Automated Cleaning: How the Compact CIP Raises the Bar
Sanitary processors need to follow strict equipment cleaning requirements – consistently, repeatably, and efficiently - to maximize productivity and prevent costly disruptions like product recalls. No matter how many prescribed procedures there are or how rigorously they're carried out, you probably know it's not possible to perform manual cleaning to exacting standards.
If your cleaning process doesn't produce consistent results from one cycle to the next, you can't guarantee that cleaning is done to standard. And with Food Safety Modernization Act requirements, consistency, accuracy, and repeatability are more crucial than ever.
Wouldn't it be great if there was a way of producing consistent and effective cleaning results every time? Thankfully these results are now possible through the use of automated cleaning.
Automated cleaning lets you see and record compliance with standards rather than merely carrying out procedures that can expose your process to inconsistencies.
Automated Clean-in-place (CIP) Systems clean and sanitize equipment - sanitary process lines, vessels, piping, and more - where it is, without removal or disassembly.
Central States Industrial (CSI) developed its Compact CIP to give sanitary processors the advantages of automated sanitizing and cleaning with the added benefit of system mobility, repeatability with automated washes, and wash process value logging capabilities – all at an affordable cost.
A Closer Look at The Compact CIP and Its Capabilities
Skid build and features:
- 100-gallon single 316/316L grade stainless steel tank and 304 stainless steel frame
- Six-inch caster wheels for easy mobility
- Small footprint – can be deployed in constrained spaces where larger units won't fit
- Robust, accurate Endress & Hauser or IFM instrumentation
- 24v 120W power supply for Programmable Logic Controller (PLC) and instruments
Controls and Automation
The standard model Compact CIP runs a choice of five built-in wash cycles with one-button touch. PLC control of pump speeds, chemical concentrations, and temperatures ensures consistent wash results cycle to cycle. If any wash cycle parameters are unmet during a wash cycle, staff can see where deviations occur and take corrective action.
Standard system functions included are:
- Automatic tank level
- Start & stop
- Temperature controls
- Recirculation or forward flow routing.
Standard status indicators included are:
- High & low temperatures
- Flow and conductivity
- Pump failure-to-start alarm
- System active/idle
- E-stop active
The CIP's user-friendly control panel, also called the Human Machine Interface or HMI, connects with the CIP's PLC to execute the desired programs, making system configuration and day-to-day operations easy.
The HMI features:
- Panelview 800 7" HMI touchscreen terminal
- Micro850 Programmable Logic Controller
- Stratix 2000 unmanaged Ethernet switches
- 2080 Series I/O Modules as needed for skid-mounted hardware
- PowerFlex 525 AC drives with embedded ethernet/IP™ communications, USB programming, and standard safety features
- Non-illuminated E-Stop, twist to release, mounted in the door
- 24v 120W power supply to power PLC and instruments
- Six-station air manifold with four solenoids for automated valves
- DIN rails, raceway and terminal blocks for panel wiring
- Stainless steel NEMA 4X enclosure
With a client-supplied USB device installed, the standard-configuration system records wash cycle values, including CIP supply flow, supply temperature, return temperature, and chemical conductivity in .csv file format while cycles run. The .csv files can then be stored or imported into wash reports.
CSI can also customize the Compact CIP to integrate it with supervisory system PLC either through hardwired or wifi connection.
This enables:
- Direct transmission of CIP data to supervisory PLC
- Remote monitoring and skid operation, including starting and stopping washes and tracking cycle phases, system alarms, and remaining cycle time remaining.
Optional/custom features:
- 30 kW electric heater for trim heating
- Automated caustic/acid dosing pump
- Return pump cart to reclaim CIP solution
- Stationary (rather than rolling) base if CIP is intended to be used in a single location – which allows for hard piping/wiring of water, power and CIP process lines.
- Custom wash programs to meet client-specific requirements
- Router/wifi antenna
- Programming to enable CIP integration with supervisory PLC
Benefits and Advantages of the Compact CIP at A Glance
| Eliminates human error – cycles are reliable and repeatable | Less than half the cost of a typical entry-level skid | Compact size and mobility mean Compact CIP can operate in tight spaces |
| Runs CIP independently, freeing operators to focus elsewhere | CSI’s vendor partnerships mean higher quality equipment at lower cost | Larger plants can dedicate Compact CIP to specific processing areas to prevent allergen crossover – after cycle completion water is sent to drain |
| Prevents employee exposure to chemicals | Repeatable cycle control saves water, energy, and cleaning agents - no over-cycling or overuse of cleaning chemicals to “make sure” | Solution for well-established plants that want to expand CIP capabilities - no commitment to an additional hard-piped, centralized system |
| Cleaning parameters validated and results recorded - can be communicated to supervisory system PLCs | Faster cleaning, less downtime for processing equipment | Can complement a centralized skid |
| Minimizes contamination risk– fewer recalls, higher consumer brand confidence | Smaller, budget-conscious businesses can take advantage of cutting-edge sanitary cleaning technology | With optional hardwire or wifi connection, data can be automatically transmitted to supervisory PLC and users can monitor and operation skid remotely |
| Less user and management time spent on operation, monitoring, addressing problems | Other optional features: 30 kW electric heater, automated caustic and acid addition, return pump cart to reclaim CIP solution, stationary base |
Next Steps
We know a Compact CIP system is a critical investment for your business, and we’re here to help. CSI’s skill and expertise spans the food, beverage, brewery, home and personal care, pharmaceutical, and biotech industries. We’ll ensure your Compact CIP fits your specific hygienic processing needs and maximizes return on investment.
CSI’s templates and configurators let us quote cost for a customized Compact CIP in minutes rather than weeks. We’re also experts in meeting clients’ needs for new equipment that integrates seamlessly with their business’s existing equipment, operations and training.
Every piece of equipment leaving CSI’s manufacturing plant has undergone Level II inspection in accordance with the latest ASNT recommended Practice No. SNT-TC-1A, so you can be sure your new Compact CIP meets industry standards. A factory acceptance test ensures systems are working properly and gives you the chance to try it out, ask questions, and request modifications.
We’re here to help you learn how the affordable Compact CIP can make your business’s sanitary processing more reliable and efficient
Clean-in-place Buying Guide
This Buying Guide for Clean-in-Place Solutions is a comprehensive resource for anyone who designs, owns, or operates processing systems and wants information about all aspects of CIP Systems.
ABOUT CSI
Central States Industrial Equipment (CSI) is a leader in distribution of hygienic pipe, valves, fittings, pumps, heat exchangers, and MRO supplies for hygienic industrial processors, with four distribution facilities across the U.S. CSI also provides detail design and execution for hygienic process systems in the food, dairy, beverage, pharmaceutical, biotechnology, and personal care industries. Specializing in process piping, system start-ups, and cleaning systems, CSI leverages technology, intellectual property, and industry expertise to deliver solutions to processing problems. More information can be found at www.csidesigns.com.