Importance of CIP System in Brewery

CIP systems (cleaning-in-place) are revolutionizing equipment use in the food and beverage industry. To produce high-quality, safe, and reliable beer, a clean and hygienic environment is essential throughout the brewing process. For breweries, CIP systems are designed to provide high-quality cleaning of product contact surfaces. They achieve fast and consistent production through automated processes and high-quality cleaning through system monitoring.

What is a CIP system?

CIP (cleaning-in-place) in breweries is a cleaning process used to clean the internal surfaces of tanks, pipes, and other equipment used in beer production without disassembling the equipment. The process involves circulating a cleaning fluid through the equipment, followed by rinsing and sanitizing to ensure all surfaces are free of contaminants, residue, and bacteria. The design of these systems can vary depending on the intended use, industry, and facility standards. They can be portable or fixed, and can even encompass multiple tanks. While they may differ in many ways, they are generally constructed in the same way and have similar functional components. Modern CIP systems can be programmed to specific cleaning protocols, reducing the risk of human error and ensuring consistent cleaning results.

How does a CIP system work?

• Preparation: Before beginning the CIP process, the equipment must be prepared by closing all valves, draining any residue, and securing all hoses and connections. This step is crucial to ensure that the cleaning solution can circulate freely through the components without leaks.

• Cleanser Circulation: The detergent cleaning phase involves using a cleaning solution to remove any remaining dirt and debris. The cleaning solution is automatically pumped through the equipment and soaks for a specified period of time to ensure all surfaces are thoroughly cleaned.

• Drain and Rinse: Next, the equipment needs to be drained and rinsed with water to remove the cleaning solution. This step is crucial to ensure that no hazardous materials, cleaning solutions, or other contaminants remain in the brewing equipment.

• Sanitization: Sanitization is accomplished by circulating a special disinfectant solution, such as sodium hypochlorite or hydrogen peroxide, through the equipment. This helps kill any remaining bacteria or other harmful microorganisms that could affect the quality of the final product.

• Final Rinse and Drain: After flushing the disinfectant, the equipment needs to be drained again to remove any remaining disinfectant. As you can see, the entire CIP process doesn't have to be complicated or time-consuming.

A CIP cycle in a winery typically takes 60 to 90 minutes. The entire process is automated, and workers don't need to worry about mixing chemicals or starting the next stage of the cycle.

CIP Equipment System Types

Single-Tank Systems

• Typically, to avoid allergen and cross-contamination issues, it's best to drain the system to the sewer after each cycle.

• Single-tank systems require a lower initial investment than multi-tank systems.

• They require less space and can be mounted on a cart for easy transport.

Two-Tank System

• Typically, the alkaline wash solution can be returned to the tank and reused multiple times, reducing water, chemical, and energy costs compared to a single-tank system.

• Prefilling and preheating each tank as needed before starting the cleaning cycle can shorten cleaning time.

• Can be mounted on a cart for easy mobility.

Three-Tank System

• Reduces cleaning time.

• Depending on the amount of soil in the treatment system, the alkaline and acid wash solutions can be returned and reused.

• Water/Alkali/Reuse: If acid washing is not required, a reusable container can collect contaminated alkaline wash solution and use it as an effective pre-rinse for the next cleaning process.

• Used for cleaning many circuits with different types of product soils requiring different types or concentrations of alkaline cleaning agents.

Why are CIP systems important to breweries?

Improved Time and Efficiency

One of the key benefits of a CIP system is the increased efficiency it brings to brewery operations. Manual cleaning procedures are time-consuming and labor-intensive. CIP systems reduce the need for these procedures, allowing breweries to focus on other important tasks. Increased productivity, reduced downtime, and faster batch turnover are all benefits of this time-saving feature.

Thorough Cleaning

A CIP system ensures a thorough and consistent cleaning process throughout the brewery. Using designated cleaning cycles and meticulous procedures, the system effectively removes contaminants and residue. This consistency ensures the quality and flavor of the beer is maintained, reduces the potential for human error, and ensures that every piece of equipment is cleaned to the same high standard.

Reduced Chemical and Water Use

Another benefit of CIP systems is their efficient water and chemical conservation. By streamlining cleaning procedures, CIP systems reduce water usage and detergent requirements. To further enhance sustainability and efficiency, these systems often utilize cutting-edge technologies such as flow meters and sensors to monitor and regulate water and chemical usage.

Reduced Contamination Risk

If there is a possibility of contamination during the brewing process, breweries can suffer serious consequences. CIP systems are crucial for mitigating this risk by ensuring adequate cleaning and disinfection. CIP systems remove organic matter, bacteria, and yeast, creating a clean environment that prevents the growth of harmful bacteria. This extends the life of brewing equipment while protecting the quality of the beer.

How to choose the best CIP system for your needs?

• Consider your needs: Every brewery's needs are unique, so choosing a CIP system that can be customized to meet your specific requirements is crucial. Consider factors such as the size of your brewery, the type of equipment, and the challenges you face during cleaning.

• Equipment Selection: To achieve optimal cleaning results from your CIP system, it's crucial to choose the right equipment. Consider the equipment's materials of construction, compatibility with cleaning solutions, and ease of maintenance. Breweries often use stainless steel equipment for its durability and corrosion resistance. Ensure the system has the necessary components, such as pumps, control panels, and spray balls, to meet your cleaning needs.

• Integrate with Existing Infrastructure: Compatibility and connectivity with existing infrastructure are important considerations when selecting a CIP system. Ensure the system operates in harmony with your brewery's automation and control systems. Compatibility will improve operational efficiency, data exchange capabilities, and monitoring capabilities.