DEP SP CIP 001 - E With Comments

SPECIFICATIONS CONTROLLED DISTRIBUTION
Code: DEP-SP-CIP-001 Date June, 2005
Version E
Engineering Dairy Title: CIP UNIT SPECIFICATION
Products Division Page 1 /42
Prepared by : Contributors:
Victor MORILLO and Didier JOANNES Charles BELZILE

WW Process Engineering Technical Department North America
Jozsef HEIZLER
Technical Department Hungary
Juan José GARCIA
Technical Department South Europe
Vincent PETITPREZ
Technical Department France
Stéphanie ALLARD
Technical Department France
Updates
Version Dates Modifier Text of the modifications
A July 2003 Didier JOANNES / Victor Creation

MORILLO
B August 2003Didier JOANNES / Victor Refer to modification marks

MORILLO
C October 2003 Didier JOANNES / Victor Refer to modification marks
MORILLO
D November 2003 Didier JOANNES / Chapters 2.2, 3.1.5, 4.1.3, 4.2.2,
Stephane RENONCOURT 4.3.2, 4.4.2, 4.5.2, 4.6.2 and 4.6.4
E June 2005 Esperanza ARMERO Modifications on design and
chapters 2.2, 4.6, 5.2
Approved by :
José Carlos RODRIGUEZ RUBIA Gabriel PAZOS PEZZI Michel SAINTAIN
WWBU Engineering Director WWBU Technical and Enginering WWBU DAQSA Manager
Director
Date: Date: Date:

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Intellectual property controls and control of engineering specification with the suppliers:
No specification is sent to a supplier prior to contract or order.
During quotation or tender the specifications can only be seen by the suppliers in Danone offices to
make sure their offer comply with our standards. Neither copy, nor electronic file can be given to them
at that stage.
Make sure that our contracts have a specific paragraph regarding the protection of the engineering
specifications against malicious use. That paragraph must be seen and checked by our lawyers. All
suppliers must clearly commit to implement measures to prevent that the specifications and other
documents issued by the engineering department are used by our competitors.
Once contracts are signed, then please use YODA to make sure you have the most updated version of
the specifications and guidelines. Only paper copy or pdf files can be communicated to the suppliers.
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Index
1. INTRODUCTION 4
1.1. PURPOSE................................................................................................................................................. 4
1.2. SCOPE OF APPLICATION..................................................................................................................... 4
1.3. RESPONSABILITIES.............................................................................................................................. 4
1.4. RELATED DOCUMENTS ...................................................................................................................... 5
2. STANDARD FLOW DIAGRAM 6
2.1. DESIGN SELECTED............................................................................................................................... 6
2.2. THE FLOW DIAGRAM AND POSSIBLE VARIATION ...................................................................... 8
3. GENERAL PRINCIPLES 15
3.1. STATE MANAGEMENT ...................................................................................................................... 15
3.2. PERSONNEL AND PROPERTY SAFETY .......................................................................................... 18
4. DESCRIPTION OF FUNCTIONS 19
4.1. CIP PRINCIPLES COMMON TO EACH FUNCTION ........................................................................ 19
4.2. RECOVERED WATER TANK PREPARATION PROGRAM ............................................................ 23
4.3. FRESH WATER TANK PREPARATION PROGRAM........................................................................ 24
4.4. SODA TANK / ACID TANK / HOT WATER TANK PREPARATION PROGRAM ......................... 26
4.5. SELF-CLEANING PROGRAM............................................................................................................. 29
4.6. CLEANING CONTROL OF A PROCESS EQUIPMENT .................................................................... 32
5. APPENDIX 39
5.1. HACCP................................................................................................................................................... 39
5.2. DEVICE LIST ........................................................................................................................................ 40
5.3. INSTRUMENTATION .......................................................................................................................... 41
KEY PERFORMANCE INDICATORS 42
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1. INTRODUCTION
This specification describes the minimum standards that a Cleaning In Place (CIP) unit must comply
with. This specification must be referred to in the technical specifications given to suppliers.
1.1. PURPOSE
The objectives of the document are to describe:
- the standard flow diagrams of the modules that form the CIP unit
- the running functions of the CIP modules and the associated parameters
- the specific automation rules and interfaces
1.2. SCOPE OF APPLICATION

The CIP is used to clean all the process installation from the milk truck to the filler machine.
The CIP unit is a group of different modules:

1. fresh water tank
2. recovery water tank
3. soda tank
4. acid tank
5. hot water tank
6. CIP lines
It is recommended to use different CIP units for the different areas into a factory:
• From Milk reception to prepasteurizer inlet – CIP done without hot water phase
• From Prepasteurizer outlet to pasteurizer or sterilizer inlet – CIP done without hot water
phase
• From Pasteurizer outlet to fermented product filler machine – CIP done with hot water
phase
• From Sterilizer outlet to dessert filler machine – CIP done with hot water phase
Prepasteurizer, pasteurizer and sterilizer have their own independent cleaning which will be described
in each module specification.
1.3. RESPONSABILITIES
The Industrial Management teams are responsible for the implementation of this specification.
It must be implemented in all newly-built plants.
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1.4. RELATED DOCUMENTS

This document is related to:
• DEP-SP-ENG-001, Rules to organize a plant into entities – Standard to classify and identify the
equipment
• DEP-SP-ENG-002, Control of sanitary states of process equipment.
• DEP-SP-ENG-003, Standard AutoCAD symbols - Process valves and pumps
• DEP-SP-ENG-004, Control of production states of process equipment.
• NEPTUNE : Guideline on cleaning and sanitation (internal document)

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2. STANDARD FLOW DIAGRAM
2.1. DESIGN SELECTED

Refer to file: DEP-SP-CIP-001_E.dwg
The attached drawing shows a CIP unit with 3 distribution lines. This drawing is extendable to more lines. Typically, number of lines is between 2 and 12.
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2.2. THE FLOW DIAGRAM AND POSSIBLE VARIATION
The flow diagram definition is based on a functional analysis, which evaluate the added value and cost
of each variation. This analysis is an internal document.
2.2.1. Basic design

The CIP unit is divided into modules:
• Acid tank
• Soda tank
• Fresh water tank
• Recovered water tank
• Hot water tank
• Each Distribution lines
The order of the modules into the unit can be the following:
FROM PROCESS
EQUIPMENT
TO PROCESS
EQUIPMENT
1 2 3 4 5
- Fresh Water Tank, Acid Tank, Soda Tank, Recovered Water Tank and Hot Water Tank;
The order of tanks can be changed as far as Fresh Water Tank or Hot Water Tank is in first position to
ensure that at the end of the cleaning the CIP collector is rinsed with at least fresh water.
• Mixes between different supply lines and tanks must be avoided by using mixproof valves.
The return lines of the CIP tanks must be equipped with mixproof valves for hot water and single seat
valves for acid, caustic and recovery water. By using of mixproof valves it is possible to prevent
mixing of CIP solutions between CIP tanks and to protect the fresh water used for final rinsing and hot
water during sanitation. In addition, the consumption of CIP solution can be optimized, too.
As these valves will not in contact with product, so it is not necessary to clean the leakage chamber.
• The CIP unit cleans equipment by controlling flow rate, temperature, time and concentration of
cleaning phases.
• Flow rate and time can be adjusted to the equipment.
• Temperature and concentration are the same for all cleanings.
• Each equipment is connected to one distribution line.
• Each line can only clean one circuit at the same time.
• More than one distribution line can work at the same time.
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• Return lines are equipped with conductivity-meters. The measure of conductivity makes the start of
timer for the cleaning phase possible and manage to recover the cleaning solutions.
• Return lines must be equipped with temperature transmitters. The temperature control will authorize
the start of timer for the cleaning phase and manage to recover the cleaning solutions.
• A flowmeter must be installed in return line to measure the flow in return and the volume of recovered
solutions.
• A filter in supply line must be installed to protect the equipment from foreign bodies: mechanical
particles, stones being created in the soda tank. Filters will not have any automatic by-pass.
Recommended grid mesh is 0.5 mm.
• Conductivity meter should be installed in return line of the condense in order to detect any leak on the
tubular heat exchanger installed in the recirculation loop and to prevent any damage in the boiler
hereby.
2.2.2. Water addition
The efficiency of preparation of cleaning solution can be increased by adding water directly into the
recirculation loop before the heat exchanger. In this case, it is necessary to install conductivity meter
before water addition. Physical break between the water line and the recirculation loop must be
assured.
2.2.3. Filters unit in return lines
Filters should be installed in return line to protect the CIP tank from particles or other solids
transported by the CIP flow especially in return lines cleaning filling fruit mixture.
The recommended grid mesh is 0,5 mm. Take care of installing a by-pass valve controlled by level
sensors installed in the filtering box.
The filter must be by-passed during first rinsing since solutions will be drained.
2.2.4. Flow rate during cleaning

