Most Common Problems When Designing A CIP System

A CIP system is a system of mechanical components and equipment that mixes water, chemicals, and heat to create a cleaning solution. This chemical cleaning solution is pumped or circulated by the CIP system to other systems or equipment for cleaning.

For those unfamiliar with the term, CIP is a cleaning system used by breweries to clean or sanitize certain process equipment, such as pipes and tanks, without human intervention. Many issues with these "out-of-the-box" CIP systems arise from incorrect information provided by suppliers.

What type of product do I want to clean?

This is important to understand because different applications must different levels of TACT. Different types of food and chemical soils present unique cleaning challenges.

• T-time

• A-action

• C-concentration

• T-Temperature

Light Cleaning

Soil dissolves and does not adhere to tank and pipe walls. A thorough pre-rinse typically removes most soil. Remaining soil is dissolved by alkaline cleaning. Because the nature of the soil in the product allows the liquid action to remove and carry away most of the soil, lower temperatures and fewer chemicals are required, and a single alkaline cleaning cycle is sufficient. In most cases, a single-tank or dual-tank system is sufficient.

Moderate to Heavy Cleaning

Products with lower solubility require higher detergent concentrations and higher temperatures to remove soil.

Have you worked with your chemical supplier to determine the appropriate chemicals, exposure times, and temperatures?

A good chemical supplier can analyze your plant's water and soil and select chemicals that will break them down in the fastest, most efficient reaction. They can typically recommend the time needed for the reaction to complete (contact time) and the optimal temperature to help the soil break down.

Are your tanks designed for CIP cleaning?

Tanks built using older processes are generally not suitable for cleaning with spray balls. For some such systems, ports can be added to the tank and work well. However, as with most tanks, adding spray balls to older tanks not designed for CIP can often result in leaks.

Can dead spots be eliminated?

The cleaning fluid must be able to flush all pipes for cleaning. If the product wets the surface but you can't flush it, it's not being cleaned properly.

Does your line have proper slopes to ensure adequate drainage?

Water remaining in pipes between cleaning steps can cause residue buildup and reduce cleaning effectiveness. Standing water in the system can harbor bacteria during downtime.

How often is cleaning-in-place (CIP) required?

CIP cycles are run after processing runs that generate normal contamination or when changing a line from one product to another. This frequency must be sufficient to ensure product safety and quality. Remember, running cleaning cycles also wastes valuable time and resources.

What functions can a CIP system perform?

Facility equipped with a CIP system can be used to perform a variety of different tasks, including cleaning tanks, piping, and equipment. Customers looking to integrate a CIP system into their facility may require it to perform one or all three of these tasks.

Are tanks typically cleaned hot or cold?

Tanks are typically cleaned at ambient temperature, but some situations may require higher temperatures. In these cases, maintaining a constant temperature during the cleaning cycle and regulating the temperature throughout the cool-down process become crucial, and more programming is required to protect the equipment.

Are tanks pressurized during cleaning?

It depends on the facility and process. Some customers prefer to use carbon dioxide to pressurize the tanks during the cleaning process. These situations are limited, require specialized chemicals, and require extra safety precautions. However, if the customer chooses not to pressurize the tank during the cleaning process, procedures should be in place to re-pressurize the tank if possible air ingestion is detected.

Why is equipment cleaning so challenging?

Equipment cleaning can be one of the most complex tasks, often requiring a high degree of customization. Equipment often has unique requirements, necessitating careful attention to CIP recipes. Whether it involves specialized programming, inter-system handshaking, or HMI step confirmation during the cycle, Degong can help optimize the solution.

Will residue cleanup be a factor?

This information determines the type of detergent or cleaning solution required. Some organic materials require an alkaline cleaning of the detergent tank, while other non-organic materials may require an acidic cleaning. Some systems may even require a combination of both. Attention must be paid to the concentration and temperature of the cleaning solution to optimize performance.

What utilities are required to operate a CIP system?

Generally speaking, a properly functioning CIP system requires a water source, a chemical source, steam and condensate returns (for heating), and drains (gravity and power). These factors play a significant role in determining the size and total number of tanks required, as well as the required piping dimensions.

Can the CIP system guarantee 360° cleaning?

During cleaning, the cleaning solution must be able to thoroughly flush all piping and equipment. If the brewing equipment cannot be flushed, some cleaning solution may remain in the equipment, affecting subsequent brewing operations.