CIP and Sanitation of Process Plant

Water soluble deposits include: Contamination is not visible under good lighting conditions
Sugars and some salts with the surface wet or dry
The surface does not give a greasy feeling to clean fingers
when they are rubbed on to the surface
Alkali soluble deposits include:
No objectionable odour is apparent
Fats A new white facial tissue wiped several times over the surface
Proteins shows no discolouration
The surface is completely wetted when water is draining from it
Acid soluble deposits include:
No sign of fluorescence is detectable when the surface is
Calcium salts inspected with a long wave ultraviolet light
Organic solvent soluble deposits After sanitising the surface it will not cause re-infection of the
Mineral Oils product coming into contact with it
Soils can be simple or highly complex mixtures depending on A commonly applied test is to determine the presence of
the food product that is being processed. The soil can be made micro-organisms in the final flush water, but in this respect, it is
more difficult to remove by the application of excessive heat important to realise that micro-organisms will usually always be
treatment. This is why the temperature difference between the present in mains and bore hole water supplies. The total count
heating medium and the product should be kept to a minimum of potable water should not exceed 100 cfu/ml (colony forming
in the case of highly fouling materials such as UHT milk - ideally units) with the absence of coliforms and E.coli in 100ml.
no more than 1 * or 20C.
It is therefore necessary to analyse the flush water for any
Only practical experience can determine how long a plant can increase in micro-organisms during passage through the plant.
be run before it has to be cleaned, and how long the cleaning
A more recent technique is the use of ATP (adenosine tri-
regime will need to be.
phosphate) sensors. ATP is a natural component and is the
If plants are allowed to run for too long it may not be possible to chemical in which energy is stored in all living cells such as
clean without dismantling. This applies especially if the flow path bacteria. ATP is also present in food soils.
becomes substantially blocked.
In the presence of luciferase (an enzyme derived from the
Any plant involving heat treatment must be carefully monitored firefly), the substrate luciferin, oxygen and magnesium ions, ATP
to identify when cleaning is required. Fouling is directly related is catalysed to ADP (adenosine di-phosphate) with the release
to the temperatures applied. of light. The quantity of light released is a direct measure of the
Dryness or ageing can influence the stability of the soil and its concentration of ATP. There are several commercial suppliers
effective removal by cleaning chemicals. of ATP sensing kits, which can detect very low levels of residual
bacteria after CI P and sanitisation.
The complexity of some soils can be illustrated by soils found in
a dairy plant: A very effective technique to determine residual soil within
a complex plant component such as a valve or pump is to
Milk remaining in a pipeline
recirculate a solution of potassium permanganate through
Air-dried films of milk
the component, whereupon it will react with any soil to form
Heat-precipitated milk constituents (protein and milkstone)
manganese dioxide. The permanganate is flushed out with
Fat
water and replaced with a solution of hydrogen peroxide, and
Hard water salts
the inlet and outlet to the component sealed. The manganese
Miscellaneous foreign matter
dioxide within the soil acts as a catalyst for the decomposition
The situation becomes even more complex in a milk UHT plant of hydrogen peroxide to water and oxygen. The production of
as protein will be the predominant soil at temperatures of up oxygen can be measured using a pressure gauge installed in the
to 115'C whilst mineral deposits will prevail as the temperature line.
increases further. The cleanliness of the surfaces of individual items of process
Each type of soil will need a specific regime for removal. equipment can also be assessed using swab tests where a
pre-determined surface area is wiped with a sterilised swab and
then incubated to detect micro-organ isms.
ASSESSMENT OF CLEANING EFFICIENCY
After CIP, the product contact surfaces must be free from Finally, the EHEDG has developed a very demanding CIP test to
residual film or soil so that they do not contaminate food validate the hygienic design of individual plant components prior