The pump capacity in supply an return line must be defined according to
• the needed flow for pipelines,
• pressure needed in spray balls,
• and estimated maximum pressure loss on circuits.
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♦ Pipelines
The flow must ensure the efficient mechanical action of cleaning solutions being one the four key
parameters for cleaning efficiency.
The flow must be created strong turbulence in the pipelines to be efficient during cleaning.
The turbulence depends on the following parameters:
- fluid characteristics (density, viscosity at certain temperature)
- velocity
- and the internal pipe diameter.
As the fluid parameters and the pipe diameters are fix, the needed flow rate will be achieved by the
velocity (or flow) ensured by the CIP supply and return pumps.
Target for the velocity recommended by NEPTUNE guideline is between 1,5 m/s and 2 m/s. These
values assure efficient mechanical action in most common pipe diameters. Considering the
differences in pipe diameters of a cleaning circuit, it is recommended to precise these values
considering the turbulence, defined by Reynolds number.
The following chart shows the flow rates recommended to ensure efficient mechanical action in
different diameters:
DIN SMS Turbulence

Diameter Diameter Speed Flow rate Diameter Speed Flow rate
DN DN
(inches) int. (m/s) (m3/h) int. (m/s) (m3/h) Re
1 25 25 2,26 4 25 23 2,47 3,7 57000
1 1/2 40 40 2,21 10 38 36 2,45 9 88000
2 50 50 1,98 14 51 48.5 2,04 13,5 99000
2 1/2 65 65 1,67 20 63 60.5 1,83 19 108000
For largest diameters turbulance is reached even with less speed than 1,5 m/s. For example, in 4” we
have a high turbulence with 1,24 m/s which corresponds to 35 m3/h
High turbulence, mesured by Reynolds number, can be reach in large diameters even with less
velocity than 1,5 m/s. Following chart shows flow rates recommended for 3” and 4” diameter.
DIN SMS Turbulence

Diameter Diameter Speed Flow rate Diameter Speed Flow rate
DN DN
(inches) int. (m/s) (m3/h) int. (m/s) (m3/h) Re
3 80 80 1,49 27 76 72.8 1,61 24 117000
4 100 100 1,24 35 104 100 1,24 35 123000
Re=(velocity*diameter*density)/dynamic viscosity
Important remarks:
- These data are based on experiences after visual check of the pipes following the cleaning.
- Especially in case of mixproof valve manifolds installed in tank outlet, the needed CIP pressure
for efficient cleaning of the seats and leakage chambers of the valves by independent plug-lifting,
it is necessary to install a dedicated CIP inlet for cleaning this part.
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Concerning the collector (product outlet path in tanks) and valves manifold, please refer to Ultra Clean
Tank specification, DEP-SP-TAN-001.
♦ Spray balls in tanks
Flow rate or pressure of CIP solutions has to be compliant with the recommendations given by tanks
suppliers to each type of spray balls.
2.2.5. : Chemical sanitation
In the hot water tank or in the acid tank when the hot water tank doesn’t exist, it is possible to put an
injection of a chemical solution. This variation is used to prepare the installation to do the chemical
sanitation of the equipment as a cleaning option. In this case is necessary to install a pump to push the
chemical solution and a vessel above the tank to dose the chemical solution.
Chemical sanitation can be done in line without a buffer tank. The chemical solution is directly
injected in supply lines of CIP station. A flowmeter has to be installed in supply line of chemical
solution and connect to flow meter in water supply.
2.2.6. Alternative : Rotation of solutions to increase the availability of the cip unit
If the time of self-clean of a CIP unit reduces the availability of production lines used full time (e.g. 7
production days/week), a CIP unit with rotating cleaning solutions needs to be implemented. The
standard CIP module does not use this functionality.
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Two options for the self-cleaning of the CIP unit:
1. Option 1 consists in emptying one CIP tank to the drain and cleaning it with the other CIP
solutions. This “classical” option is used in most of Danone plants.
Refer to point 4.5 for details.
2. Option 2 is the “CIP unit with rotating cleaning solutions”.
This option is recommended when it is necessary to increase the availability of the CIP unit
(production lines used full time).
Principles of a CIP unit with rotating solutions:
The cycle of rotation of cleaning solutions is automatically defined and monitored.

The operator triggers the rotation of solutions.
Initial conditions required:
- availability of the line for the transfer of the cleaning solutions from a CIP tank to another.
- availability of the line for the rinsing of tanks.
Operating principle:
1. The recovered water tank (tank n°. 1) is completely emptied,
2. The previous recovered water tank (tank n°. 1) is rinsed with lost solution of caustic soda,
3. The caustic soda solution is transferred to tank n°1 from tank n°2,
4. The caustic soda tank (tank n°. 2) is completely emptied,
5. The previous caustic soda tank (tank n°. 2) is rinsed with lost solution of acid (sent to drain),
6. The acid solution is transferred to tank n°. 2 from tank n°. 3,
7. The acid tank (tank n°. 3), is completely emptied,
8. The previous acid tank (tank n°. 3) is rinsed with lost solution of fresh water,
9. The solution of sanitation water is transferred to tank n°. 3 from tank n°. 4,
10. Tank n°. 4 becomes the recovered water tank.
Advantages (+) / Disadvantages (-) of this option:

• + increase of the availability of the CIP unit (cleaning of production lines possible without
stopping the CIP unit …)
• + Regular and efficient cleaning of the tanks of the cleaning unit
• - For the human safety, it is mandatory to set up, on site, a means of identification of the
solutions contained in the tanks (color code).
• - Cost of the station is bigger, because all the tanks, except the fresh water tank, are designed
as the hot water tank and with the injection of two concentrate, to permit to prepare soda or acid
Remark: the rotation time decreases if the use of the CIP unit increases. During the entire cycle of
rotation of the solutions, water is no longer recovered (there is no longer a recovered-water tank).
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2.2.7. Recovery of the hot water contained in the CIP lines to save energy
At the end of a cleaning program (last phase is hot water), it is possible to recover the hot
water contained in the CIP lines in order to save heating energy. Cost savings are bigger in
case of long CIP lines containing a lot of cleaning solution.
The energy saving procedure proposes to recover hot water by pushing hot water contained in
CIP line with fresh water. For sanitary reason, pushing through the process equipment is
forbidden. Closed loop has to exist after the last process equipment on each CIP line for this
recovery.
Procedure when using additional closed loop: At the end of the CIP program, make a water
flush of the CIP line – separated from the process and packing circuit by physical break - and
recover the hot water in the hot water tank.
Caution: if a cleaning program of process equipment is aborted, it is required to clean the CIP line
before sanitizing another process equipment by the same CIP line.
The cleaning return (water rinsing + Soda + soda rinsing) has to be done through the additional closed
loop in order to prevent pollution of process equipment (cleaning solution can contain organic matter).
In all case, periodic cleaning of closed loop line is required.
CIP LINE
CIP inlet CIP outlet
Process
Physical equipment
Break Process
equipment
Traditional Design
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CIP LINE CIP outlet

