Presentation on theme: "Principles and Practice of Cleaning in Place"— Presentation transcript:
1Principles and Practice of Cleaning in Place Graham BroadhurstBRIGGS of Burton INC
2Contents CIP/SIP – Definitions / Function Principles of CIP CIP DetergentsCIP SystemsVessel CIPMains CIPMonitoring/Control
3CIP / 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 PlaceTo ensure product contact surfaces are sufficiently sterile to minimise product infection.
4How CIP Works Mechanical Chemical Sterilant/Sanitiser Removes ‘loose’ soil by Impact / TurbulenceChemicalBreaks up and removes remaining soil by Chemical actionSterilant/Sanitiser‘Kills’ remaining micro-organisms (to an acceptable level)
6CIP Operation PRE-RINSE - Mechanical Removal of Soil DETERGENT - Cleaning of Remaining Soil - Caustic, Acid or BothFINAL RINSE - Wash Residual Detergent/SoilSTERILANT/SANITISER - Cold or Hot
7Typical CIP Times Vessel CIP Mains CIP Pre-Rinse 10 to 20 mins Vessel CIPMains CIPPre-Rinse10 to 20 mins5 to 10 minsCaustic Detergent30 to 45 mins20 to 30 minsRinse10 to 15 minsAcid Detergent15 to 20 minsSterilant
8Typical CIP Temperature Brewhouse Vessels Hot 85°CBrewhouse Mains Hot 85°CProcess Vessels Cold < 40°CProcess Mains Hot 75°CYeast Vessels Hot 75°CYeast Mains Hot 75°C
9CIP Detergent - Requirements Effective on target soilNon foaming or include anti-foamFree rinsing / Non taintingNon corrosive – Vessels/pipes, jointsControllable - ConductivityEnvironmental
10Caustic Detergents Advantages Disadvantages Excellent detergency properties when “formulated”Disinfection 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.
11Acid Detergents Advantages Disadvantages Effective 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
12Detergent 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.
13Sterilant / Sanitiser Requirements Effective against target organismsFast ActingLow HazardLow CorrosionNon TaintingNo Effect On Head RetentionAcceptable Foam Characteristics
20Single Use vs Recovery Single Use CIP Recovery CIP Low Capital Cost Small Space Req.Low Contamination RiskTotal LossHigh Water UseHigh Energy UseHigh Effluent Vols.Longer Time/DelayUse for YeastRecovery CIPHigh Capital CostLarge Space Req.Higher Contamination RiskLow LossLow Water UseLow Energy UseLow Effluent Vols.Shorter Time/DelayUse for Brewhouse & Fermenting
21CIP Systems CIP Tank Sizing Pre-RinseCIP Flow x TimeDetergentVol of CIP in Process Mains & Tank + LossesFinal RinseFlow x Time – Water Fill
22CIP Systems Practical Points CIP Supply PumpRecirculationShared/Common with CIP Supply, orDedicated to TankCIP Supply StrainerCIP Return StrainerCIP Tank Connections
23Types of CIP VESSEL CIP - Sprayhead Selection - Scavenge Control MAINS CIP - Adequate Velocity - Total Route CoverageBATCH/COMBINED CIP - Complex Control - Time Consuming
24Vessel CIP Flow of CIP fluid from CIP supply to vessel sprayhead Internal surfaces cleaned by spray impact / delugeReturn from vessel by CIP scavenge (return) pumpCIP ReturnCIP SupplyCIP Scavenge PumpProcess VesselCIP Gas pipeIsolate from Process
26Vessel CIP – Sprayballs AdvantagesNo 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
28Vessel CIP – Cleaning Machines AdvantagesHigh impact, aggressive cleaningGood for heavy duty cleaningLow water/energy useLow effluentEffective in large vesselsLower absorption of CO2 by causticLower Flow means smaller Pipework
30Mains 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 linesCIP ReturnCIP SupplyIsolate from ProcessIsolate from other Process routesProcess Route being CIP’d
35Process Pipework Design for CIP Ensure Total Route coverageAvoid Split routesAvoid Dead endsAvoid TeesMost Critical on Yeast & nearer packaging
36Process Pipework Design for CIP Isolate CIP from ProcessMixproof ValvesFlowplatesCIP ReturnProcess Line – Not being CIP’dProcess Line –being CIP’dFLOWPLATEPhysical Break between routes
37Batch/Combined CIP Combines CIP of Why ? Vessel/s and Pipework 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.
38Batch/Combined CIP Supply of a batch volume of CIP to process vessel Internal recirculation of CIP within/through process vesselTransfer of CIP to next vesselPumped return of CIP batch volume to CIP set.
39CIP Monitoring & Control On-Line Detergent TemperatureDetergent Strength - ConductivityReturn ConductivityDetergent Start InterfaceDetergent End InterfaceRinse ConductivityReturn FlowRecirc/Return TimeSupply Pressure