Principles and Practice of Cleaning in Place

Principles and Practice of
Cleaning in Place
Graham Broadhurst
BRIGGS of Burton INC
Contents
CIP/SIP Definitions / Function

Principles of CIP
CIP Detergents
CIP Systems
Vessel CIP
Mains CIP
Monitoring/Control
CIP / SIP - Definition

CIP = Cleaning in Place
To clean the product contact surfaces of
vessels, equipment and pipework in place.
i.e. without dismantling.
SIP = Sterilise in Place

To ensure product contact surfaces are
sufficiently sterile to minimise product
infection.
How CIP Works

Mechanical
Removes loose soil by Impact / Turbulence
Chemical
Breaks up and removes remaining soil by
Chemical action
Sterilant/Sanitiser
Kills remaining micro-organisms
(to an acceptable level)
Factors affecting CIP

Mechanical
Chemical
Temperature
Time
CIP Operation
PRE-RINSE
- Mechanical Removal of Soil
DETERGENT
- Cleaning of Remaining Soil
- Caustic, Acid or Both
FINAL RINSE
- Wash Residual Detergent/Soil
STERILANT/SANITISER
- Cold or Hot
Typical CIP Times

Vessel CIP
Mains CIP
Pre-Rinse
10 to 20 mins
5 to 10 mins
Caustic Detergent
30 to 45 mins
20 to 30 mins
Rinse
10 to 15 mins
5 to 10 mins
Acid Detergent
20 to 30 mins
15 to 20 mins
Rinse
15 to 20 mins
10 to 15 mins
Sterilant
10 to 15 mins
5 to 10 mins
Typical CIP Temperature
Brewhouse Vessels
Brewhouse Mains
Process Vessels
Process Mains
Yeast Vessels
Yeast Mains
Hot 85C
Hot 85C
Cold < 40C
Hot 75C
Hot 75C
Hot 75C
CIP Detergent Requirements
Effective on target soil

Non foaming or include anti-foam
Free rinsing / Non tainting
Non corrosive Vessels/pipes, joints
Controllable - Conductivity
Environmental
Caustic Detergents
Advantages
Excellent detergency
properties when
formulated
Disinfection properties,
especially when used hot.
Effective at removal of
protein soil.
Auto strength control by
conductivity meter
More effective than acid in
high soil environment
Cost effective
Disadvantages
Degraded by CO2 forming
carbonate.
Ineffective at removing
inorganic scale.
Poor rinsability.
Not compatible with
Aluminium
Activity affected by water
hardness.
Acid Detergents
Advantages
Effective at removal of
inorganic scale
Not degraded by CO2
Not affected by water
hardness
Lends itself to automatic
control by conductivity
meter.
Effective in low soil
environment
Readily rinsed
Disadvantages
Less effective at removing
organic soil.
New formulations more
effective.
Limited biocidal properties New products being
formulated which do have
biocidal activity
Limited effectiveness in high
soil environments
High corrosion risk - Nitric
Acid
Environment
Phosphate/Nitrate discharge
Detergent Additives
Sequestrants (Chelating Agents)
Materials which can complex metal ions in
solution, preventing precipitation of the insoluble
salts of the metal ions (e.g. scale).
e.g. EDTA, NTA, Gluconates and Phosphonates.
Surfactants (Wetting Agents)

Reduce surface tension allowing detergent to
reach metal surface.
Sterilant / Sanitiser
Requirements
Effective against target organisms

Fast Acting
Low Hazard
Low Corrosion
Non Tainting
No Effect On Head Retention
Acceptable Foam Characteristics
Sterilants / Sanitisers
Chlorine Dioxide
Hypochlorite
Iodophor
Acid Anionic
Quaternary Ammonium
Hydrogen Peroxide
PAA (Peroxyacetic Acid) 200-300 ppm
CIP Systems
Single Use
Water/Effluent/Energy costs
Recovery
Detergent Recovery
Rinse/Interface Recovery
Tank Allocation
Number of Circuits
Single Use CIP Systems