CIP inlet
Process
Physical equipment
Break Process
equipment
Additional closed Loop line

New design with closed loop for hot water recovery
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3. GENERAL PRINCIPLES
3.1. STATE MANAGEMENT
The CIP unit is composed by several equipment:
• fresh water tank
• recovery water tank
• soda tank
• acid tank
• hot water tank
• CIP lines
For each equipment, sanitary and production states have to be controlled.
3.1.1. Sanitary state management
Cleaning solution Cleanliness state

fresh water tank Clean
recovered water tank NOT clean
soda tank NOT clean
acid tank NOT clean
hot water tank Clean
CIP line cleanliness state is the same as the content cleaning solution.
Particular attention should be taken on sanitary state management for CIP lines. Initial
condition for sanitation of a process equipment is “equipment AND CIP line are clean”.
It is forbidden to start a sanitation if there is recovered water or soda or acid in CIP line.
3.1.2. Production state management

They are defined in the Specification DEP-SP-ENG-004 “Control of production states of process
equipment”.
3.1.3. General production states :

1. Standby (prepared)
2. Undergoing Maintenance
3. On “running functions” (refer to the list of detailed running functions hereafter) (*)
4. End of run
5. In fault
6. Pause
3.1.4. (*) Detailed Running functions list for CIP Tank :

The running function can take the following values
• Function : Preparation of Cleaning solutions
• Function : Cleaning of process equipment
• Function : Self-Cleaning of CIP tanks
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3.1.5. Specific production and sanitary states for each CIP tank module :
- “Prepared state” means that the cleaning solution in the corresponding CIP tank module is ready to
be used. In general, a tank is prepared when level; concentration and temperature are between limits.
- “Dirty state»: means that the CIP tank has to be cleaned. The dirty state depends on timer and
maximum number of cleanings.
CLEAN
End of maximum_time_to_do_self_cleaning timer
OR End of self
maximum_number_of_cleanings_to_self_cleaning cleaning
reached
DIRTY
Level, temperature or
PREPARED Level, temperature and
concentration are out of limits concentration are under limits
OR AND
Tank is dirty Tank is not dirty
OR AND
Number of simultaneous Number of simultaneous
running cleanings is over running cleanings is over
limit
NOT limit
PREPARED
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Module Conditions to set “prepared state” Conditions to reset “prepared state”

Fresh water • LSMxx62 is covered and, • LSLxx61 is uncovered or,
Tank • Preparation program running • Preparation program stopped
Caustic Soda • LSMxx62 is covered and, • LSLxx61 is uncovered or
Tank • Soda_temp_limit – • TTxx61 < soda_temp_limit -
T_soda_tolerance_inf < TTxx61 < T_soda_tolerance_inf or
soda_temp_limit + T_soda_tolerance_sup • TTxx61> soda_temp_limit +
and, T_soda_tolerance_sup or
• Soda_conductivity_limit – • CTxx63 < soda_conductivity_limit -
C_soda_tolerance_inf < CTxx63 < C_soda_tolerance_inf or
soda_conductivity_limit + • CTxx63 > soda_conductivity_limit +
C_soda_tolerance_sup and, C_soda_tolerance_sup or,
• Preparation program running and • Preparation program stopped or,
• Tank is not dirty • Tank is dirty
Acid tank • LSMxx62 is covered and • LSLxx61 is uncovered or

• acid_temp_limit - T_acid_tolerance_inf • TTxx61 < acid_temp_limit -
< TTxx61 < acid_temp_limit + T_acid_tolerance_inf or
T_acid_tolerance_sup and, • TTxx61> acid_temp_limit +
• acid_conductivity_limit – T_acid_tolerance_sup or
C_acid_tolerance_inf < CTxx63 < • CTxx63 < acid_conductivity_limit -
acid_conductivity_limit + C_acid_tolerance_inf or
C_acid_tolerance_sup and, • CTxx63 > acid_conductivity_limit +
• Preparation program running and, C_acid_tolerance_sup or,
• Tank is not dirty • Preparation program stopped or,
• Tank is dirty
Recovered • LSL1261 is covered and • Preparation program stopped or,
water Tank • Preparation program running and, • Tank is dirty
• Tank is not dirty
Hot Water • LSMxx62 is covered and • LSLxx61 is uncovered or
Tank • Hot_water_temp_limit - • TTxx61 < hot_water_temp_limit –
T_hot_water_tolerance_inf < TTxx61 < T_hot_water_tolerance_inf or
hot_water_temp_limit + • TTxx61> hot_water_temp_limit +
T_hot_water_tolerance_sup and, T_hot_water_tolerance_sup or
• hot_water_conductivity_limit – • CTxx63 <
C_hot_water_tolerance_inf < CTxx63 < hot_water_conductivity_limit -
hot_water_conductivity_limit + C_hot_water_tolerance_inf or
C_hot_water_tolerance_sup and, • CTxx63 >
• Preparation program running and, hot_water_conductivity_limit +
• Tank is not dirty C_hot_water_tolerance_sup or,
• Preparation program stopped or,
• Tank is dirty
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3.1.6. Specific production states of CIP lines:
- “Supply state”: the CIP line supplies a cleaning solution from a CIP tank to the installation to be
cleaned without returning the cleaning solution to the CIP tanks (no recovery of cleaning
solutions).
Example: after first rinse of the installation with water, the caustic soda is send to the installation
to be cleaned and the CIP return line is open to the drain.
The caustic soda will be recovered in the caustic soda tank of the CIP unit as soon as the
temperature and the conductivity are correct. At this time, the CIP line goes to a “balanced state”.
- “Balanced state”: the CIP line supplies cleaning solution to the installation to be cleaned and
return the cleaning solution to the CIP tank.
This is the normal state during the cleaning of installations.
- “Return state”: cleaning solution pushes another cleaning solution through a CIP line and returns
it to the CIP tank.
Example: at the end of the acid phase, acid is pushed with fresh water. To save cleaning solution,
the remaining acid in the CIP circuit returns to the acid tank of the CIP unit.
Then, the water goes the recovered water tank of the CIP unit (balanced state).
3.2. PERSONNEL AND PROPERTY SAFETY
An emergency push button (PB) has to be installed in the unit. When this PB is pressed, all the
running functions are set to fault position.
It is necessary to install a shower for the security of people in each CIP unit area and use the safety
clothing when it is necessary to work in the CIP unit area.
If the CIP unit is into the building, it is necessary to drive the CIP vents to the exterior.
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4. DESCRIPTION OF FUNCTIONS
The principal CIP unit functions are:
- Preparation of Cleaning solutions : permanent control of temperature, concentration and level in

CIP tanks
- recovered water tank preparation program
- fresh water tank preparation program
- acid tank preparation program
- soda tank preparation program
- hot water tank preparation program
- CIP unit self-cleaning
- Cleaning control of a process equipment

- temperature
- flow
- duration
- concentration
- pressure
PREREQUISITE:
Unless specified, there are timeout on all level switches. Timeout are adjustable for each transmitter.
4.1. CIP PRINCIPLES COMMON TO EACH FUNCTION
4.1.1. Maximum filling and heating time of CIP tanks

