CIP (Clean-in-Place) Buying Guide

CIP systems vary widely in configuration, capacity, quality, and level of automation. They also vary by industry. Differences in product characteristics and regulatory considerations between the various processing industries will strongly impact the design of your CIP system.

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FOOD, DAIRY, AND BEVERAGE

The number of CIP applications for food, dairy, and beverage process systems has grown dramatically in recent years. Processors in these industries recognize the importance of fast, efficient CIP. The range of product types and cleaning requirements in these industries is virtually endless, so when you are looking to install or upgrade a CIP system it is imperative to consider your particular cleaning needs.

Resist the urge to buy a “cookie cutter” solution. While it might purport to sufficiently clean any application, this might not necessarily be the proper solution for your system.

In most food, dairy, and beverage systems, the surface finish for product contact areas tends to be the standard sanitary surface finish of 32Ra minimum. This is rougher than the finishes required in the pharmaceutical world, but it is smooth enough to allow most product residues to release fairly easily. Requirements for validation and recording of cleaning data vary from product to product, but as data monitoring, tracking, and recording technology becomes more user-friendly and affordable, more and more food, dairy, and beverage processors are electing to incorporate it into their CIP controls.

The CIP cycles to clean common food, dairy, and beverage products may include pre-wash, detergent, acid, and various rinse cycles, but may also include a sterilization cycle for an extended shelf life (ESL) product. Sterilization is more common for pharmaceutical CIP.

Many beverage CIP applications require less time and energy and fewer chemicals when the product is less viscous and doesn’t contain proteins or fats. The acidity of many beverages also naturally inhibits the growth of microorganisms, which could mean cleaning less frequently.

Milk and dairy products are particularly vulnerable to spoilage and the rapid growth of bacteria. Clean-in-place systems in dairies must be very specific regarding temperatures, cycle times, and chemical concentrations to effectively prevent contamination from harmful microorganisms such as salmonella, listeria, and E. coli. Additional acid washes may also be needed to eliminate milk scale buildup.

Pasteurizers and other equipment containing heating surfaces (known as “hot components”) may require separate cleaning programs from the nonheated components of the system such as tanks and piping.

BREWERIES

Most modern breweries are highly automated closed systems, so they lend themselves well to cleaning in place. The tanks and vessels used in brewing sometimes have a large capacity and may require multiple high capacity spray devices to be properly cleaned. A phosphoric acid wash may be required in some cases to remove beerstone buildup.

PHARMACEUTICAL

The highest level of CIP technology and state-of-the-art controls are usually found in pharmaceutical CIP systems. The exacting standards of the industry demand a level of hygiene, documentation, and automation that isn’t required in other processing industries. Process line sizes tend to be smaller and the product is often less viscous than many food products, so high flow volumes and powerful spray devices may not be necessary for proper cleaning.

The design of pharmaceutical process piping should be sloped properly and be free of undrainable low points.

The pumps, valves, and fittings used in pharmaceutical processing generally have the highest level of clean-ability designed into them, which makes them easier to clean and less likely to have hidden, hard-to-clean areas.

Depending on the process and the product being cleaned, your CIP system could be a simple, single tank, single-pass system to clean one small circuit, or a complex multi-tank, multi-supply system to service multiple circuits or kitchens simultaneously.

Before anyone embarks on the journey to purchase or upgrade a clean-in-place system, it is critical that they arm themselves with the information they need to tell the difference between a quality, efficient, and cost-effective system and a “wanna-be” system. It is possible to install a clean-in-place system that outwardly has the appearance and functionality of a cleaning system but fails to address the countless details that go into building a quality CIP system.

To ensure you get the maximum return on your CIP investment, partner with an experienced company that, above all, understands process systems and has a proven history of engineering effective custom CIP systems. A qualified cleaning system vendor will guide you through the entire process–from proper planning and design through fabrication and installation to the final steps of training and start-up.

Working together with a knowledgeable vendor will provide you with a reliable, worry-free CIP system for many years.