{"id":1612,"date":"2023-10-31T02:18:56","date_gmt":"2023-10-31T02:18:56","guid":{"rendered":"https:\/\/processequipmentandcontrols.com\/?p=1612"},"modified":"2024-07-23T10:13:41","modified_gmt":"2024-07-23T14:13:41","slug":"clean-in-place-cip-systems-for-hygienic-manufacturing","status":"publish","type":"post","link":"https:\/\/processequipmentandcontrols.com\/clean-in-place-cip-systems-for-hygienic-manufacturing\/","title":{"rendered":"Clean-In-Place (CIP) Systems for Hygienic Manufacturing"},"content":{"rendered":"<section id=\"wg-section-block_ebef3ba2e4c2f6651fee062b7ede8fc5\" class=\"blockPadding wg-section wg-sectionblock_ebef3ba2e4c2f6651fee062b7ede8fc5 has--background-color\"><div class=\"wrapper\"><div class=\"acf-innerblocks-container\">\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"470\" src=\"https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/Pharmaceutical-Manufacturing-5.jpg\" alt=\"Mezzanine in pharmaceutical manufacturing plant\" class=\"wp-image-1243\" srcset=\"https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/Pharmaceutical-Manufacturing-5.jpg 800w, https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/Pharmaceutical-Manufacturing-5-300x176.jpg 300w, https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/Pharmaceutical-Manufacturing-5-768x451.jpg 768w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/figure>\n\n\n\n<p class=\"\"><a href=\"https:\/\/processequipmentandcontrols.com\/market\/industrial-food-beverage\/\">Food and beverage<\/a> processing facilities understand that maintaining impeccable hygiene and cleanliness is vital to ensuring product quality, safety, and purity. Even the slightest lapse in sanitation standards can greatly impact the final product, consumer satisfaction and the company\u2019s reputation.<\/p>\n\n\n\n<p class=\"\">This explains why most food, beverage, dairy, pharmaceutical, cosmetic, and <a href=\"https:\/\/processequipmentandcontrols.com\/market\/bio-science-manufacturing\/\">biotechnology companies<\/a> have invested in clean-in-place (CIP) systems. The main objective of these systems is to automate parts of the sanitation process to deliver a faster and repeatable approach to cleaning manufacturing systems with minimal downtime.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">What Is a CIP System?<\/h2>\n\n\n\n<p class=\"\">A clean-in-place (CIP) system is a combination of mechanical components and devices used to clean the interior contact surfaces of a processing system without dismantling parts of the equipment to accommodate cleaning. These systems combine water, chemicals, and heat to create efficient cleaning solutions for mixers, fermenters, piping vessels, fillers, blenders, and other equipment within a manufacturing or processing system.<\/p>\n\n\n\n<p class=\"\">After every processing run, a <strong>CIP cycle usually removes material buildup, soil, and other contaminants.<\/strong> It is also used to clean, rinse, and sanitize the equipment before switching the processing line from one product to another.<\/p>\n\n\n\n<p class=\"\">CIP system designs vary greatly depending on the application, facility standards, and industry. Even though the basic components usually remain the same, the differences in how they\u2019re designed and used distinguish a CIP system for a dairy processing plant from that of a brewery.<\/p>\n\n\n\n<p class=\"\">CIP Skids are pre-engineered and prefabricated systems designed as an easy-to-install solution to fulfill specific requirements. They provide a physical framework for the CIP system components, allowing operators to quickly and easily assemble the system. The skid also acts as a containment base for wastewater created during the cleaning process.