The following CIP tanks needs make-up water:
- fresh water tank
- hot water tank
- soda and acid tank
Water flow rate is checked during the filling operations to ensure continuous water supply.
* Maximum filling time:

Filling with a water flow rate below the threshold is allowed, but an alarm is triggered during a
predetermined time. After that time, if the filling is not finished, the cleaning solution preparation
program stops with a fault; the operator is informed with a fault message.
The maximum filling time control is enforced in two different situations: filling starting with an
empty tank and normal filling operation.
* Maximum heating time:

In the same way as filling time, a maximum heating time of cleaning solution in the CIP tanks is
monitored.
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4.1.2. Parameters to control for cleaning solutions preparation (soda, acid and hot water tanks).
The temperature and conductivity of CIP solution tanks are controlled in the preparation programs.
In order to save disponibility avaibility of the CIP unit, automatic actions have to be taken before
being out of range.
In addition of states conditions described in paragraph 3.1.3:
- Cleaning solutions can be used when temperature and conductivity are between minimum and
maximum “prepared value”.
- When temperature or conductivity is below “Low preparation threshold value” or higher than
“High preparation threshold value” solutions can be used but automatic action are launched to
reach the set point.
See the following picture for a description of ranges, and the derive actions and state of CIP tanks.
Automatique actions depending on

Tank is not in prepared state
temperature and conductivity
ERR
OR
Maximum 'Prepared' value

s OK ing
V alue Warn
Range of High Preparation Threshold value
temperature K
and es O
Valu
conductivity Preparation set-point
values for OK
Va l ue s
« prepared Low Preparation Threshold value
state » n t
s OK e t-poi
V alue ver s
Reco
Minimum 'Prepared' value
Tank is not in prepared state
State of equipement depending on

temperature and conductivity
4.1.3. Optimisation of cleaning solutions consumption

The objective of this optimisation is:
• to increase availability of CIP unit : to be sure that there is enough solution in CIP tanks to
clean equipment
• to increase recovery of solution: control maximum high level in CIP tanks to recover all
cleaning solutions.
In order to optimise the cleaning solutions consumption, the volume of recovered solution is
estimated to prevent over consumption of fresh solutions
The volume of the CIP tanks will be estimated by means of a litre count. The amount of litres of
solution used for cleanings will be subtracted from the amount of water supplied through the water
line. This data will be used in further calculations, such as reports and consumption.
Refer to following chapter as an example of methodology save cleaning solutions.
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To extract cleaning solution from a CIP tank, three different level points will be considered:
- Security Level (analogue threshold*): under this limit, a new cleaning phase will not be
allowed to start. When the tank recovers the security level, the new phase will be able to start
automatically.
- Low security Level (analogue threshold*): below this point, all the cleanings in supply
state will pause.
- Level Switch Low (digital transmitter): the CIP tank is empty and all the cleanings using
this tank must stopped except the lines in return state.
*Analogue level in CIP tanks is measured by level transmitters
The following chart gives an example of four CIP lines in different states.
This chart indicates how are estimated the cleaning solutions supply in the CIP lines and the return
volume to the CIP tank.
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Amount of solution recovered in line 4: 0 l
Network
Water Amount of solution recovered in line 1: 0 l
CIP Line 3 in returning state: Cleaning of a machine

Empty level
CIP Line 1 in supplying state:Cleaning of a line
CIP Line 2 in balance state:Cleaning of a tank

4630 l
Amount of solution in the CIP lines

3370 l
Tank capacity: 40000 liters
CIP Line 4 inactive

Tank Estimated level
32000 l
Security Level : Don't Start new
cleaning phases
Low security Level : Pause the programs
in supplying state
Level Switch Low : Stop all the cleaning
programs except lines in returning state
Amount of solution supplied in line 1: 420 l
Amount of solution supplied in line 2: 3240 l
Amount of solution supplied en line 3: 2120 l
Amount of solution supplied in line 4: 0l
Amount of solution in the CIP lines

CIP line 1: solution supplied - solution recovered = 420 l - 0 l = 420 l - Litres supplied into the line for pushing purposes
CIP line 2: solution supplied - solution recovered = 3240 l - 1290 l = 1950 l - Litres contained in the whole circuit
CIP line 3: solution supplied - solution recovered = 2120 l -1120 l = 1000 l - Litres left to recover in current push out
Total = 420 l + 1950 l + 1000 l = 3370 l
Tank expected level = Amount of solution in the CIP lines + Tank Estimated Level = 3370 l + 32000 l = 35370 l
Water required = Tank capacity - Tank expected level = 40000 l - 35370 l = 4630 l
A filling operation will be performed every time a phase ends to recover the estimated loss of product in that cleaning.
The aim is to achieve an empty level of 0 litres before the begining of any new cleaning phase
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4.2. RECOVERED WATER TANK PREPARATION PROGRAM
4.2.1. Description
This program maintains the recovered water tank ready to be used for rinsing purposes in the cleaning
programs. The program maintains a sufficient level in the tank by water addition.
The program is running continuously except during maintenance and self-cleaning.
4.2.2. Program conditions
INITIAL CONDITIONS BLOCKING CONDITIONS FINAL CONDITIONS

• Recovered water tank is • One device on flow is in not in • Preparation program ended
waiting automatic operation or in fault by operator request
• Recovered water tank is not • One device adjacent to the
dirty flow is not controlled in good
• All devices on flow are in position
automatic operation, unmasked • Emergency PB activated
faults and not in fault • PLC fault (hardware or
• All devices adjacent to the software)
flow are controlled in good
position
• Emergency PB not activated
• PLC in good operation
(hardware and software)
4.2.3. Grafcet
START on
Operator
request
Operator request
Tank level
holding
Stop request
END
4.2.4. List of parameters to control:

Parameter Type Meaning
Conductivity_of_recovered_water_tank Conductivity (mS) Maximum conductivity to recover
Temperature limit to allow recovery of Temperature (°C) Under this temperature,
hot water
Time_to_carry_out_a_new_self-cleaning Timer (s)
Version E
4.3. FRESH WATER TANK PREPARATION PROGRAM
4.3.1. Description
This program maintains the fresh water tank ready to be used for rinsing purposes in the cleaning
programs. The program maintains a sufficient level in the tank by water addition.

• Fresh water tank is waiting • One device on flow is in not in • Preparation program ended
• All devices on flow are in automatic operation or in fault by operator request
automatic operation, unmasked • One device adjacent to the flow
faults and not in fault is not controlled in good position
• All devices adjacent to the • Emergency PB activated
flow are controlled in good • PLC fault (hardware or
position software)
• Emergency PB not activated • Maximum_time_of_filling
• PLC in good operation finished
(hardware and software) • Maximum_time_to_recover_lev
el_setpoint finished
• Water flow FTxx01 <
minimum_water_flow during
filling
4.3.3. Grafcet
During filling, the valve AV1161 on water line is open.
START on
Operator
request
Operator request
Filling
LSMxx62 uncovered LSHxx63 covered
Tank level
holding
Stop request
END
Version E

Maximum_time_of_filling Timer (min) Time allowed to fill the tank when it
is empty
Maximum_time_to_recover_level_setpoint Timer (min) Time allowed to fill the tank after
LSM uncovered
Minimum_volume_to_start_new_cleaning_ph Volume (l.)
ases
Volume_to_pause_the_programs_in_supplyin Volume (l.)
g_state
Liters_for_minimum_level Volume (l.) Tank level to digital minimum level
Liters_for_medium_level Volume (l.) Tank level to digital medium level
Liters_for_maximum_level Volume (l.) Tank level to digital maximum level
Maximum_time_of_water_addition Timer (min) Maximum time of water addition to
begin to fill another tank
Maximum_volume_of_water_addition Volume (l.) Maximum volume of water addition
to begin to fill another tank
Minimum_water_flow Flow (l / h) Minimum requested to check that
water inlet is operational
Version E
4.4. SODA TANK / ACID TANK / HOT WATER TANK PREPARATION PROGRAM
4.4.1. Description
This program is applicable for preparation of
1. the tank of hot water, or
2. tank of acidified water, and
3. the tank of acid, and
4. the tank of soda.
For each tank, it does exist different programs of preparation.
This program controls the “prepared” states of the tanks by adjusting level, temperature and
concentration.

