2 - 7 CIP - DesignGuide

Tetra Pak Processing System
Plant Solutions
Handled by Owner Approved by Date Version Page
Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 1 (16)
Design Guide
CIP Station
Centralized
Copyright © 2008 Tetra Pak Processing Systems, Lund Tetra Pak Internal
Plant Solutions
Design guide – CIP Station
Content
1 Welcome to the design guide - CIP Station 3

2 Mechanical design demands 4
2.1 General 4
2.2 CIP Flow requirements 4
2.3 Capacities of CIP tanks (general) 7
2.4 Design of cleaning distribution systems 10
2.5 Design of Concentrate dosing system (general) 14
2.6 Material demands 15
2.7 Dimensioning/Engineering/Choice of components 16
Plant Solutions
1 Welcome to the design guide - CIP Station

The main purpose of this document is to supply guide-lines and rules to engineer a centralized
CIP station and its distribution system. The guide-line is written in the form of a reference
document, i.e. for every issue you find tangible information guiding you to a good solution for
the given requirements.
The main users of the document will be the pre-project engineer to do pricing and quotations
as well as the implementation organization to do the detailed engineering on order received.
The documents include all important issues like CIP flow requirements, capacities,
distribution systems and concentrate dosing.
NOTE! This document is made for YOU, NOT TO BE GIVEN TO THE CUSTOMER!
Plant Solutions
2 Mechanical design demands

2.1 General
Location of tanks
The order of CIP tanks connected to the CIP lines is important and it should be in the
following way: In the end of the line is the hot water sanitation small tank placed then comes
the water tank, the caustic tank the acid tank and finally the rinse water tank.
2.2 CIP Flow requirements

Temperatures
The required temperatures on outgoing detergents are recommended to be as follows:
Pre-rinse temperature 25 °C
Caustic temperature 75 °C
Acid temperature 65 °C
Water temperature between caustic and acid phases 40 °C
Water temperature final rinse No heating is required
Hot water sanitation temperature 90-95 °C
Dimensioning of heat exchangers in the lines is based on maximum flow rate, see below and a
delta T = 20 °C per passage of the flow.
Dimensional CIP flow to tanks
The required capacity and pressure for the cleaning of a tank is determined by the number and
type of the cleaning devices (spray balls, spray nozzles or spray turbines). In addition
sufficient flow must be achieved in the inlets and the outlets of the tank.
A flow rate of approx. 1500- 21 00 l/m circumference is needed for the cleaning of a vertical
tank.
A flow rate of approx. 300 l/m2 of inner surface is needed for the cleaning of a horizontal
tank.
Dimensional CIP flow in pipes
For 1” – 3” (25-76 mm) pipes a mean velocity of 1.5 m/s should be reached.
For 4” (102 mm) pipe a speed of 1.0 m/s can be accepted.
Pipelines with a high number of valves and dead ends may need a higher velocity, as the dead
ends are cleaned by the turbulence created by high velocities. It is also essential to orientate
the T-pieces so that they are cleanable.
Plant Solutions
Picture showing good and bad designs for T-pieces.

Flow requirements for pipe cleaning:
Dimensioning of CIP flow for pipes with Heat Exchangers

The calculation shall be done in such a way that the thermal duty will be performed by the
smallest number of plates and also at the same time offer a good cleaning possibility. The
channels shall be cleaned with the flow rates given in the specification from the supplier.
Normally it shall be possible to clean a PHE with a detergent flow rate relation of 1-1.2
compared with the product flow. Due to the lower viscosity of the warm cleaning solution
compared to the product, the centrifugal pump in the plant will normally give that flow rate
without any problems. For viscous products a higher relation for the cleaning solution may be
used.
The cleaning flow rate shall be indicated in the quotation for the heat exchanger.
To get a good cleaning result, the number of channels in parallel shall be of approx. the same
size in all sections. The variation ought to be less than ratio 1:2. This is not always possible on
very small groups of plates.
Plant Solutions
Depending on what type of product and temperature the plate heat exchanger is used for there
are three different kind of fouling:
1. High fouling - Heating of milk products 60-1 00°C