8 22003-05-02-201 3-GB
 CIP and Sanitation of Process Plant

('lP
- rip-zinn rritpri.q
.0. - -- -
minutes. Typically 1 00 ppm at 25C for two minutes is adequate
for pre-cleaned surfaces.
Not only is it essential that the equipment is properly cleaned, Great care is needed should there be any aluminium, copper or
it is also fundamental that the product is protected from any bronze product contact surfaces in the line. This should not be
possibility of contamination by CI P solutions. the case, however, in a modern process plant. Such materials are
commonplace in older brewery process units. Caustic soda is
Plant is cleaned by the combination of dissolving the soil or
corrosive to aluminium whilst acids will attack copper and bronze.
removing it by scouring of the surfaces. Before cleaning any
product in the plant must be reclaimed.
CIRCULATION TIME
After cleaning the plant must be sanitised (removal of any
The period of circulation depends on the degree of fouling
pathogenic organisms but not necessarily all m icro-o rgan isms).
and the type of equipment being cleaned. Typically 20 mins of
A system of maintaining a physical break between a product line caustic circulation is required for pipework and vessels.
and a CI P line must be adopted at all times in order to eliminate
Pasteurisers and UHT plants which suffer from higher levels of
the possibility of chemical contamination of the product.
fouling may require up to 40 mins of caustic circulation. Acid
circulation is normally 10 mins.
CHOICE OF CHEMICALS
The choice of chemicals is governed by the materials of
OPERATING TEMPERATURES
construction of the plant. As mentioned previously, the most
Contrary to popular belief, the higher the temperature the poorer
common material of construction is austenitic stainless steels,
the soil removal with an optimum at 50C. In practice, caustic is
which are very resistant to most cleaning solutions (with the
usually circulated at higher temperatures in order to improve the
exception of high-chloride solutions).
sanitising effect.
In the food industry, the most common form of fouling is the
deposition of proteins. These are nearly always removed by hot
FLOW VELOCITY
alkali (caustic soda) assisted by wetting agents that break up Process plant should always be cleaned under turbulent flow
the protein into water soluble units. Typically 2% caustic soda
conditions. The efficiency of cleaning under laminar flow
will be used at temperatures of up to 85C. For highly fouled
conditions, i.e. < 1.4 m/s, is not sufficient. For this reason, flow
surfaces of up to 4% can be applied.
velocities in the region of 1.5 to 2.1 m/s are usually applied.
Milkstone and calcium deposits are easily removed by the use
The use of a high velocity also improves cleaning efficiency in
of a dilute mineral acid. Nitric acid is the most common although
small dead legs, for example at instrumentation or sample valves.
phosphoric acid can also be used. Typically 0.5% nitric acid at
temperatures up to 50C is used. Above this temperature, heat It has been generally considered that flow velocities in excess
exchanger gaskets can be adversely affected. Hydrochloric or of 2.1 m/s are not beneficial, but recent work indicates that the
sulphuric acids should never be used. application of even higher flow velocities can enable a beneficial
reduction in cleaning chemicals.
Apart from basic caustic soda and nitric acid, special
formulations have been developed by detergent manufacturers
containing added components such as sequestrants. A typical SELECTION OF SPRAY DEVICES
sequestering application is the solubilisation of calcium and Scouring and wetting of the surfaces inside tanks and vessels
magnesium salts using EDTA (ethylenediaminetetra-acetic acid) is achieved by the use of spray devices. Simple spray balls are
to prevent precipitation by alkaline detergents. the most commonly used. The holes are positioned to provide
maximum impingement in areas of high fouling. These devices
Acid should never be used ahead of the alkaline clean when run at relatively low pressures (1 to 2 bar).
removing milk deposits. Acid will cause the precipitation of
Rotating jet devices must be used for vessels with a high degree
protein with the result that it is more difficult to subsequently
remove. of fouling or with large diameters (>3m). These operate at
higher pressures (5 bar).
Sanitation is achieved by the use of hot water, hypochlorite or
one of the peroxide based sterilants such as Oxonia P4. Vessels with top mounted agitators must always be fitted with
two spray balls to overcome shadows cast by the agitator shaft
If hypochlorite (sodium) is used for sanitising the strength and blades. A similar consideration often exists for tank vents
should not exceed 150ppm free chlorine, the temperature be where a small spray ball may need to be positioned at the vent
kept below 40C, and the circulation time kept below twenty to improve CIP.