• Tank is not dirty • One device on flow is in not in • Preparation program
• Tank is waiting automatic operation or in fault ended by operator request
• All devices on flow are in • One device adjacent to the flow is
automatic operation, not controlled in good position
unmasked faults and not in • Emergency PB activated
fault • PLC fault (hardware or software)
• All devices adjacent to the • Water flow FTxx01 <
flow are controlled in good minimum_water_flow during filling
position • Maximum_filling_time reached
• Emergency PB not • Maximum_time_to_recover_level_se
activated tpoint reached
• PLC in good operation • Maximum_dosing_time reached
(hardware and software) • Maximum_heating_time reached
• Maximum_time_to_recover_temp_se
tpoint reached
• No concentrates flow (external
condition)
• Maximum_time_to_recover_cond_se
tpoint reached
• Maximum_time_to_do_self_cleaning
reached
Version E
4.4.3. Grafcet
START
Operator request
Filling
Tank Empty
or CIP phase Tank full
finished
Heating and
dosage
Temperature or
Conductivity NOT in
Temperature and
set points tolerance
Conductivity in set
points tolerance
Prepared
state holding
Stop request
END
When a CIP tank is not used (no cleaning program using the solution of this tank), the tank is filled to
the maximum tank level.
The estimated amount of water to add will be: 'tank capacity' minus 'estimated level of the tank' minus
'the estimated solution still in the lines'. This amount should correspond to the estimated loss of
cleaning solution in the last cleaning phase.
While filling, the heating regulation is activated. The tank will be considered filled if the maximum
level is maintained for a predetermined time (timeout) or when the calculated amount has been
incorporated.
A cycle of recirculation (loop on the CIP tank) will be carried out at a determined frequency to check
conductivity of the solution in the CIP tank.
If either the conductivity or the temperature fall below the low threshold values, the concentrated acid
or soda addition and/or the heating are activated to get the preparation set point. At this time, the
filling in progress stops. When the preparation values are achieved again, the filling operation
continues with a recalculated amount.
Version E

Solution_temp_setpoint Temperature (°C)
Threshold_variance_allowed_for_the_temperature_fro Temperature (°C)
m_the_setpoint
Prepared_variance_allowed_for_the_temperature_from Temperature (°C)
_the_setpoint
Recovering_variance_allowed_for_the_temperature_fro Temperature (°C) To define the temperature to start to
m_the_setpoint recovering
Solution_conductivity_setpoint Conductivity (mS)
Threshold_variance_allowed_for_the_conductivity_fro Conductivity (mS)
m_the_setpoint
Prepared_variance_allowed_for_the_conducitivity_fro Conductivity (mS)
m_the_setpoint
Recovering_variance_allowed_for_the_conducitivity_fr Conductivity (mS) To define the conductivity to start to
om_the_setpoint recovering
Conductivity_deviation_to fine_adjustment Conductivity (mS) Until this value the dosage is in
continuous after in cycles
Time_of_dosage_cycle Timer (s)
Time_of_awaiting_between_dosage_cycles Timer (s)
Recirculation_time Timer (s)
Time_without_recirculation Timer (s)
Maximum_dosage_time Timer (s) If the conductivity is not reached an
error is generated
Maximum_time_to_recover_cond_setpoint Timer (s)
Maximum_time_of_solution_addition Maximum time of solution addition to
begin to dosage another tank
Maximum_filling_time Timer (s) If the level setpoint is not reached, an
error is generated
Maximum_time_to_recover_level_setpoint Timer (s)
Minimum_volume_to_start_new_cleanings_phases Volume (l)
Volume_to_pause_programs_in_supplying_state Volume (l)
Maximum_temperature_in recirculation_loop Temperature (°C)
Maximum_heating_time Timer (s) Tank heated from initial conditions
Maximum_time_to_recover_temp_setpoint Timer (s)
Maximum_time_to_do_self_cleaning Timer (d)
Temperature_variation_between_tank_and_loop Temperature (°C) Recommended to adjust the
temperature control set point upper to
the objective to be sure to get it
Liters_for_minimum_level Volume (l) Tank level to digital minimum level
Liters_for_medium_level Volume (l) Tank level to digital medium level
Liters_for_maximum_level Volume (l) Tank level to digital maximum level
Maximum_time_of_water_addition Timer (min) Maximum time of water addition to
Maximum_volume_of_water_addition Volume (l) Maximum volume of water addition to
Minimum_water_flow Flow (l/h) Minimum requested to check that
water inlet is operational
Version E
4.5. SELF-CLEANING PROGRAM
4.5.1. Description
This program cleans the tanks of the own CIP unit.
All tanks are to be cleaned except fresh water tank.
The cleaning of each tank is done by the following way:

1. Emptying the tank to clean to the drain
2. Cleaning with cleaning solutions (rinsing, soda, rinsing, acid, rinsing) by using a short loop on
CIP line 1. Soda tank does not use soda for self cleaning, Acid tank does not use acid for self-
cleaning.
Cleanliness state of each tank is control by timers and number of cleanings:
CLEAN
End of maximum_time_to_do_self_cleaning timer
OR End of self
maximum_number_of_cleanings_to_self_cleaning cleaning
reached
DIRTY
• At the beginning of the self cleaning the maximum_time_to_do_self_cleaning timer is
reseated
• At the end of the self cleaning the maximum_time_to_do_self_cleaning timer is started and :
maximum_number_of_cleanings_to_self_cleaning is reseated

INITIAL CONDITIONS BLOCKING CONDITIONS FINAL
CONDITIONS
• CIP tank to clean in waiting • One device on flow is in not in automatic • Self-cleaning ended
• Line 1 is waiting operation or in fault by the program (see
• All devices on flow are in • One device adjacent to the flow is not final conditions in the
automatic operation, controlled in good position grafcet)
unmasked faults and not in • Emergency PB activated • Cleaning program
fault • PLC in fault (hardware or software) ended by operator
• All devices adjacent to the • Maximum_time_to_tank_drainage reached request
flow are controlled in good • Maximum_time_to_solution_drainage
position reached
• Emergency PB not • Maximum_time_without_pressure reached
activated
• PLC in good operation
(hardware and software)
Version E
4.5.3. Grafcet
Grafcet shows cleaning phases (soda, acid…)
During each phase (soda, acid…), two cleaning paths needs to be done: through the spray-
ball and through the solution inlet.
START 1 2
Tank Drainage Alkali Drainage Acid Drainage
Tank empty Tank empty Tank empty
First Rinsing Medium Rinsing Last Rinsing

Filling Filling Filling
Tank with n Litres Tank with n Liters Tank with n Liters
First Rinsing Medium Rinsing

