Principles and Practice of Cleaning in PlaceGraham BroadhurstBRIGGS of Burton INC

ContentsCIP/SIP Definitions / FunctionPrinciples of CIPCIP DetergentsCIP SystemsVessel CIPMains CIPMonitoring/Control

CIP / SIP - DefinitionCIP = Cleaning in PlaceTo clean the product contact surfaces of vessels, equipment and pipework in place. i.e. without dismantling.SIP = Sterilise in PlaceTo ensure product contact surfaces are sufficiently sterile to minimise product infection.

How CIP WorksMechanicalRemoves loose soil by Impact / TurbulenceChemicalBreaks up and removes remaining soil by Chemical actionSterilant/SanitiserKills remaining micro-organisms (to an acceptable level)

Factors affecting CIPMechanical Chemical Temperature Time

CIP OperationPRE-RINSE - Mechanical Removal of SoilDETERGENT - Cleaning of Remaining Soil - Caustic, Acid or BothFINAL RINSE - Wash Residual Detergent/SoilSTERILANT/SANITISER - Cold or Hot

Typical CIP Times

Typical CIP TemperatureBrewhouse VesselsHot 85CBrewhouse MainsHot 85CProcess VesselsCold < 40CProcess MainsHot 75CYeast VesselsHot 75CYeast MainsHot 75C

CIP Detergent -RequirementsEffective on target soilNon foaming or include anti-foamFree rinsing / Non taintingNon corrosive Vessels/pipes, jointsControllable - ConductivityEnvironmental

Caustic DetergentsAdvantagesExcellent detergency properties when formulatedDisinfection properties, especially when used hot.Effective at removal of protein soil.Auto strength control by conductivity meterMore effective than acid in high soil environmentCost effectiveDisadvantagesDegraded by CO2 forming carbonate. Ineffective at removing inorganic scale.Poor rinsability.Not compatible with AluminiumActivity affected by water hardness.

Acid DetergentsAdvantagesEffective at removal of inorganic scaleNot degraded by CO2Not affected by water hardnessLends itself to automatic control by conductivity meter.Effective in low soil environmentReadily rinsedDisadvantagesLess effective at removing organic soil. New formulations more effective.Limited biocidal properties - New products being formulated which do have biocidal activityLimited effectiveness in high soil environmentsHigh corrosion risk - Nitric AcidEnvironment Phosphate/Nitrate discharge

Detergent AdditivesSequestrants (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 / SanitiserRequirementsEffective against target organismsFast ActingLow HazardLow CorrosionNon TaintingNo Effect On Head RetentionAcceptable Foam Characteristics

Sterilants / SanitisersChlorine DioxideHypochloriteIodophorAcid AnionicQuaternary Ammonium Hydrogen Peroxide PAA (Peroxyacetic Acid) 200-300 ppm

CIP SystemsSingle Use Water/Effluent/Energy costsRecoveryDetergent Recovery Rinse/Interface RecoveryTank AllocationNumber of Circuits

Single Use CIP Systems

Recovery CIP Systems1 x Supply 3 Tank System

Recovery CIP Systems2 x Supply 4 Tank System Separate Recirc

Recovery CIP System

Single Use vs RecoverySingle Use CIPLow Capital CostSmall Space Req.Low Contamination Risk Total LossHigh Water UseHigh Energy UseHigh Effluent Vols.Longer Time/DelayUse for Yeast

Recovery CIPHigh Capital CostLarge Space Req.Higher Contamination RiskLow LossLow Water UseLow Energy UseLow Effluent Vols.Shorter Time/DelayUse for Brewhouse & Fermenting

CIP SystemsCIP Tank SizingPre-Rinse CIP Flow x TimeDetergentVol of CIP in Process Mains & Tank + LossesFinal RinseFlow x Time Water Fill

CIP SystemsPractical PointsCIP Supply PumpRecirculationShared/Common with CIP Supply, orDedicated to TankCIP Supply StrainerCIP Return StrainerCIP Tank Connections

Types of CIPVESSEL CIP - Sprayhead Selection - Scavenge ControlMAINS CIP - Adequate Velocity - Total Route CoverageBATCH/COMBINED CIP - Complex Control - Time Consuming

Vessel CIPFlow of CIP fluid from CIP supply to vessel sprayheadInternal surfaces cleaned by spray impact / delugeReturn from vessel by CIP scavenge (return) pump