Flow
Water
Conductivity
CIP Return
CIP
Buffer
Tank
Steam
Temperature
CIP
Supply
CIP Heater
CIP
Supply
Pump
Flow
Conductivity
Recovery CIP Systems

1 x Supply 3 Tank System
Water
Flow
Conductivity
CIP Return
CIP Return
/ Recirc
LSH
LSH
LSH
Final
Rinse
Tank
Caustic
Tank
PreRinse
Tank
LSL
Temp
Steam
LSL
LSL
CIP
Heater
CIP
Supply /
Recirc
Pump
CIP
Supply /
Recirc
Temperature
Flow
CIP
Supply
Recovery CIP Systems

Water
2 x Supply 4 Tank System Separate Recirc

Flow
Cond
CIP Return B
Flow
Cond
CIP Return A
LSH
Final
Rinse
Tank
Caustic
Tank
PreRinse
Tank
LT
LT
Temp Cond
LSH
LSH
Temp
LT
Caustic
Recirc Pump
LSH
Cond
Acid
Tank
LT
Acid Recirc
Pump
CIP Supply A
CIP Supply
A Pump
Flow
CIP Supply
B Pump
Flow
CIP Supply B
Recovery CIP System
Single Use vs Recovery

Single Use CIP
Low Capital Cost

Small Space Req.
Low Contamination Risk
Total Loss
High Water Use
High Energy Use
High Effluent Vols.
Longer Time/Delay
Use for Yeast
Recovery CIP
High Capital Cost
Large Space Req.
Higher Contamination
Risk
Low Loss
Low Water Use
Low Energy Use
Low Effluent Vols.
Shorter Time/Delay
Use for Brewhouse &
Fermenting
CIP Systems
CIP Tank Sizing
Pre-Rinse
CIP Flow x Time
Detergent
Vol of CIP in Process Mains & Tank
+ Losses
Final Rinse
Flow x Time Water Fill
CIP Systems
Practical Points
CIP Supply Pump
Recirculation
Shared/Common with CIP Supply, or
Dedicated to Tank
CIP Supply Strainer

CIP Return Strainer
CIP Tank Connections
Types of CIP
VESSEL CIP
- Sprayhead Selection
- Scavenge Control
MAINS CIP
- Adequate Velocity
- Total Route Coverage
BATCH/COMBINED CIP
- Complex Control
- Time Consuming
Vessel CIP
Flow of CIP fluid
from CIP supply to
vessel sprayhead
Internal surfaces
cleaned by spray
impact / deluge
Return from vessel
by CIP scavenge
(return) pump
CIP Supply
CIP
Gas
pipe
Process
Vessel
Isolate from
Process
CIP Return
CIP Scavenge Pump
Vessel CIP - Sprayheads

Static Sprayballs
High Flow / Low Pressure
Rotating Sprayheads
Low Flow / Medium Pressure
Cleaning Machines
Low Flow / High Pressure
High Impact
Vessel CIP Sprayballs
Advantages
No moving parts
Low Capital Cost
Low pressure CIP supply
Verification by Flow
Disadvantages
High Water & Energy Use

High Effluent volumes
Limited throw Small vessels
Spray Atomises if Pressure High
No impact - long CIP time and/or high
detergent strength
Higher absorption of CO2 by caustic
Vessel CIP Rotary

Sprayheads
Advantages
Not too Expensive

Some Mechanical Soil Removal
Lower Flow
Reasonable Water/Energy Usage
Reasonable Effluent
Disadvantages
Moving parts
Limited throw Small vessels
Possible blockage
Rotation verification
Supply strainer
Vessel CIP Cleaning

Machines
Advantages
High impact, aggressive
cleaning
Good for heavy duty
cleaning
Low water/energy use
Low effluent
Effective in large vessels
Lower absorption of CO2
by caustic
Lower Flow means
smaller Pipework
Vessel CIP Cleaning