Last Rinsing
First Rinsing Medium Rinsing Last Rinsing

Time End Time End Time End
First Rinsing Medium Rinsing Acid Tank Last Rinsing

Drainage Alkali Tank Drainage cleaning Drainage
cleaning
Tank empty
Tank empty Tank empty
Alkali Filling Acid Filling END
Tank with n Liters Tank with n Liters
Alkali Acid
Alkali Time End Acid Time End
1 2
INCORPORER
Acid_liters Volume (l) Quantity to fill in the acid filling step
Soda_liters Volume (l) Quantity to fill in the soda filling step
Water_liters Volume (l) Quantity to fill in the medium or final rinsing
filling step
Maximum_time_to_tank_drainage Timer (s) Security time
First_rinsing_time Timer (s) Duration of the step
Medium_rinsing_time Timer (s) Duration of the step
Last_rinsing_time Timer (s) Duration of the step
Soda_time Timer (s) Duration of the step
Acid_time Timer (s) Duration of the step
Maximum_time_to_solution_drainage Timer (s) Security time for first rinsing, medium rinsing,
Version E
last rinsing, soda and acid drainage

Emptying_time_without_pump Timer (s) Extra time to be sure that the tank is emptied for
the tank drainage collector
Time_path_n Timer (s) Duration of phase on path n
Flow_path_n Flow (l/h) Flow set point controlled by FTx101
Minimum_pressure_path_n Pressure Adjustable minimum pressure required
(bar) depending on path
Maximum_time_without_pressure Timer (s) Pressure checked on PT8101 to guarantee
cleaning flow through spray balls
Version E
4.6. CLEANING CONTROL OF A PROCESS EQUIPMENT
4.6.1. Description
This program cleans the parts of the process installation or filler machines selected through CIP unit
and distribution line X.
All equipment has the same cleaning program structure.
Before starting the program, a selection will be available to choose the type of CIP program to
perform.
4.6.2. Cleaning principles.

Cleaning programs are managed by the PLC of CIP unit. Process PLC is working as a “slave” during
the cleaning of the equipment.
The effective cleaning of equipment is achieved if the TACT parameters are respected.
(TACT parameters: Temperature, Mechanical Action, Concentration of solutions and Time)
The effective cleaning time is counted when the 3 parameters, temperature, concentration and flow
rate reach the thresholds. These thresholds must be compliant with the Quality Assurance
Specification.
Effective cleaning time recommended is presented in the following chart:
SODA ACID
Spray balls 15 min 7 min
Pipelines 6 min 3 min
Control points:
- temperature and concentration are measured on the return CIP lines
- flow rate is measured on supply lines
NB: the flow meter on the return line is required to guarantee the integrity of the cleaning paths
(no return means leakage or loss of solution to drain).
In the case of circuits with more than one path, effective cleaning time must be defined and achieved
for each path of the circuit. Total cleaning time on each flow path can be achieved by more cleaning
circles (number of circles: “n”)
1. First rinsing with recovered water:

The step concludes when reaching the cleaning target time or volume of the phase.
2. Soda / acid / hot water flush:

The flush concludes when the conductivity and the temperature on the return line are correct.
3. Soda / acid / hot water phase:

During soda or acid phase, the cleaning time is stopped if the temperature or conductivity on the
return line is not correct or flow rate value in supply line is under the threshold.
After a timeout, if the temperature, concentration or flow is still not correct, the cleaning program
is stopped and a fault informs the operator.
Version E
When restarting, the program will move back to the soda/acid or hot water flush, to ensure the
conditions for a proper cleaning phase.
The step concludes when reaching the cleaning target time of the phase in all paths.
During hot water phase (sanitation), the cleaning program resets the timer if the temperature
and/or the conductivity on the return line are not correct.
4. Fresh water flush:

5. The step concludes when the conductivity on the return line is correct.
6. Fresh water phase:

The program stops the phase time if the return conductivity value is too high (above the soda or
acid threshold recovery point).
When restarting, the program will move back to the soda/acid or hot water flush, to ensure the
conditions for a proper cleaning phase.
The step concludes when reaching the cleaning target time or volume of the phase.
Lifting in mixprof valves must be done during each phase except during first rinsing and sanitation
with hot water. Duration of liftings to be adjusted during the start up (approx. 2 seconds).

• First tank used by cleaning • Cleaning solutions of the tank • Cleaning program
program is prepared. Prepared state used by cleaning program not completed
is controlled before using next tanks. prepared(1) • Cleaning program ended
• All CIP tanks to use during the • One device on flow is in not in by operator request
cleaning program are clean automatic operation or in fault
• First tank used by cleaning • One device adjacent to the flow
program has less cleanings running is not controlled in good position
that numbers of cleaning at the same • Emergency PB activated
time parameterized for this tank • PLC fault (hardware or
• CIP line is waiting software)
• Equipment selected to be cleaned • In case of filling machine or an
is in waiting and empty (external equipment that needs CIP
condition) (filling machine has to be confirmation, it is not in CIP mode
in CIP mode) • Time_maximum_push_step
• All devices on flow are in reached
automatic operation, unmasked • Maximum_time_without_return
faults and not in fault _temperature under limit exceeded
• All devices adjacent to the flow • Maximum_time_without_return
are controlled in good position _conductivity under limit exceeded
• Emergency PB not activated • Maximum_time_without_return
• PLC in good operation (hardware _flow under limit exceeded
and software) • Maximum_time_without_feed_f
• Level in the first CIP tank to use < low under limit exceeded
Minimum_volume_to_start_new_cle • Maximum_time_without_pressu
anings_phases re under limit exceeded
• Maximum_time_for_emptying_
steps reached
• Level in the CIP tank to use <
Minimum_volume_to_start_new_c
Version E
leanings_phases
• Man hole of equipment in
cleaning not closed
(1)
The lost of prepared state due to the timer of clean state is not a blocking conditions during a
cleaning program.
4.6.4. Communication between CIP unit and equipment to clean

This part is very important to control cleanings by good coordination between solutions sent by CIP
unit and position of the equipment that receive solutions.
Communications with other equipment are described in each equipment module specification.
The CIP unit sends to the module equipment to clean the following information, all the time unless
specified in comment.
INFORMATION SENT FROM CIP COMMENT

UNIT TO EQUIPMENT
Cleaning running status To inform that the cleaning is in operation
Flow running
CIP in fault To inform that the CIP is stopped for a default
Path request number x To ask to the equipment to open and close some valves to direct
cleaning solutions through different paths. Communication
specified in steps if required
Flip request on valve group y To ask to the equipment to flip at the same time some valves.
Groups are defined in the equipment specification
Pump request To ask to the pump on the return line to start/stop. This pump is
common to few tanks and belongs to the return line equipment
The module equipment sends to the CIP unit the following information, all the time unless specified in
comment
INFORMATION SENT FROM COMMENT

EQUIPMENT TO CIP UNIT
Equipment on path x The path number is set when all valves are in the position defined
in the step.
Flip done on valves group y After valves of the group y have flipped (based on limit switches
on valves), acknowledgement is sent. Communication specified
in steps if required
Equipment production states Waiting, running function, fault, maintenance…
Process values requested by the CIP For cleaning a tank, process value required by CIP is tank level
and tank pressure
Pumps state To inform about pump state if it exists to return the CIP solution
(running/stop, fault)
Version E
4.6.5. Types of cleanings programs:

Cleaning function is started by operator. Type of cleaning is chosen according to situation.
The operator has to choose in a list of available cleaning recipes.
The following figure shows the list of cleaning recipes, the solutions used and the order of using
cleaning solutions.
Type Program Solution used RECOVERY SODA FRESH ACID HOT