Vessel CIP - SprayheadsStatic SprayballsHigh Flow / Low PressureRotating SprayheadsLow Flow / Medium PressureCleaning MachinesLow Flow / High PressureHigh Impact

Vessel CIP SprayballsAdvantagesNo moving partsLow Capital CostLow pressure CIP supplyVerification by FlowDisadvantagesHigh Water & Energy UseHigh Effluent volumesLimited throw Small vesselsSpray Atomises if Pressure HighNo impact - long CIP time and/or high detergent strengthHigher absorption of CO2 by caustic

Vessel CIP Rotary SprayheadsAdvantagesNot too ExpensiveSome Mechanical Soil RemovalLower FlowReasonable Water/Energy UsageReasonable EffluentDisadvantagesMoving partsLimited throw Small vesselsPossible blockageRotation verificationSupply strainer

Vessel CIP Cleaning MachinesAdvantagesHigh impact, aggressive cleaningGood for heavy duty cleaningLow water/energy useLow effluentEffective in large vesselsLower absorption of CO2 by causticLower Flow means smaller Pipework

Vessel CIP Cleaning MachinesDisadvantagesExpensiveMoving partsHigh pressure CIP supply pumpPossible blockageRotation verificationSupply strainer

Mains CIPFlow of CIP fluid from CIP supply, through process pipework and back to CIP setThe entire process route must see turbulent CIP FlowNo/Minimal Tees/dead legsIsolate from other process lines

Mains CIPTurbulent & Laminar Flow

Mains CIPTurbulent & Laminar FlowTurbulent FlowFlat velocity profileThin Boundary layerEffective CIPLaminar FlowStreamline flowVelocity profile, faster at centreIneffective CIP

Mains CIPTurbulent Flow Re > 3000Minimise 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

Sheet1

Process Pipe dia (mm)Minimum CIP Flow (m3/h)CIP Supply / Return dia (mm)Pipe I/D (mm)Calc Min CIP Flow (m3/h)Calc Flow RoundingFlow Rounding

252.12522.22.10.170.1

385.23834.95.20.400.2

50105047.69.60.800.5

65166560.315.41.201

7524657322.62.002

100427597.640.43.002

1257010012566.25.005

15010012515095.38.005

200170150200169.514.0010

250280200250264.821.0020

300400200300381.431.0020

350520250350519.142.0020

400700250400678.054.2050

Min CIP Velocity1.5m/s minimum8%

Based on o/d tube to 100 mm and metric I/d above 100 mm.

Look-up

NomO/DiaI/DiaPumped or PressureGravity or SuctionMax FlowNom

Dia mmmmmmm/sm3/hm/sm3/hm3/hDia mm

2525.422.21.41.91.01.40.012

3838.134.91.86.21.24.11.525

5050.847.62.214.11.59.61.938

6563.560.32.5261.8186.250

7576.273.03.0452.03014.165

100101.697.63.5942.56725.775

1251253.51542.511045.2100

1501504.02542.515994.2125

2002004.04523.0339154150

2502504.07063.0530254200

3003004.511443.5890452250

3503504.515573.51211706300

4004004.520343.515821144350

pipe1557400

2034450

size

Rounding

0.10.1

0.20.2

0.50.5

11

22

55

1010

2020

5050

100100

rounding

&LCUB YATALA BREWHOUSE&C&"Arial,Bold"&12&U&A&R&D &T

&L&"MicrogrammaDBolExt,Regular"&12BRIGGS&C&F&Rpage &P of &N

Process PipeworkDesign for CIPEnsure Total Route coverageAvoid Split routes Avoid Dead ends Avoid Tees Most Critical on Yeast & nearer packaging

Process PipeworkDesign for CIPIsolate CIP from Process Mixproof Valves Flowplates

Batch/Combined CIPCombines CIP of Vessel/s andPipework in one cleanWhy ?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 CIPSupply of a batch volume of CIP to process vesselInternal recirculation of CIP within/through process vesselTransfer of CIP to next vesselPumped return of CIP batch volume to CIP set.

CIP Monitoring & ControlOn-LineDetergent TemperatureDetergent Strength - ConductivityReturn ConductivityDetergent Start InterfaceDetergent End InterfaceRinse ConductivityReturn FlowRecirc/Return TimeSupply Pressure

CIP Monitoring & ControlOff-LineVisual InspectionFinal Rinse return samplingpHMicroATPVessel/Pipework swabspHMicroATP

Principles and Practice of Cleaning in Place