I T Y S P R AY S E PA R AT I O N CAV I T Y S P R AY
CLEAN I NG M ECHAN ISM CLEAN I NG M ECHAN ISM
P R OVI D E D FO R O PTI O NAL U S E. P R OVI D E D FO R O PTI O NAL U S E.
I N S TA L L AT I O N , C O M M I S S I O N I N G A N D M A I N T E N A N C E
E A S I E R , FA ST E R
M E TA L L I C STO P C O N T R O L S T H E COM M ISION I NG AN D
S E AT L I F T I N G ST R O K E L E N GT H . MAI NTE NANCE.
R E DUCES CI P CONSU M PTION.
E A S E O F S E A L I D E N T I F I CAT I O N
I D E N T I F I CAT I O N N U M B E R S
FOR OR DE R I NG AN D
MAR K E D O N P R O F I LE D S EALS.
MAI NTE NANCE PU R POSES.
L E S S S PA C E R E Q U I R E D F O R
LO W W E I G H T/ C O M PA C T I N STA L L AT I O N .
D E S I G N C O M PA R E D W I T H E A SY, S A F E A N D R E D U C E D
T Y P I CA L C O M P E T I TO R VA LV E S . C O ST I N STA L L AT I O N A N D
MAI NTE NANCE.
E A SY, O N E - P E R S O N R E M O VA L
A D J A C E N T U P P E R A N D LOW E R
AN D R E P LAC E M E NT O F S HAFTS
SHAFT COU PLI NG.
DU R I NG MAI NTE NANCE.
N O A D J U ST M E N T R E Q U I R E D
F I X E D STE M P O S ITI O N
D U R I N G I N STA L L AT I O N A N D
P R OX I M I T Y S W I TC H E S .
MAI NTE NANCE.
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CIP and Sanitation of Process Plant
I N N O VAT I V E N E W C I P T E C H N O L O GY
F E AT U R E S B E N E FITS
The latest development in CIP technology is the use of electro-
L I F E CYC L E C O S T S chemically activated water (ECA) to produce both cleaning and
sanitisation solutions at considerably lower cost than normal
S E AT L I F T I N G AS A STA N DA R D
- N OT E S O M E C O M P E T I TO R S R E D U C E D C O ST O F chemicals.
O N LY O F F E R T H I S AS A N AC Q U I S I T I O N .
OPTION.
ECA water is produced through the electrolysis of a solution
D R A M AT I CA L LY R E D U C E S
P R O D U CT LO S S D U R I N G of sodium chloride. In the absence of a permeable membrane,
O P E R AT I O N O F VA LV E -
C O M PA R E D W I T H LO S S E S
a mixture of anolyte and catholyte will be produced. This is
G E N E R AT E D BY U S E O F A X I A L essentially a mixture of sodium hydroxide and hypochlorous acid.
R A D I A L S E AT S E A LS . S E AT S E A LS .
C L E A N E R O P E R AT I N G
E N V I R O N M E N T D U E TO When a permeable membrane is positioned between the
E L I M I N AT I N G E VA P O R AT I O N O F
P R O D U CT LO S S E S CAU S E D BY electrodes, it is possible to separate the two electrolytes. A
U S E O F A X I A L S E AT S E A L S .
variation of the flow rate past the respective electrodes enables
OPTI M ISE D CI P PROCESS
M E TA L O R I F I C E S C O N T R O L C I P WITH M I N I M IZ E D CI P FLU I D different concentrations of the two electrolytes to be obtained.
F LO W D U R I N G S E AT L I F T. CONSU M PTION.
A U N IQU E SE LLI NG POI NT! In practice, the pH of the anolyte will be adjusted to pH 7.0 - 7.5
SEAL SIZ ES AR E G ROU PE D
O V E R S E V E R A L VA LV E S I Z E S ,
in order to maximise the concentration of active hypochlorous
R E D U C E D I N V E N TO RY A N D
FOR EXAM PLE SAM E KIT FOR:
M A I N T E N A N C E C O STS . acid and prevent it converting to free chlorine or hypochlorite.
DN40, DN50, DN65 AN D 1.5", 2",
2.5", 3". This adjustment may be through addition of small amounts of
R E DUCE COM PR ESSE D AI R catholyte or sodium bicarbonate.
L I N E S A N D C O N N E CT I O N S .
O P T I O N A L LY AVA I L A B L E
E L I M I N AT E E X T E R N A L
WITH APV CONTROL U N IT
T E C H N O LO GY I N C L U D I N G
S O L E N O I D VA LV E CA B I N E TS . The electrolytes need to be stored in plastics containers until
R E D U C E E L E CT R I CA L C O N T R O L
D I R E CT W I R E D O R F I E L D B U S
WI R I NG. diluted for use.
C O N T R O L A LT E R N AT I V E S .
R E D U C E S VA LV E R E S P O N S E
TI M E.
Hypochlorous acid is some 50 times more effective a sanitiser
than hypochlorite. It is the chemical that the body naturally
produces in response to an infection. When an infection is
detected, the body sends neutrophil blood cells to encircle the
bacteria or virus and produce a number of cytokine, including
hypochlorous acid.
N AO H CI2
A concentration of just 0.1ppm hypochlorous acid is sufficient to
H2 O2
H2 O2 HOCI
secure a log 3 reduction of E.coli within 10 secs.