Number WATER WATER WATER
Type of cleaning
Cleaning 1 CIP type 1 1 2 3, 5 4
Cleaning 2 CIP type 2 1 4 3, 5 2
Cleaning 3 Short CIP type 1 1 2 3
Cleaning + 4 CIP and 1 2 3, 5 4 6
sanitization DESINFECTING type 1
Cleaning + 5 CIP and 1 4 3, 5 2 6
Cleaning + 6 Short CIP and 1 2 3 4
Sanitization 7 DESINFECTING 1
Cleaning 8 RINSING 1
Customized cleanings have to be programmed in case of using additional disinfecting solution

in acid tank. In this case, temperature set point has to be adjusted and frequency of
customized cleanings adjustable.
These additional disinfecting have to be applicable to equipment before last heat treatment.
Cleaning type recommended:

• The standard cleaning recommended are programs number 4 and 6 when it is necessary to do the
sanitation.
• As minimum, one time per week it is recommended to do a cleaning with acid, in this case, it is
recommended to lunch programs 1 or 4 when it is necessary to do the sanitation (the number of
recommended cleanings with acid depends on the equipment and the quality of the water).
• During weekends (Saturday, Sunday), when there is no production, it is recommended to do on
Friday or Saturday the cleaning without sanitation (program 1 or 3), and on the Sunday or
Monday, when the production starts to do the sanitation (program 7).
Version E
4.6.6. Gracet
This grafcet is applicable to all cleaning programs.
START
Operator request
and initial conditions
Waiting
Alkali and/or
Acid cleaning
Only Rinsing Only Hot Water

First Water
Phase
Time and emptying

completed
Not acid in second
Acid in first Not acid in first Not soda position
position position
1 2 3 4
Soda Acid in second position
Acid Push Soda push Acid push Hot Water Push
Hot Water in
Acid on the return Acid on the return Acid on the return return
Soda on the return
Acid Soda Acid Hot Water Phase
End Time
Time and emptying Time and emptying Time and emptying
Desinfection
completed completed completed
Medium Water Medium Water Final Water Push Cooling with

Push Push sterile water
Water on the return Water on the return Water on the return

End time
Medium Water Medium Water Final Water END

Phase Phase Phase
Time and emptying Time and emptying Time and emptying

completed completed completed
Drainage
2 3 4
Not Hot Water End of drainage time

Version E
4.6.7. Management of the return solutions

The management of the cleaning solutions to return to the CIP tanks depends on the conductivity and
temperature.
See in the following chart the destination of the “return solution” when the conductivity and
temperature values are between the different ranges.
Conductivity(mS)
and temperature(°C)
on return line
Soda Soda Acid Acid
Hot Water
Soda recovery limits Acid recovery limits Phase on

return line
Drain Drain Hot Water

recovery limits
Water recovery
Drain Drain Drain
limits
Recovery Recovery
Water Water
CIP Tanks
Recovery-water soda fresh-water acid fresh-water hot-water
• recovery limits on Soda and Acid based on conductivity

• recovery limits on Water based on conductivity
• recovery limits on Hot Water based on temperature
Recovery fresh water after soda phase is not recommended due to risk of cross contamination.
It is no recommended to recover condesate water.
Version E
4.6.8. List of parameters to control for each piece of equipment (cleaning recipe) :
Unless specified, there are timeout on all level switches. Timeout are adjustable for each transmitter.
Parameters Type Meaning

Maximun_cleanings_at_the_same_time Integer Limit of cleanings at the same time
(hydraulic limitation)
Number_of_paths Integer Number of different paths to clean
Flow_Path_n Flow (l/h) Flow for each different path
Minimum_flow_path_n Flow (l/h)
Minimum_pressure_path_n Pressure (bar)
Agitator_activation_time_in_path_n Time (s)
Volume_of_circuit_from_CIP_to_equipment Volume (l.)
Volume_of_circuit_from_equipment_to_CIP Volume (l.)
Time_path_n Timer (s) Duration required to clean path n
Number_of_group_valves_to_flip Integer
Time_before_flip Timer (s)
Time_for_double_seats_cleanings Timer (s) Time to make the cleaning of sampling
valves and mixproof valves
Time_maximum_push_steps Timer (s) Security time duration of push steps
Time_minimum_push_steps Timer (s)
Time_first_rinsing Timer (s) Duration of this phase
Time_soda Timer (s) Duration of this phase
Time_medium_rinsing Timer (s) Duration of this phase
Time_acid Timer (s) Duration of this phase
Time_final_rinsing Timer (s) Duration of this phase
Time_hot_water Timer (s) Duration of this phase
Drainage_time Timer (s) Duration of this phase
Maximum_stop_time_to_go_back_to_push_step Timer (s)
Time_for_drainages_cleaning Timer (s) Time of cleaning of drainage valves
Maximum_time_for_emptying_steps Timer (s)
Time_to_confirm_empty_equipment Timer (s)
Filler_tank_level_to_consider_it_empty Threshold (l)
Cooling_with_sterile_water_time Timer (s)
Soda_conductivity_limit_for_recovery Conductivity (mS)
Soda_conductivity_limit Conductivity (mS)
Soda_temperature_limit_for_recovery Temperature (°C)
Soda_temperature_limit Temperature (°C)
Acid_conductivity_limit_for_recovery Conductivity (mS)
Acid_conductivity_limit Conductivity (mS)
Acid_temperature_limit_for_recovery Conductivity (mS)
Acid_temperature_limit Conductivity (mS)
Hot_water_conductivity_limit_for_recovery Conductivity (mS)
Hot_water_conductivity_limit Conductivity (mS)
Hot_water_temperature_limit_for_recovery Conductivity (mS)
Hot_water_temperature_limit Threshold
Maximum_time_without_return_temperature Timer (s)
Maximum_time_without_return_conductivity Timer (s)
Maximum_time_without_return_flow Timer (s)
Maximum_time_without_pressure Timer (s)
Maximum_time_without_feed_flow Timer (s)
Version E
5. APPENDIX
5.1. HACCP
Refer to attached file: Risk analysis_CIP.xls
The attached document gives an analysis of the main risks identified on CIP unit.
This document does not replace HACCP, which must be carried out taking into consideration the
entire process.
This document is designed to assist the overall HACCP of the process but is not a substitute for it.
Version E
5.2. DEVICE LIST

Type Label Description Recommended model
LSL --LSL—61 Conductive Level transmitter E+H FTL 50H-AGW2AC?G6A + 520011051
LSM -- LSM--62 Conductive Level transmitter Dito LSL--61
LSH --LSH—63 Conductive Level transmitter Dito LSL--61
LT --LT1x61 Level transmitter E+H Deltapilot S DB50L-AC 00 ?? 1 3 E G 30
PT --PT8x01 Pressure transmitter on supply line E+H Cerabar PMP 45-R E1 3P 1 A 1 ?? F
FT --FT8x01 Flow transmitter on supply line E+H Promag 50H ??- ? H 0 A 1 A A 0 A 4 A A
FT --FT8x02 Flow transmitter on return line E+H Promag 50H ??- ? H 0 A 1 A A 0 A 4 A A
FT --FT0201 Flow transmitter on water addition E+H Promag 50H ??- ? H 0 A 1 A A 0 A 4 A A
TT --TT—61 Tank Temperature transmitter E+H Omnigrad TR 45 ?? 5 ? 1 S 2 H A 4 0 0 0
class A
TT --TT—63 Heating Loop Temperature transmitter class A Dito TT--61
TT --TT—01 Supply line Temperature transmitter class A Dito TT--61
CT --CT—63 Heating loop Conductivimeter E+H CLS 52 ? A1 ??? A ? and transmitter CLM 253-ID ? 1 05
CT --CT—01 Return line Conductivimeter Dito CT—63
MV --MV—61 Modulating valve Samson mod. 241-7
AV --AV—01 Mixproof valve GEA KL or KT
type MP2u or 3u Alfa Laval SMP-BC
Definox DCX3 DE
Type MP2u or 3u Alfa Laval SMP-BC
Definox DCX3 DE
Type MP2u or 3u Alfa Laval SMP-BC
Definox DCX3 DE
AV --AV—31 Shut off valve GEA NT
Type SV3 ALFA LAVAL SRC30
AV --AV1531 Mixproof valve GEA KL or KT
Type MP3u Alfa Laval SMP-BC
Definox DCX3 DE
Definox DCX3 DE
Definox DCX3 DE
AV --AV1161 Shut off valve GEA NL
AV --AV__61 Mixproof valve GEA KL or KT
Definox DCX3 DE
AV --AV__62 Shut off valve GEA NL
Definox DCX3 DE
AV --AV—63 Shut off valve GEA NL
AV --AV—66 Shut off valve Type BBA2 Ball valve
AV --AV8101 Shut off valve GEA NB
Version E
AV --AV8102 Shut off valve GEA XU