22003-05-02-201 3-GB 9
 CIP and Sanitation of Process Plant

CALCULATION OF FLOW RATES Chemical dosing pumps for adding concentrates to bulk tanks
FOR SPRAY BALLS should be sized to transfer at as high a rate as is feasible
The size of the spray device and its capacity are dependent depending on the concentrate storage method. Normally
on the diameter of the vessel. Spray balls are only suitable for carboys are used which limit the rate to 250 l/h.
vessels up to 3m in diameter. Chemical dosing pumps for adding concentrates in-line should
For vertical vessels (incl. silos): be sized to give an even addition to the flow. A flow rate of 60
Flow rate (l/h) --diam (m) x 3.14 x 1490 l/h is typically used.

For horizontal tanks:

-- PURGING OF PRODUCT FROM
Flow rate (l/h) diam (m) + length (m) x 2 x 1490
THE PROCESS PLANT
For other tanks:
--
Recovery of product from process lines is increasingly important
Flow rate (l/h) side (m) + end (m) x 2 x 1490
in todays economic environment. In atypical 1 million litres day
When the rate is known the correct size of spray ball can be drinking milk plant a 0.5% loss of milk is equivalent to a loss of
selected. Orifice pieces will be used to set the rates. raw material valued at 1,300 per day or 475,000 per year. It
is thus appropriate to pay special attention to product recovery.
A range of spray devices is available from specialist manufacturers.
Purging can be achieved using water, air or an inert gas and can
SELECTION OF CIP PUMPS either be part of a process sequence or the first stage of a CIP
CIP supply pumps should always be of the centrifugal type to sequence. Accuracy is important to ensure product is not left in
give the necessary variations in flow and pressure. Each CI P the line nor that purge medium is added to the product.
supply pump should be individually sized to handle the highest
rate and highest pressure circuit it will supply.
Water purging is the most accurate medium and time is
Orifice pieces should be used where reduced rates are required commonly used to control the process. But this can be
(for example before spray balls as mentioned previously). inaccurate unless combined with positive pumps.
CIP return pumps should always be of the self priming liquid Where possible flow meters should be used combined to known
ring type due to the scavenging duty required. CI P return pumps pipe volumes and conductivity probes provide an accurate
should be sized to return fluids at a rate 10% greater than the detection of the interface between product and water.
supply pump.
Purging of heat exchangers can result in large interfaces
CIP booster pumps should also be of the centrifugal type and especially in multi-pass machines.
should be carefully sized so as not to introduce cavitation into
Diluted product can be recovered for addition back to the raw
the circuit.
feed (except in the case of drinking milk where legislation