Machines
Disadvantages
Expensive
Moving parts
High pressure CIP
supply pump
Possible blockage
Rotation verification
Supply strainer
Mains CIP
Flow of CIP fluid from
CIP supply, through
process pipework and
back to CIP set
The entire process
route must see
turbulent CIP Flow
No/Minimal Tees/dead
legs
Isolate from other
process lines
CIP Supply
Isolate
from
Process
other
Process
routes
Process
Route being
CIPd
CIP Return
Mains CIP
Turbulent & Laminar Flow
Mains CIP
Turbulent & Laminar Flow
Turbulent Flow
Flat velocity
profile
Thin Boundary
layer
Effective CIP
Laminar Flow
Streamline flow
Velocity profile,
faster at centre
Ineffective CIP
Thin Boundary
Layer at pipe wall
Mains CIP
Turbulent Flow
Re > 3000
Minimise Boundary layer

Laminar layer on internal pipe wall
Minimum CIP velocity (in process pipe)

1.5 m/s.
Excessive velocity
High Pressure drop / Energy input
Mains CIP CIP Flow

Process
Pipe dia
(mm)
Minimum
CIP Flow
(m3/h)
CIP Supply /
Return dia
(mm)
25
38
50
65
75
100
125
150
200
250
300
350
400
2.1
5.2
10
16
24
42
70
100
170
280
400
520
700
25
38
50
65
65
75
100
125
150
200
200
250
250
Min CIP Velocity

1.5
m/s minimum
Based on o/d tube to 100 mm and metric I/d above 100 mm.
Process Pipework
Design for CIP
Ensure Total Route
coverage
Avoid Split routes
Avoid Dead ends

Avoid Tees
Most Critical on
Yeast & nearer
packaging
Process Pipework
Design for CIP
Isolate CIP from
Process
Mixproof Valves
FLOWPLATE
Flowplates
Process Line
Not being CIPd
Process Line
being CIPd
Physical Break
between routes
CIP Return
Batch/Combined CIP
Combines CIP of
Vessel/s and
Pipework in one clean
Why ?
Pipework too large for mains CIP
e.g. Brewhouse 200 to 600 mm.
Pipework linked to Vessel
e.g. Recirculation Loop or EWH.
Batch/Combined CIP
Supply of a batch volume of CIP to
process vessel
Internal recirculation of CIP
within/through process vessel
Transfer of CIP to next vessel
Pumped return of CIP batch volume to
CIP set.
CIP Monitoring & Control

On-Line
Detergent Temperature
Detergent Strength - Conductivity
Return Conductivity
Detergent Start Interface
Detergent End Interface
Rinse Conductivity
Return Flow
Recirc/Return Time
Supply Pressure
CIP Monitoring & Control

Off-Line
Visual Inspection
Final Rinse return sampling
pH
Micro
ATP
Vessel/Pipework swabs
pH
Micro
ATP
Principles and Practice of

Cleaning in Place

Principles and Practice of Cleaning in Place

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Principles and Practice of

CIP/SIP Definitions / Function

CIP / SIP - Definition

SIP = Sterilise in Place

How CIP Works

Factors affecting CIP

Typical CIP Times

Typical CIP Temperature

CIP Detergent Requirements

Effective on target soil

Surfactants (Wetting Agents)

Effective against target organisms

Single Use CIP Systems

Recovery CIP Systems

Recovery CIP Systems

2 x Supply 4 Tank System Separate Recirc

Recovery CIP System

Single Use vs Recovery

Low Capital Cost

CIP Supply Strainer

CIP Scavenge Pump

Vessel CIP - Sprayheads

Vessel CIP Sprayballs

High Water & Energy Use

Vessel CIP Rotary

Not too Expensive

Vessel CIP Cleaning

Vessel CIP Cleaning

Minimise Boundary layer

Minimum CIP velocity (in process pipe)

Mains CIP CIP Flow

Min CIP Velocity

Avoid Dead ends

CIP Monitoring & Control

CIP Monitoring & Control

Principles and Practice of

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