Type DVB112 ALFA LAVAL SRC22
PU --PU—61 Pump PU Centrifugal type
PU --PU—01 Pump PU Centrifugal pump
SY --SY—01 Frequency variator Siemens / Danfoss / Schneider
All valves must have at least one position switch on de-energized position.
5.3. INSTRUMENTATION
No ceramic, no glass in transmitters.
5.3.1. Temperature measurement

• TT x61 is request to control the tank temperature. Range transmitter : 0-100 °C
• TT x63 is request to control the heating of the solution in the tank. Range transmitter : 0-100 °C.
Included in the conductivity transmitter
• TT x01 is request to control the return temperature. Range transmitter : 0-100 °C. Included in the
conductivity transmitter
5.3.2. Conductivity measurement

• CT x01 is request to control the return conductivity. Range transmitter : 0-200 mS
• CT x63 is request to control the conductivity in the tank. Range transmitter : 0-200 mS
5.3.3. Flow measurement

• FT x01 is request to control the supply flow. Range: 0-70000 l/h. Accuracy 0.5%
• FT x02 are request to control the return flow. Range: 0-70000 l/h. Accuracy 0.5%
• FT 0201 is request to control the water addition. Range is variable depending of the CIP size.
Accuracy : 0.5 %
5.3.4. Pressure transmitter

• PT x01 is request to control the supply pressure to clean the tanks by balls.
Range transmitter: 0-10 bar.
5.3.5. Level Transmitter

• LT1x61 is requested in order to control level in all CIP tanks
Version E
6. KEY PERFORMANCE INDICATORS
typical typical
Indicator unit rule of calculation Instrumentation required Improvement plan
physical value cost
Raw material consumption

define unit consumption per equipment
kg of pure total consumption divided by flow meter on concentrated
Soda and adjust cleaning and recovery
soda number of cleanings soda distribution to CIP unit
parameters ; check transmitters
total consumption divided by flow meter on concentrated
Acid kg and adjust cleaning and recovery
number of cleanings acid distribution to CIP unit
check heat exchangers efficiency,
total consumption divided by flow meter on steam supply
steam kWh PCI recovery of cold solutions, temperature
number of cleanings distribution to CIP unit
set points
total consumption divided by flow meter on water supply
Water m3 and adjust cleaning and recovery
number of cleanings distribution to CIP unit
CIP duration
CIP duration total duration of all cleanings no transmitter required,
define unit time per equipment and
linked to total of all equipment divided by process control system ha s
% adjust cleaning and recovery parameters
operational total theorical duration of to detect stat and stop of
and transmitters
duration operation cleanings
no transmitter required,
CIP duration per duration of cleaning for define unit time per equipment and
process control system ha s
class of time tanks, process lines, heat adjust cleaning and recovery parameters
to detect stat and stop of
equipment exchangers, filling machines and transmitters
cleanings
CIP Unit Availability

duration af all "not prepared adjust CIP tanks preparation programs,
process control system ha s
CIP unit states" after request of hydraulic installation, self cleaning
% to detect duration of
availability phase / total duration of all efficiency, "prepared state" control and
unsatisfied requests of CIP
cleanings transmitters
phase
duration of
total time of utilisation of process control system ha s adjust distribution of process equipment
utilisation of time
each CIP line to detect stat and stop of on CIP lines
each line
cleanings for each line

DEP SP CIP 001 - E With Comments

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DEP SP CIP 001 - E With Comments

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SPECIFICATIONS CONTROLLED DISTRIBUTION

Code: DEP-SP-CIP-001 Date June, 2005

Victor MORILLO and Didier JOANNES Charles BELZILE

Version Dates Modifier Text of the modifications

A July 2003 Didier JOANNES / Victor Creation

B August 2003Didier JOANNES / Victor Refer to modification marks

Date: Date: Date:

Code: DEP-SP-CIP-001 Date June, 2005

No specification is sent to a supplier prior to contract or order.

Code: DEP-SP-CIP-001 Date June, 2005

Code: DEP-SP-CIP-001 Date June, 2005

1.2. SCOPE OF APPLICATION

The CIP unit is a group of different modules:

Code: DEP-SP-CIP-001 Date June, 2005

1.4. RELATED DOCUMENTS

• DEP-SP-ENG-002, Control of sanitary states of process equipment.

• DEP-SP-ENG-003, Standard AutoCAD symbols - Process valves and pumps

• DEP-SP-ENG-004, Control of production states of process equipment.

• NEPTUNE : Guideline on cleaning and sanitation (internal document)

Code: DEP-SP-CIP-001 Date June, 2005

2. STANDARD FLOW DIAGRAM

2.1. DESIGN SELECTED

Code: DEP-SP-CIP-001 Date June, 2005

Code: DEP-SP-CIP-001 Date June, 2005

2.2. THE FLOW DIAGRAM AND POSSIBLE VARIATION

2.2.1. Basic design

Code: DEP-SP-CIP-001 Date June, 2005

2.2.2. Water addition

2.2.3. Filters unit in return lines

2.2.4. Flow rate during cleaning

Code: DEP-SP-CIP-001 Date June, 2005

DIN SMS Turbulence

DIN SMS Turbulence

Code: DEP-SP-CIP-001 Date June, 2005

♦ Spray balls in tanks

2.2.5. : Chemical sanitation

Code: DEP-SP-CIP-001 Date June, 2005

Two options for the self-cleaning of the CIP unit:

Principles of a CIP unit with rotating solutions:

The cycle of rotation of cleaning solutions is automatically defined and monitored.

Advantages (+) / Disadvantages (-) of this option:

Code: DEP-SP-CIP-001 Date June, 2005

CIP inlet CIP outlet

Code: DEP-SP-CIP-001 Date June, 2005

CIP LINE CIP outlet

Additional closed Loop line

Code: DEP-SP-CIP-001 Date June, 2005

For each equipment, sanitary and production states have to be controlled.

3.1.1. Sanitary state management

Cleaning solution Cleanliness state

3.1.2. Production state management

3.1.3. General production states :

3.1.4. (*) Detailed Running functions list for CIP Tank :

Code: DEP-SP-CIP-001 Date June, 2005

Code: DEP-SP-CIP-001 Date June, 2005

Module Conditions to set “prepared state” Conditions to reset “prepared state”

Acid tank • LSMxx62 is covered and • LSLxx61 is uncovered or

Code: DEP-SP-CIP-001 Date June, 2005

3.1.6. Specific production states of CIP lines:

3.2. PERSONNEL AND PROPERTY SAFETY

Code: DEP-SP-CIP-001 Date June, 2005

- Preparation of Cleaning solutions : permanent control of temperature, concentration and level in

- CIP unit self-cleaning