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"470\" src=\"https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/food-processing-industry-3-1.jpg\" alt=\"process piping and holding tanks in a dairy processing plant\" class=\"wp-image-1145\" srcset=\"https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/food-processing-industry-3-1.jpg 800w, https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/food-processing-industry-3-1-300x176.jpg 300w, https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/food-processing-industry-3-1-768x451.jpg 768w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\">Essential Components of a CIP System<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li class=\"\">One or multiple tanks connected to a clean water source. The size and number of tanks depend on the size of the processing plant and the complexity of the required cleaning<\/li>\n\n\n\n<li class=\"\">Shell and tube heat exchangers<\/li>\n\n\n\n<li class=\"\">Pump with adequate flow rate and pressure<\/li>\n\n\n\n<li class=\"\">Pumps to add chemical sanitizers<\/li>\n\n\n\n<li class=\"\">Centrifugal pumps and valves for water supply<\/li>\n\n\n\n<li class=\"\">Discharge strainer<\/li>\n\n\n\n<li class=\"\">Electronic or manual method of recording data<\/li>\n\n\n\n<li class=\"\">Water addition assembly<\/li>\n\n\n\n<li class=\"\">Suction, return valves, and process piping<\/li>\n\n\n\n<li class=\"\">Instrumentation and automated controls<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Steps Involved in a Clean-In-Place Cycle<\/h2>\n\n\n\n<p class=\"\">CIP cycles&#8217; sequence, duration, and elements vary from one processing system to another. However, the following are the most common steps followed by most CIP cycles:<\/p>\n\n\n\n<div class=\"zig-zag-list-block\">\n    <div class=\"acf-innerblocks-container\">\n\n<div class=\"zig-zag-list-item-block\">\n\n    <div class=\"acf-innerblocks-container\">\n\n<p class=\"zig-zag-list-item-block-counter\">1<\/p>\n\n\n\n<div class=\"wp-block-group is-layout-flow wp-block-group-is-layout-flow\">\n<h3 class=\"wp-block-heading has-medium-font-size\">Pre-rinse<\/h3>\n\n\n\n<p class=\"\">A well-executed pre-rinse does the following:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li class=\"\">Soaks the interior surfaces of the process piping and tanks<\/li>\n\n\n\n<li class=\"\">Removes most of the remaining material buildup<\/li>\n\n\n\n<li class=\"\">Melts fats and dissolves sugars<\/li>\n\n\n\n<li class=\"\">Provides a pressure test of the CIP system<\/li>\n<\/ul>\n<\/div>\n\n<\/div><\/div>\n\n\n<div class=\"zig-zag-list-item-block\">\n\n    <div class=\"acf-innerblocks-container\">\n\n<p class=\"zig-zag-list-item-block-counter\">2<\/p>\n\n\n\n<div class=\"wp-block-group is-layout-flow wp-block-group-is-layout-flow\">\n<h3 class=\"wp-block-heading has-medium-font-size\">Caustic Wash<\/h3>\n\n\n\n<p class=\"\">A caustic wash softens fats and makes them easier to remove from the system. Sodium hydroxide is often used for most caustic washes due to its high pH. In most cases, the alkali is used in a concentration range of 0.5-2.0%. However, plant operators can use high concentrations of up to 4% in cases where the internal surfaces are highly contaminated.<\/p>\n<\/div>\n\n<\/div><\/div>\n\n\n<div class=\"zig-zag-list-item-block\">\n\n    <div class=\"acf-innerblocks-container\">\n\n<p class=\"zig-zag-list-item-block-counter\">3<\/p>\n\n\n\n<div class=\"wp-block-group is-layout-flow wp-block-group-is-layout-flow\">\n<h3 class=\"wp-block-heading has-medium-font-size\">Intermediate Rinse<\/h3>\n\n\n\n<p class=\"\">The intermediate rinse helps flush out the remaining residue from the caustic wash. It&#8217;s important to use proper instrumentation for every step of the CIP cycle to ensure efficient cleaning.