PH 12 - 13 P H C I R CA 3.5
ECA water has several important benefits to food processors:
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CIP and Sanitation of Process Plant
Glossary
The following definitions of terms are commonly used in the design of CIP systems:
B
Bactericide
An agent that destroys bacteria.
Bacteriostatic
A state of inhibiting the growth of bacteria.
Beerstone
A mixture of proteinaceous debris, water hardness and calcium oxalate mineral salts.
Biocide
An agent that kills living material .
Biodegradable
A substance possessing the means of being broken down by biological action. In effect, complex molecules are broken
down by bacterial action to simpler substances.
Buffering
Stabilising the pH value of a solution under cleaning conditions.
C
Carbohydrates
A large group of organic compounds composed of carbon, hydrogen and oxygen only. Usually the hydrogen and oxygen
atoms are in a ratio of 2:1 as in water. This group includes sugars, gums, starches and cellulose.
Chelation
Similar to sequestration, except that the chelating agent forms a typical ring structure with water hardness constituents.
Cleaning
The cleaning process, as distinct from sterilisation. The term 'cleansing' is construed as applying to a combination of
cleaning and sterilisation.
Corrosion inhibitors
See Inhibitors.
D
Deflocculation - or dispersion
is the action of breaking-up soil aggregates into individual particles.
Descalant
A scale removing agent, usually an acid used to remove water hardness salt.
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CIP and Sanitation of Process Plant
Detergents
Substances capable of assisting the cleaning when added to water. They include soaps, organic surface active agents,
alkaline materials and acids in certain instances.
Disinfection
The destruction of all pathogens. Often used within the context of C.I.P. as being synonymous with sanitation.
Dissolving
A chemical reaction which produces water-soluble product from water-insoluble soil.
Diversion
The act of bringing into and keeping in suspension undissolved soiling matter.
E
Emulsification
A mechanical action of breaking-up fat and oil into very small particles which are uniformly mixed with the water used.
Eutrophication
A process of enrichment of water by plant nutrients as a result of which there is increased productivity of algae and
aquatic vegetation.
F
Fats
Natural organic compounds which occur in plants and animals and serve as storage materials. The distinction between
fats and oils is largely one of melting point.
H
Hygroscopic
Having a tendency to absorb moisture.
I
Inhibitors
Substances capable in specific instances of minimising the corrosion of certain metals.
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CIP and Sanitation of Process Plant
M
Micron
One thousandth of a millimetre. Usually written ‘µm’.
Milkstone
A deposit. which contains calcium caseinate and calcium phosphate with associated proteinaceous debris.
Mineral salts
Mixtures and compounds of inorganlc composition such as calcium, magnesium, iron, or phosphorus not belonging to the
class of carbon compounds associated with organic chemistry.
P
Pathogens
Disease-producing organisms.
Penetration
This is the action of a liquid entering into porous materials through cracks, pinholes or small channels. Often this action
can be considered as a part of wetting.
Peptizing
This involves degradation in molecular size and is the physical formation of solutions from soils which may be only partially
soluble.
pH value
A measurement of the hydrogen ion to determine the acidity or alkalinity of the solution. It is defined as a base 10 logarithm
of the reciprocal of the hydrogen ion concentration. A neutral solution has a pH of 7 and an acid solution has a pH of less
than 7. An alkaline solution has a pH greater than 7. The range extends from 0-14 and applies only to dilute solutions.
Protein
High molecular weight organic compounds containing carbon, hydrogen, oxygen, nitrogen, built up from amino-acids. Es-
sential in food to build body tissues.
R
Rinsing
Rinsing is aided by reducing the surface tension of the water used. This enables the solution of suspension to be flushed
easily from a surface.
S
Sanitisation
This defines the state of physical cleanliness, which requires the removal or destruction of micro-organisms that can
cause destruction or infection of the object being sanitised. There can thus be sanitisation without sterilisation. This
process reduces the number of bacteria in plant and utensils to a level consistent with acceptable quality control and
hygienic standards.
Saponification
Saponification is the chemical reaction between an alkali and an animal or vegetable fat resulting in a soap.
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CIP and Sanitation of Process Plant
Softening
Water softening is the removal or inactivation of the hardness of water. This can be achieved in a variety of ways such as
precipitation or sequestration.
Soil
The milk or beer residues, scale and other deposits which have to be removed from plant and containers during the clean-
ing process.
Sterilisation
Sterilisation is explicitly defined as the complete and total destruction of all living organisms. Note that this can still mean
the equipment can be physically dirty, although by definition sterile..
Stoichiometry
Relationships in chemistry dealing with determinations of combining proportions or chemical equivalences.
Substrate
The foundation for soil deposition, i.e. the vessel or pipeline inner surface.
Suspension
Is the action which holds up insoluble particles in a solution.
Synergism
A combined or coordinated action, between two or more components, which produces a greater total effect than the ef-
fected sum of all the individual actions considered in isolation.
W
Wetters'
A jargon term used for agents that lower the surface tension of a solution and improve wetting, i.e. surfactants.
Wetting
Wetting is the action of water in contacting all surfaces of soil or equipment.
References:
Hasting, APM (2008) Cleaning-In-Place: Dairy, Food and Beverage Operations, 3rd Edition, Society of Dairy Technology, Huntingdon,
UK
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A B O U T S PX
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