Professional Documents
Culture Documents
CIP Optimization
Design, Implementation and Operation
John M. Hyde
Chairman and Founder
Hyde Engineering + Consulting
Boston Chapter Meeting
19 January 2017
– Client Focused
– Founded 1993
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• Concept Design
• Process/Facility Requirements and Constraints
• Cycle Requirements
• Detailed Design
• CIP Skids
• CIP Circuitry
• Commissioning/Cycle Development
• Skid Operations
• Circuit Flow Paths
• Cleaning Validation
• Initial Testing at Commercial Scale
• Ongoing Monitoring of Cleaning Performance
• Benefits of Efficient CIP Design
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• Process Requirements
• Unit Operations
• Interconnecting Piping
• Containment/Contamination Control Requirements
• Bio-Safety Level
• Pre/Post Virus Removal
• Production Targets (e.g., Lots/Year, Changeovers, etc.)
• Facility Constraints
• PW and WFI Supply
• Drain Capacities and Waste Treatment Requirements
• CIP Skid Location and Space Requirements
• Skids Preferably Located at or Below Elevation of
Process Equipment Being Cleaned
Connecting Pharmaceutical Knowledge ispe.org 5
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• CIP Skids
• Tankage Requirements
• Number of CIP Skid Vessels
• Size of CIP Skid Vessels
• Vessel Pressure Rating Requirements
• Wash Solution Make-Up Methodology
• Batching of Cleaning Solutions in the CIP Skid Tank
• Formulation of Cleaning Solutions in the Cleaning Circuit
• Control of Cleaning Critical Control Parameters
• Required for Effective Cleaning
• Required for Repeatable and Reliable Cleaning
• Required for Efficient Cleaning
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• CIP Circuitry
• Cleaning of Vessels
• Cleaning of Interconnecting Piping
• Piping is Often Cleaned Independently from Vessels
• Results in Increase of Cycles Per Lot Requirement by Factor of 2
to 3
• Often Results in Significant Increase in Valves Required due to
Leak Protection
• Circuitry Layout Strategies
• Clean Vessels with Outlet Piping in Reverse Flow
• Clean Filter Housings Inline
• Ultimate goal is to Have no Circuits That are Just Piping
• Clean and Dirty Hold Time Considerations
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• Test Plan
• Author an experimental test plan describing the approach
used to conduct bench scale cleaning process developmental
studies for post production residues
• Cleaning Agent Selection
• Test each residue using a designed experiment to
screen alkaline, neutral, and acidic post production
residues over a range of typical cleaning process
temperatures to determine an appropriate cleaning
agent for a particular post production residue
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5 cm
~1 in2
5 cm
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Coupon Soiling
Representative Post-Production
Residue Applied to Coupon
Soiled Coupon Dried to Simulate
Post-Production Conditions
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Coupon Testing
Gravimetric Assessment
Laboratory Microbalance
Accuracy ±0.00005 grams
Tare mass of coupons
Amount of residue spiked on
coupons
Amount of residue remaining after
cleaning assessment
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10.00
Water 25C
Water 65C
8.00
Rate of Removal [mg/sec]
COSA‐CIP‐92 25C
COSA‐CIP‐92 65C
COSA‐CIP‐72 25C
6.00
COSA‐CIP‐72 65C
COSA‐PUR‐80 25C
COSA‐PUR‐80 65C
4.00
2.00
0.00
0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240
Duration [sec]
C D
90%
80% E F
70%
G H
% Residue Remaining
60%
I J
50%
K L
40%
30% Q M
20%
N O
10%
P
0%
0 2 4 6 8 10 12 14 16 18 20
Cleaning duration (seconds)
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4
Rate
3
6
pH 60
9 50
40
12 30 Temp
Re ≥ 34,000
CIP Supply
High
Low Level
Variable Level
CIP (‐)
(+)
System
Concentration 1% 2%
CIP Return Temperature 25°C 65°C
Energy NRe 3,000 34,000
Re ≥ 3,000
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Bioreactor Example
• Not all components may be cleaned simultaneously
• Many components to be cleaned in this complex CIP Circuit
Cleaning vessel with sprays
Cleaning multiple lines to bioreactor
• CIP system can only provide a limited flow rate to the
bioreactor
• Bioreactor has limited drain rate
• Clean components in sets with toggle sequences:
• Toggle CIPS valves to clean sets
• Clean all sets of components sequentially
• Use short toggle times and repeat toggles to get required
contact time
• Base Exposure Times for Piping on Residue to be Removed
• Gas Lines Versus Product or Media Containing Lines
Bioreactor Example
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Cleaning Validation
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Benefits of Efficient
CIP Design
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• CIP Systems
• Large CIP Vessels Sized to Batch CIP Solutions
• CIP-100 Only Cleaning Agent Used
• CIP Circuits
• Piping and Vessels Cleaned Separately
• Piping Circuits Cleaned “Once-Through”, e.g., CIP-100
Solution Not Recirculated
• Performed Optimization Study
• Analyzed CIP Parameters and Operational Sequences
• Combined Piping and Vessel Cleaning
• Eliminated Once-Through CIP-100 Washes
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WFI Consumption
Operational Number of WFI Usage (L) Number of WFI Usage (L)
Mode Cycles Per Lot Per Lot Lots per Year per Year
WFI Consumption
Operational Number of Skid Usage Number of Skid Usage
Mode Cycles Per Lot (H) per Lot Lots per Year (H) per Year
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WFI Consumption
Operational Number of CIP-100 Usage Number of CIP-100 Usage
Mode Cycles Per Lot (L) Per Lot Lots per Year (L) per Year
Questions?
Please use the microphone indicated so
our recording includes audio of your
question
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Contact Information
john.hyde@hyde-ec.com
+1.303.641.5468
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