- Pulpy products
2. Normal fouling - Heating of milk products 0-60°C

- Cooling of milk, most other food products
3. Low fouling - Particularly for cooling of none fouling, viscous product 0-50°C
Example:
Type of heat exchanger: xx
Type of plates: Normal plates/High fouling
Grouping: 3 x 4 + 3 x 4
Flow rate/channel: 2000 l
Required flow rate: 4 x 2000 = 8000 l/h
Cleaning of valves
Mixproof valves, like Unique mixproof valves, need to do seatlifts to clean their seats to the
leakage chamber. This activity could be one of the factors that have the most impact on water
consumption.
Specific mixproof valves, like Unique UltraClean and HighClean, also need to clean the outer
parts of the balance plugs and the leakage chamber. This is done through a separate small pipe
separated from the main pipe with a valve. The distances between valves and pipes for this
internal cleaning must be as short as possible. If this solution is not correctly designed it can
consume a large amount of water.
When flip times are set as short as possible there will be an increased need for more cleaning
result inspections.
Sizing of CIP pressure pumps

The rated capacity of cleaning equipment should be more than 50% of the nominal capacity.
The choice of the pressure (distribution) pump for each cleaning line is based on the
calculated pressure drop (length of pipes, number of bends, static pressure, spray balls etc.)
and nominal capacity.
Plant Solutions
If objects with both high and low capacities are connected to the same cleaning line, it must be
assured that the pump could handle also the low capacities (in some cases flow restrictions
need to be added).
2.3 Capacities of CIP tanks (general)

The basic documents for designing a CIP- plant are:
• P&ID for the food production
• Production Time Schedule
• Machinery Layout
Procedure:
Make a list of all the cleaning circuits and indicate the cleaning capacity, cleaning program
and area for each circuit.
Prepare a time (occupation) schedule to determine the number of cleaning lines. Based on the
production program, the starting time might be fixed for each circuit to avoid possible
conflicts.
The most difficult part of the design job is the grouping of the circuits. Capacities of the
circuits, basic layout of the plant and availability have to be taken into consideration.
As a dimensioning rule a cleaning line for long programs (PHE) can be used 3 times a day, i.e.
the running time will be about five (5) hours a day and a cleaning line for short programs
(tanks and pipe lines) 10-15 times a day corresponding to a running time of 6 – 7.5 hours.
These figures may, however, only be used as approximate ones.
First of all you have to look upon each cleaning circuit to determine the volume of the circuit.
Line cleaning
You have to determine which diameter the pipe has and then do a rough calculation of the
length of the circuit and the line to and from the cleaning plant.
Plant Solutions
Example
The cleaning circuit: 130 m pipe diam. 76 =540 l
25 m pipe diam. 63.5 = 72 l
The cleaning line: 15 m pipe diam, 76 = 62 l
(pressure and return) 25 m pipe diam, 76 = 104 l
= 778 l
Tank cleaning
The main volume needed for a tank cleaning is in the line to and from the tank. So first of all
you have to determine the diameter of the pressure and the return line and the length of the
lines as above.
The volume which is inside the tank during cleaning is as follows:
Example
Cleaning of a vertical tank 10 000 1
Tank: = 75 l
Line: 47 m pipe diam, 63.5 = 134 1
23 m pipe diam. 51 = 43 1
= 252 l
Milk Pasteuriser
For calculating the cleaning volume for a pasteuriser, use a figure of 7% of the nominal
capacity for the product flow (20 000 l x 0.07 = 1400 l)
Nowadays, the regenerative effect has increased very rapidly from 80% to 90% and even to
96%. If you are going to clean a pasteuriser with 96% regenerative, you must have the
required volume of cleaning solution tanks to be able to circulate.
This calculation is based on P&ID, layout and isometric drawings:
Plant Solutions
Detergent Tanks
The determination of the necessary volumes of the detergent tanks (caustic and acid) is based
on the maximum volume of the cleaning solution that can be simultaneously in the cleaning
lines (Cleaning System Volume = VCS). This volume is equal to the volume of the largest
circuit of each cleaning line.
The volume for a system for cleaning of plate heat exchangers is equal to the volume of the
pipe line plus the volume of the heat exchanger itself.
The volumes of all the lines that could be in operation at the same time are added together.
Example 1 (Cleaning system volume for three lines)
Line Volume
W01 650 Litres
W02 200 Litres
W03 350 Litres
Total 1200 Litres
Four additional volumes are added:
1. Volume between overflow pipe and LSH = 20 % of VCS.
2. Margin volume between LSM and LSL = 30 % of VCS.
3. Volume between distribution pipe and LSL = 10 % of VCS.
4. Volume in the cone of the tank (dependent on diameter and slope)
• LSH -Located just below (1%) the over flow