10 22003-05-02-201 3-GB
 CIP and Sanitation of Process Plant

prohibits any dilution with water) or used for animal feeding. In Do not mix large diameter with small diameter line cleans.
the case of drinking milk, SPX has developed reverse osmosis Always ensure that every component in the line receives a
membrane technology to concentrate the milk solids back to the turbulent flow rate even if this means other components see a
original level. The recovered milk can then be blended with fresh higher rate. For example a plate heat exchanger in a pipeline
milk for production of products such as cheese or yoghurt. circuit may require a flow rate higher than 2.1 m/s in the line.
Avoid very long line cleans.
A 1 million/day drinking milk plant can generate 25 to 35,000
Where possible clean tanks individually and not in pairs.
litres of white water per day equivalent to some 10,000 litres
Do not try to clean equipment that is not designed for CIP (for
normal milk. The value of this white water over a year can be as
example cheese vats and tanks with lift off lids).
high as 900,000 per annum, easily justifying the installation of
A CI P cycle is generally made up of a combination of the
a reverse osmosis recovery system.
following steps:
With other dairy products, it is often possible to blend a small
Initial purge to recover product, either into product tanks or to
proportion of recovered diluted product with the next batch of
a product recovery system.
raw feed.
First rinse using recovered water (from final flush of previous
CIP cycle) to remove gross soil.
RE-USE OF CLEANING SOLUTIONS Caustic wash with or without recovery to remove residual
It is common practice and economically prudent to re-use both adhering debris.
caustic soda and acid solutions. Where high degrees of fouling Intermediate rinse to clear caustic from the system.
are encountered (for example in milk pasteurisers), it is not Acid wash with or without recovery to remove mineral scale.
always practical to recover the solutions. Final rinse to clear any remaining chemicals from the system.
To minimise water usage, final rinse water is usually recovered Sanitation using heat or chemical sanitiser to destroy any
and used as the first rinse of the next clean. After a certain residual organisms.
number of cleans (approx. 100) it is advisable to dispose of the Additional special operations that may be included are:
solutions due to a build-up of solids in the chemical solutions. Warm pre-rinse prior to initial rinse to remove fats from pipe
Alternatively, SPX has also developed membrane systems to walls
actively filter the soil from cleaning solutions to enable effective A two stage caustic wash in the case of heavily fouled
re-use. equipment - the first wash is routed to drain whilst the second
wash is recovered and re-used.
If it is mandatory that no contamination occurs between batches,
Intermediate cleans while maintaining sterility in the case of
single use systems must be used. a U HT plant where the production run length is compromised
It is not practical to re-use sanitising solutions such as by fouling to an extent that a high delta T is required at the
hypochlorite or oxonia due to a short active life. heat transfer surfaces to maintain production temperatures.
A high delta T can lead to a runaway situation where deposit
forms at an exponential rate.
CIP CYCLES
At the end of each CI P cycle the unit should automatically dose
Every CI P circuit will have its own unique sequence of
fresh cleaning chemical into the bulk tanks to make up for that
operations and cycle times. The different types of clean in
lost during the clean.
an automated operation will usually include the following
operations: Each day a service cycle should be run to check the
concentrations, then dose to achieve the correct strength, and to
Caustic wash
warm up the bulk tanks.
Full clean (with acid)
Hot rinse Service cycles should also be available for dumping the caustic/
Cold clean acid tank and making up fresh solutions..
Intermediate clean
An example of typical dairy pipework clean is as follows:
Pulse cleans (not recommended)
Snake cleans Normal daily clean:
Useful guidelines for the design of the CIP operation are: - Product recovery using fresh purge water
- niItial rinse (3 to 5 mins) using recovered water to drain
Do not mix line cleans with tank cleans.
- Caustic wash at 75C (10 to 20 mins) with recovery
Size the cleaning rate for the largest pipe diameter in the
- Final rinse (3 to 5 mins), fresh water to recovery tank
circuit.

22003-05-02-201 3-GB 11
 CIP and Sanitation of Process Plant

- Cold sanitation (3 to 5 mins) The following instrumentation is required as a minimum:

- Flush with fresh water and drain plant if hypochlorite is used
Temperature loops for control of the caustic and acid
- Leave full if Oxonia is used and drain the following day
temperatures
Once a week the following extra operations will be added, Conductivity transmitters for monitoring of the caustic and
primarily to remove mineral deposits originating from rinsing acid strengths
water: Temperature probes in the return lines for detecting when the
return temperature has reached the desired set point and the
Intermediate rinse (2 to 5 mins), following caustic wash fresh
timers can be started
water to recovery tank
Conductivity probes in the return lines to detect the interface
Acid wash at 50C (1 0 to 15 mins) with recovery
between rinse water and caustic or acid solutions. Also used
DESIGN OF CIP BULK UNITS to ensure that sterilants have been added to the final rinse
The bulk unit is the heart of a CIP system. water
Conductivity probe to detect white water when product
A bulk unit consists of a combination of the following: recovery is incorporated
Bulk tanks for: The question that must then be asked is whether there will
- Fresh water be a central or distributed CIP system. In a central system the
- Recovered water complete process facility is supplied by a single centralised
- Dilute caustic system. In a distributed system, individual sections of the plant
- Dilute acid (optional) can be cleaned with a local dedicated unit.
- Hot water (optional) A dedicated CIP unit will be mandatory for some process
The size of the tank should be calculated by calculating the operations such as membrane processing systems that cannot
capacity of the worst case circuit on each of the CI P supply tolerate the use of aggressive caustic or nitric acid cleaning
pumps, adding them together and doubling the result. solutions and require specially formulated chemicals so as not to
irreversibly damage the membranes.
Product recovery tank (optional)
CIP supply pump(s) As mentioned previously, there should be no more than 6 supply
As a general rule there should not be more than 6 circuits pumps from each unit and separate units should be considered
per CIP supply pump to avoid overloading and/or congestion for pasteurised and raw milk areas.
amongst the routes With fermented dairy products, the fermentation CIP should
Filters on each supply line to prevent blockage of the spray always be separate from the fresh milk section to avoid possible
balls contamination of the milk with bacteriophage, which will reduce
CI P solution heater(s), either in-line on each circuit or as re- or even prevent the fermentation process of the next product
circulation heaters on the bulk tanks. In-line heaters are used batch.
if hot water sterilisation employed. Recirculation heaters are
U HT plant should also always be cleaned separately from
used if there are a large number of circuits
In some cases heat exchangers with regeneration are used to upstream sections of the process.
eliminate the need for insulated bulk tanks and to provide a
gentle heating profile CIP OF THE CIP UNIT
Restrictor valves on the pump outlets are used to reduce Frequently overlooked with multi-use CIP systems is the need
the flow when following a hot cycle with a cold cycle on tank to CIP the system itself to remove soil that has built up during
cleans to prevent implosion cleaning of the process plant. The chemical storage tanks
Alternatively pumps may be fitted with variable speed motor should be partially drained to remove the soil and any product
drives to adjust the flowrate optimally for each CIP cycle and water storage and recovery tanks fully drained. CIP fluids
Double seat ball valves on bulk tanks are used to reduce risk should then be recirculated through spray balls in each vessel.
of accidental leakage of CI P chemicals into the rinse water
At the end of this sequence, the chemical storage tanks are
stream
replenished and the water/product storage and recovery tanks
Dosing pumps for concentrated caustic and acid. Dosing
rinsed with water before re-use.
pumps for sterilant with injection points on each supply line
Recirculation loops for sterilant circulation or break tanks

12 22003-05-02-201 3-GB
 CIP and Sanitation of Process Plant

Apart from the installation of large bulk units and/or ed CIP units The CIP M I DI is intended for small to medium CIP applications,
during initial plant design, SPX also manufactures a range of and will cater for the following capacities and sizes, up to a
standard skid-mounted CIP modules for cleaning of individual maximum of two CIP circuits per CIP set.
process units. These systems are ideal for upgrading of CI P
systems to reduce bottlenecks and enable the plant to go back on
BASIC SPECIFICATIONS
commercial production.
Sanitary, reclaim CIP, multi-compartment horizontal tank (alkali,
Three standard ranges are available: acid )
Rinse water by direct supply
APV MINI - basic single use skid-mounted system with optional
One circuit or two circuits
water rinse and product recovery tanks
Five standard volumetric sizes, (1,000, 1,500, 2,000, 3,000 and
APV MIDI - multiple use skid-mounted system
4,000 litres)
APV MAXI - multiple use system with multiple circuits and
Three standard circulation rates, (8,000, 12,500, 20,000 lph)
tanks custom built on application
Frame mounted equipment and panel (Stainless Steel)
Free-standing horizontal multi-compartment tank
APV CIP MINI SYSTEM
CI P Solution heating in-tank by APV ParaTube, Stainless Steel
The CI P M I N I is is a single-use system with a choice of tank sizes
shell and tube, 12C per pass
and is designed for efficient cleaning of pipeline systems, tanks
Stainless steel steam control (Samson) w/float trap (Sarco FT
and processing plants.
series)
Pneumatic, single-seat rising stem sanitary valves std.
BASIC SPECIFICATION Control tops w/dual feedbacks and solenoids on APV valves
Sanitary, single use CIP w/o recovery, single tank and pilot air svs on service valves
Four standard volumetric sizes, (400, 600, 850 and 1,250 EHEDG APV process equipment (valves, pumps and fittings)
litres) EHEDG sanitary Endress & Hauser Instrumentation
Four standard circulation rates, (8,000, 12,500, 20,000 and (temperature and level)
36,000 lph) CI P supply flow transmitter (magnetic)
Frame mounted tank, equipment and panel (Stainless Steel) AC variable speed drive (Danfoss or Allen-Bradley Powerflex)
CIP Solution heating by APV ParaTube, Stainless Steel shell on CIP supply pump
and tube, 12C per pass CI P return conductivity transmitter
Stainless Steel steam control (Samson) w/float trap (Sarco FT CI P return flow switch
series) Std. I P65 Stainless Steel, high and low voltage panel
Single chemical delivery system (pump, injector and valves) Integral, I P65 panel mounted - Siemens Simatic S7-315-2 PN/
Pneumatic, single-seat rising stem sanitary valves std. DP Siemens M P277 1 0'' H M I panel, mounted in the door of the
Control tops w/dual feedbacks and solenoids on APV valves control panel
and pilot air svs on service valves Std. three-step CIP (prerinse, alkali circulation, postrinse, acid
CIP supply temperature transmitter
circulation, postrinse)
CIP return temperature transmitter I EC electrical std. (230/460V, 3-Phase, 50 Hertz)
EHEDG APV process equipment (valves, pumps and fittings)
. a
EHEDG sanitary Endress & Hauser Instrumentation
(temperature and level)
Std. I P65 Stainless Steel, high and low voltage panel
Integral, I P65 panel mounted - Siemens Simatic S7-315-2 PN/
DP Siemens MP277 10" HMI panel, mounted in the door of
the control panel
Std. three-step CIP (prerinse, alkali circulation and postrinse)
I EC Electrical Std. (230/460V, 3-Phase, 50 Hertz)

