1. Brewing Science
Cleaning

2. Brewery Cleaning and Sanitation
Cleaning and sanitation are integral parts of successful brewing
Cleaning: removal of organic and inorganic residues and microorganisms
Sanitation: reduce the population of viable microorganisms and prevent microbial growth

3. Cleaning
Cleaning agents broadly fall into alkaline or acidic detergents; often with added surfactants, chelating agents, and emulsifiers
Must (1) wet surfaces, (2) penetrate residue deposits, (3) hold particles in suspension, and (4) keep inorganic ions in solution

4. Alkaline Detergents
Effectively remove organics: oils, fats, proteins, starches
Hydrolyze peptide bonds, breaking down proteins
Ineffective against inorganics such as calcium oxalate and can leave “beerstone”
PBW is a good example

5. Alkaline Detergents
Sodium Hydroxide: “Its effectiveness in dissolving proteinaceous soils and fatty oils by saphonification is virtually unsurpassed. This makes it a natural choice for cleaning sludge off the bottoms of boilers and for cleaning beer kegs. Sodium hydroxide is an acutely excellent emulsifier too. It is unrivaled in its ability to dissolve protein and organic matter if used in conjunction with chlorine, surfactants, and chelating agents.”
Sodium Hydroxide / Hypochlorite Solutions: “Caustic/hypochlorite mixtures are particularly effective in removing tannin deposits, but are used for a great variety of cleaning tasks. These mixtures can be used in CIP systems for occasional purge treatments or to brighten stainless steel.”

6. Acid Detergents Often used in two step process with alkaine detergents
Less effective against soil, tannins, oils, resins, and glucans
Remove beerstone / calcium oxalate, waterscale (Ca and Mg carbonates), and aluminum oxides
More effective against bacteria

7. Acid Detergents
Phosphoric Acid: widely used to remove deposits, enhanced by acid-stable surfactants. Generally less effective below 16 centigrade.
Nitric Acid: removes deposits and has biocidial properties, particularly in mixture with phosphoric acid. Also breaks down protein. Acid Cleaner #5 is an example.

8. Additives Surfactants / Wetting Agents
Chelating Agents (EDTA, sodium gluconate, sodium tripolyphosphate)
Emulsifiers (orthophosphates and complex phosphates)

9. Sanitation
Sanitizing or disinfecting agents used to reduce the level of microorganisms
Simple physical methods include hot water or hot steam
Chemical sanitizers range in effectiveness, temperature, and contact time requirements

10. Alkaline Sanitizers
Chlorine: Broad spectrum germicides that disrupt membranes, inhibit glucose metabolism, and oxidize protein. Active at low temperatures, inexpensive, leaves low residue
Quaternary Ammonium: stable and non-corrosive, rapid bactericidal action at low concentrations. Efficient against gram-positive bacteria, yeast, and mold. Ineffective against gram-negative bacteria. (Quantum)

11. Acidic Sanitizers
Hydrogen Peroxide: broad spectrum, better against gram-negative.
Peroxyacetic Acid: germicidal, no vapor issues or foam. Requires relatively high concentrations.
Anionic Acids (Star San)
Iodophores: wide biocidal spectrum, equally effective to all microorganisms, but may have staining problems. (IO Star)

12. Methods in Brewery Cleaning
Manual: “Many craft brewers do not have the luxury of cleaning-in-place systems and have to manually clean and sanitize their equipment. They often have to use soft-bristled brushes, non-abrasive pads, cloths, and handheld spray hoses for cleaning. When cleaning manually, great care must be taken to assure that brushes and equipment are cleaned to avoid cross-contamination.”
Clean in Place

13. In Depth CIP Principles and Practice of Cleaning in Place
The following slides are from:
Principles and Practice of Cleaning in Place
Graham Broadhurst
Great Lakes Water Conservation Conference, October 2010

14. 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.