pipe
• LSM (LT) -Located 20% of VCS under the
over flow pipe
• LSL (LT) -Located 10% of VCS over
distribution pipe from tank
• LSLL -Located at the bottom of the tank
(used for emptying/cleaning)
Plant Solutions
The summary of these 5 volumes gives the necessary size of the CIP tank. The nearest
standard tank size is chosen.
The Matrix Toolbox No 28 “CIP Circuits and Tank) gives help with the calculation.
The dimensioning of the Detergent tanks should normally allow all CIP lines to operate in the
same step at the same time. Especially at extensions of the number of CIP lines in one existing
CIP station the number of CIP lines operating at the time could be limited. An extra interlock
is then added in the software.
The feeding capacity of water to these tanks should be enough to refill an empty tank in less
than 60 minutes.
Water tanks
Pre-rinse water (collected post-rinse water from the previous cleaned circuit).
The necessary volume of the pre-rinse water tank is based on the maximum rinsing throughput
required simultaneously and the estimated time for the pre-rinse phase.
Necessary volume = max. throughput (litres) x Time (min) / 60 (min)
The necessary volume of the fresh water tank is calculated in the same way.
The feeding capacity of water to this tank should be approx. 30% of the maximum rinsing
flow.
Neutralisation tank
The necessary volume of the neutralisation tank is based on 2.5-3 times the volume of the
detergent tanks.
Hot water sanitation small tanks

The volume between LSL and the overflow pipe should be line capacity (litres) / 120.
The feeding capacity of water to this tank should be approx. 2 times the line capacity.
2.4 Design of cleaning distribution systems

CIP return part of cleaning distribution system must provide sufficient pressure (1-2 bar) in
CIP circuit with seat lift function of mixproof valves. This could be achieved with orifice or a
butterfly valve with drilled holes.
Dead ends are to be avoided in cleaning distribution systems both on pressure and return side.
Sizing of cleaning distribution system

The sizing of the distribution system is often designed to be ones size smaller than the pipes
(or connections) in the cleaning circuit itself. This rule will give rather high pressure drop in
Plant Solutions
the distribution system and it is possible to design the system in the same dimension as the
circuit (Option).
Circuit Cleaning flow Distr system Pressure Option Pressure

size (1,5 m/s) l/h High velocity Drop Medium Drop
m/s
mmwc/m velocity m/s mmwc/m
25 2500 1,7 (SMS25) 19 1,7 (SMS25) 19
38 5500 3,8 (SMS25) 85 1,5 (SMS38) 8
51 10000 2,8 (SMS38) 26 1,5 (SMS51) 5
63 15000 2,2 (SMS51) 12 1,5 (SMS63) 4
76 24000 2,3 (SMS63) 9 1,5 (SMS76) 4
102 41000 2,5 (SMS76) 10 1,5 (SMS102) 2
102 27000 (1 m/s) 1,7 (SMS76) 5 1,0 (SMS76) 5
Parts in the cleaning distribution system