-.40

22003-05-02-201 3-GB 13
 CIP and Sanitation of Process Plant

PROCESS
CIP PLANT MINI
WATER
~> - - m m --0 WATER
I .
*- RETURN

I
VIF,
.I
.1 Awftr
I

I
,- - , ~ - , -- .
~JIT
. I

(( - ' .., , ~) ,( ).
11
I
I
now ,, !
~ I ~4-*O~k''A-~ )
~, 11~(; 101~,
,-
!)

II ~
, C:r. I , ,,00'-~M-*,, 0 if, 4 ~ 1 14 ~:,- STUN
-
Ii -U~,
-,~ 'A f ,,~ I 11 -ff~V,K~ 4
I I (I
I (I ,I 0
ii 0 II
.6
i.~
.
,,~ejj-, ,%, --::,I V . -,~
, -
- r a
I

I
~-.la~J~0,
" -- -a----
I
--- 00-- w

AA;L ( ~-A~ q I f-n D n --~->,~

- -
~ ,
,,.~,
~-:jll--IRII'--''~\~lF~:DJ')I~J=o
- - .
04... ?

Fig. 3: APV CI P M I N I system

EQUIPMENT SIZING (PRODUCTION CAPACITIES)

CIP MINI SIZING INFORMATION

FLOW RATE TANK SIZE TANK DROP DISCHARGE &

1. RETURN
MODEL
LPH GPM (US) LITRES GALLONS (US) O.D. INCHES O.D. INCHES
1 1

MINI 1.5 8,000 35 400 106 2 1.5

MINI 2 12,500 55 600 158 2.5 2

MINI 2.5 20,000 88 850 224 3 2.5

MINI 3 36,000 158 1,250 330 4 3

PRODUCTION CAPACITIES

CIP MINI WASHING DUTY SECTION

PIPELINE WASH (2M/S) TANK WASH **

MODEL
MAX. PIPE DIA. (IN) MAX. PIPE LENGTH (M) TANK SIZE (L) TANK SIZE (GALLONS US)

MINI 1.5 1.5 200 2,000 - 10,000 500 - 2,500

MINI 2 2 150 5,000 - 25,000 1,300 - 6,500

MINI 2.5 2.5 150 10,000 - 50,000 2,500 - 12,500

MINI 3 3 150 20,000 - 100,000 5,000 - 25,000

INDICATIVE ONLY - SIZING SHOULD BE BASED ON SPECIFIC TANK SPRAY DEVICE REQUIREMENT

14 22003-05-02-201 3-GB