15. How CIP Works Mechanical Chemical Sterilant/Sanitiser
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)

16. Factors affecting CIP
Mechanical
Chemical
Temperature
Time

17. 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

18. Typical CIP Times Vessel CIP Mains CIP Pre-Rinse 10 to 20 mins
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
Acid Detergent
15 to 20 mins
Sterilant

19. Typical CIP Temperature
Brewhouse Vessels Hot 85°C
Brewhouse Mains Hot 85°C
Process Vessels Cold < 40°C
Process Mains Hot 75°C
Yeast Vessels Hot 75°C
Yeast Mains Hot 75°C

20. 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

21. Caustic 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 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.

22. Acid Detergents Advantages Disadvantages
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

23. 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.

24. Sterilant / Sanitiser Requirements
Effective against target organisms
Fast Acting
Low Hazard
Low Corrosion
Non Tainting
No Effect On Head Retention
Acceptable Foam Characteristics

25. Sterilants / Sanitisers
Chlorine Dioxide
Hypochlorite
Iodophor
Acid Anionic
Quaternary Ammonium
Hydrogen Peroxide
PAA (Peroxyacetic Acid) – ppm

26. CIP Systems Single Use Recovery Tank Allocation Number of Circuits
Water/Effluent/Energy costs
Recovery
Detergent Recovery
Rinse/Interface Recovery
Tank Allocation
Number of Circuits

27. Single Use CIP Systems Sterilant Caustic Acid Water CIP Return
CIP Buffer Tank
Water
Conductivity
Flow
CIP Return
Caustic
Acid
Sterilant
CIP Supply
CIP Supply Pump
Temperature
CIP Heater
Steam

28. Recovery CIP Systems 1 x Supply – 3 Tank System
Final Rinse Tank
Water
Conductivity
Flow
CIP Return
Caustic
Acid
Sterilant
CIP Supply
CIP Supply / Recirc Pump
Temperature
CIP Heater
Steam
Pre-Rinse Tank
Caustic Tank
CIP Return / Recirc
CIP Supply / Recirc
LSH
LSL
Temp

29. Recovery CIP Systems 2 x Supply – 4 Tank System – Separate Recirc
CIP Supply A
LSH
Final Rinse Tank
Water
Cond
Flow
CIP Return A
Caustic
Sterilant
CIP Supply A Pump
Pre-Rinse Tank
Caustic Tank LT
Temp
Caustic Recirc Pump
Acid
Acid Tank
Acid Recirc Pump
CIP Return B
CIP Supply B
CIP Supply B Pump

30. Recovery CIP System

31. Single Use vs Recovery Single Use CIP Recovery 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

32. 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

33. 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

34. Types of CIP VESSEL CIP - Sprayhead Selection - Scavenge Control
MAINS CIP - Adequate Velocity - Total Route Coverage
BATCH/COMBINED CIP - Complex Control - Time Consuming

35. 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 Return
CIP Supply
CIP Scavenge Pump
Process Vessel
CIP Gas pipe
Isolate from Process

36. Vessel CIP - Sprayheads
Static Sprayballs
High Flow / Low Pressure
Rotating Sprayheads
Low Flow / Medium Pressure
Cleaning Machines
Low Flow / High Pressure
High Impact

37. 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

38. 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

39. 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

40. Vessel CIP – Cleaning Machines
Disadvantages
Expensive
Moving parts
High pressure CIP supply pump
Possible blockage
Rotation verification
Supply strainer

41. 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 Return
CIP Supply
Isolate from Process
Isolate from other Process routes
Process Route being CIP’d

42. Mains CIP Turbulent & Laminar Flow

43. 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

44. Mains CIP Turbulent Flow – Minimise Boundary layer –
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

45. Mains CIP – CIP Flow

46. Process Pipework Design for CIP
Ensure Total Route coverage
Avoid Split routes
Avoid Dead ends
Avoid Tees
Most Critical on Yeast & nearer packaging

47. Process Pipework Design for CIP
Isolate CIP from Process
Mixproof Valves
Flowplates
CIP Return
Process Line – Not being CIP’d
Process Line –being CIP’d
FLOWPLATE
Physical Break between routes

48. Batch/Combined CIP Combines CIP of Why ? 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.

49. 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.

50. 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

51. CIP Monitoring & Control Off-Line
Visual Inspection
Final Rinse return sampling pH
Micro
ATP
Vessel/Pipework swabs