The cleaning distribution system consists of different design elements as seen below.
V50 and V58 are distributing and collecting the CIP detergents. V51-V54 are distributing and
giving CIP safety when having many similar CIP circuits located near each other. V56 and
V57 are design elements with CIP return pumps and are needed when objects with open
surfaces to the atmosphere are cleaned, i.e. tanks, fillers etc.
V50 is distributing cleaning detergents to the different cleaning circuits connected to the same
CIP pressure line. Activations and error control is done from the cleaning circuit.
Plant Solutions
V58 is collecting cleaning detergents from the different cleaning circuits connected to the
same CIP pressure line.
V56 is pumping back cleaning detergents from a tank, filling machine or equal. The suction
side is connected to tank lines, balance tanks or equal. The pressure side is connected to the
CIP return collecting system V58. Activations and error control is done from the cleaning
circuit.
V57 is pumping back cleaning detergents from a tank, filling machine or equal. The suction
side is connected to tank lines, balance tanks or equal. The pressure side is connected to the
CIP return collecting system V58. It is possible to bypass the pump if a part of the CIP circuit
is a pipe (i.e. the tank line) that needs to be cleaned with a higher CIP flow than the rest of the
CIP circuit (i.e. tank and tank line together). Activations and error control is done from the
cleaning circuit.
CIP safety when splitting CIP line to many circuits

Cleaning detergents are distributed in the plant in different ways, see above. The different
alternatives V51, V52, V53 and V54, for giving CIP safety when having many circuits
connected to one in coming CIP line, will give different performances. The functionalities and
benefits are described briefly below. Activations and error control is done from the cleaning
circuit.
Plant Solutions
V51 Includes vertically positioned Single seat valves which makes the installation use little
floor space. (In this installation there is a slight risk of having CIP liquid in the wrong tank if
the valve plug is indeliberately detached from the actuator.)
V52 Includes horizontally positioned Single seat valves. No risk of having CIP liquid in the
wrong tank if the plug is indeliberately detached from the actuator. It needs more welding than
V51.
V53 Includes a swing bend plate where the different CIP circuits are connected manually
when needed. Proximity switches could be necessary to avoid CIP liquid in the wrong tank.
This solution is mostly used for CIP circuits that are not cleaned with the normal daily
production, for example CIP tanks.
V54 Includes vertically positioned mix proof valves which makes the installation use little
floor space. The valves normally don’t need seat lifts.
Sizing of CIP return pumps
The rated capacity of cleaning equipment should be more than 50% of the nominal capacity.
The choice of the return pump for each cleaning line is based on the calculated pressure drop
(length of pipes, number of bends, static pressure, spray balls etc.) and nominal capacity.
To save energy for the CIP return pumps they could be equipped with speed controllers.
Plant Solutions
2.5 Design of Concentrate dosing system (general)

Dosing system
Dosing equipment for caustic, acid or another type of detergent consists of a dosing pump, a
concentrate container (200-500 lit.) and a set of fittings and hoses.
This equipment regulates the concentration of the detergent that decreases after every
cleaning. The quantity of dosing can be adjusted as per experience or automatically by means
of a conductivity transmitter and switches.
Concentrate tanks
Tanks for storing of concentrated caustic and acid shall easur the demands according to
local rules and regulations. Information which effects the construction of the tanks shall be
handed over to the tank manufacturer.
The tanks shall be equipped with an inspection opening, min, diam. 450 mm, with external
tightening manhole.
Each tank shall be equipped with an air vent pipe and if the opening of this pipe is high above
the tank, the tank must be constructed considering the higher pressure occurring. Tanks used
for storing of e.g. nitric acid must, due to gas evolution, be absolutely tight and equipped with
an air vent pipe leading outside the building.
For level measuring the tanks shall be equipped with two level guards for low level, where
one is for empty tank and the other is for ordering new caustic or acid, and two level guards
for high level, where one is for controlling a shut-off valve in the filling line as protection
against overfilling.
The tanks shall be placed in certain “safety basins”. These basins must be dimensioned to hold
the necessary volumes of the tanks. If the basins are equipped with drains, it must be possible
to close these drains. As an option instruments for leakage detection could be placed in the
basins.
If the tanks are placed indoors, the room must be sufficiently ventilated in view of gas
evolution. Nitrous fumes are heavier than air and therefore exhaustion should also be done at
floor level.
Tanks placed outdoors must sometimes be equipped with heating devices due to climate
conditions. Heating is mainly used on caustic tanks. The caustic tank should also be equipped
with an agitator.
Plant Solutions
Diaphragm pumps are suitable for dosing caustic and acid. The pumps must be equipped with
flexible connections on both suction and pressure side and a suitable overflow valve leading
the concentrate back to the respective tank.
In order to avoid that the pumps are drowned if the “safety basin” is filled up due to tank
leakage, they should be placed on consoles on the wall or outside the basins.
Pipes and Fittings
Thick walled acid proof steel shall be used and everything shall, if possible, be welded
together. The dimensions of the pipes should be ½”- 1 “,
The flexible connections for the dosing pumps must be resistant against concentrated caustic
and acid.
The valves shall be acid proof ball valves and, if they should be remote controlled, equipped
with pneumatic actuators and feedbacks.
The inlets and outlets of the tanks must be equipped with shut-off valves.
All fittings shall be made of acid-proof steel with pressure limits and temperature limits
according to local regulations.
Protective shields must be erected around such equipment where leakage can occur, e.g, pump
connections, valves etc.
Tanks, pipes etc. must be marked with special warning signs against corrosive chemicals.
2.6 Material demands

Equipment used in contact with liquids in the cleaning station must be suitable for food
production. The equipment must also be resistant to cleaning agents and agents used for
chemical sterilisation. Normally stainless steel 1.4307 is sufficient for caustic and nitric acid
which are the most common detergents. If other detergents are used the material choice must
be reassessed. Concentrated chemicals should be handled in equipment made of material
stainless steel 1.4404.
Plant Solutions
Seals should for resistant to the cleaning agents used. For connections to the recovery system
the resistance against the food products must be secured.
2.7 Dimensioning/Engineering/Choice of components

• Manual steam valves max 30m/s
• Automatic steam valves 25m/s
• Regulating valve and condensate trap according Toolbox.
• Header pipes out from and in to detergent and rinse water tanks dimensioned to
have a velocity between 1.5-2 m/s
• Overflow pipes should be located inside the tank and dimensioned 1-2 sizes
larger than the header pipes. Inside location maximizes the use of the tank volume
and the ventilation connection could be taken out. Much less vapour will come
through the ventilation going downwards.
• Drain pipes from tanks to be 2½”
• Valve cluster layout should be compact to avoid mix zones when changing of
phases.
• Valves should be mounted to avoid water hammer.
o The use of balanced mixproof valves on suction side of pressure pumps
must be considered.
o For water filling valves the problem could be reduced by
adding orifice in line, to split pressure drop to two places and
lower velocity
using a different type of valve, eg an angle seat valve (Burkert)
which closes against the flow
• Valves should be mounted to avoid opening if a water hammer occurs.
• Conductivity transmitters need to have good accuracy in different measuring
ranges. To avoid negative influence on the signal from air and foam in the return
liquid it is advisable to mount the sensor from underneath, as below.
•
• Instruments need to be fast reacting to be able to control the separation of liquids
in the CIP returns in the best way.

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Tetra Pak Processing System

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 1 (16)

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 2 (16)

Design guide – CIP Station

1 Welcome to the design guide - CIP Station 3

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 3 (16)

1 Welcome to the design guide - CIP Station

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 4 (16)

2 Mechanical design demands

2.2 CIP Flow requirements

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 5 (16)

Picture showing good and bad designs for T-pieces.

Dimensioning of CIP flow for pipes with Heat Exchangers

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 6 (16)

1. High fouling - Heating of milk products 60-1 00°C

2. Normal fouling - Heating of milk products 0-60°C

Sizing of CIP pressure pumps

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 7 (16)

2.3 Capacities of CIP tanks (general)

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 8 (16)

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 9 (16)

• LSH -Located just below (1%) the over flow

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 10 (16)

Hot water sanitation small tanks

2.4 Design of cleaning distribution systems

Sizing of cleaning distribution system

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 11 (16)

Circuit Cleaning flow Distr system Pressure Option Pressure

Parts in the cleaning distribution system

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 12 (16)

CIP safety when splitting CIP line to many circuits

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 13 (16)

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 14 (16)

2.5 Design of Concentrate dosing system (general)

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 15 (16)

2.6 Material demands

Markus Andersson Fredinand Franz Fredinand Franz 2009-03-17 1.1 16 (16)

2.7 Dimensioning/Engineering/Choice of components

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