<\/p>\n<\/div>\n\n<\/div><\/div>\n\n\n<div class=\"zig-zag-list-item-block\">\n\n    <div class=\"acf-innerblocks-container\">\n\n<p class=\"zig-zag-list-item-block-counter\">4<\/p>\n\n\n\n<div class=\"wp-block-group is-layout-flow wp-block-group-is-layout-flow\">\n<h3 class=\"wp-block-heading has-medium-font-size\">Final Rinse<\/h3>\n\n\n\n<p class=\"\">In this step, plant operators rinse the processing system using deionized water (DO), water processed through reverse osmosis (RO), or clean city water to remove residual cleaning agents.<\/p>\n\n\n\n<p class=\"\">The final rinse water can be recovered and reused for pre-rinsing to minimize wastage. The chemicals and heat retained by the rinse water will make the next pre-rinse even more effective and efficient.<\/p>\n<\/div>\n\n<\/div><\/div>\n\n\n<div class=\"zig-zag-list-item-block\">\n\n    <div class=\"acf-innerblocks-container\">\n\n<p class=\"zig-zag-list-item-block-counter\">5<\/p>\n\n\n\n<div class=\"wp-block-group is-layout-flow wp-block-group-is-layout-flow\">\n<h3 class=\"wp-block-heading has-medium-font-size\">Sanitizing Rinse<\/h3>\n\n\n\n<p class=\"\">A sanitizing rinse is often necessary for killing germs before starting the next production run. Many experts recommend using sodium, potassium, or calcium hypochlorite solutions in your CIP cycle as sanitizers.<\/p>\n<\/div>\n\n<\/div><\/div>\n<\/div><\/div>\n\n\n<h2 class=\"wp-block-heading\">Benefits of CIP Systems<\/h2>\n\n\n\n<p class=\"\">Manual cleaning of processing equipment is usually costly, tedious, and time-consuming. Since all processing facilities are required to maintain a certain degree of cleanliness, investing in a CIP system is the best possible cleaning solution.<\/p>\n\n\n\n<p class=\"\">The following are the advantages of a CIP system:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li class=\"\"><strong>Process Consistency &#8211; <\/strong>Automating the cleaning processing equipment means no missed steps, no missed residue, no wrong combination of chemicals, or any other form of human error.&nbsp;<\/li>\n\n\n\n<li class=\"\"><strong>Employee Safety &#8211; <\/strong>Containing cleaning solutions inside the system minimizes chemical exposure to all personnel.<\/li>\n\n\n\n<li class=\"\"><strong>Quality Assurance &#8211; <\/strong>Predictable and repeatable cleaning makes maintaining product quality and purity easier. Minimized contamination risk also translates to fewer product recalls and a good reputation for the brand.<\/li>\n\n\n\n<li class=\"\"><strong>Faster Turnaround Time &#8211;<\/strong> With automated cleaning, the processing plant can get back to production in the shortest time possible. This increases production and generates more revenue for the plant.<\/li>\n\n\n\n<li class=\"\"><strong>Cost Savings &#8211; <\/strong>This system reduces the water, energy, labor, and time needed to clean processing equipment.<\/li>\n\n\n\n<li class=\"\"><strong>Improved Food Safety &#8211; <\/strong>Thoroughly sanitizing and cleaning the interior surfaces of a processing system minimizes the risk of foodborne illnesses. It also ensures a processing plant\u2019s compliance with the FSMA regulations.<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1000\" height=\"750\" src=\"https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/IMG_20161230_183844-Ryan-Loew.jpg\" alt=\"Conveyor Automation\" class=\"wp-image-966\" srcset=\"https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/IMG_20161230_183844-Ryan-Loew.jpg 1000w, https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/IMG_20161230_183844-Ryan-Loew-300x225.jpg 300w, https:\/\/processequipmentandcontrols.com\/wp-content\/uploads\/2023\/10\/IMG_20161230_183844-Ryan-Loew-768x576.jpg 768w\" sizes=\"(max-width: 1000px) 100vw, 1000px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Factors To Consider When Specifying a CIP System<\/h2>\n\n\n\n<p class=\"\">Consider the following when choosing a CIP system for your processing facility:<\/p>\n\n\n\n<p class=\"\"><strong>Size of the Facility &#8211;<\/strong> The size of the processing facility will determine the type of CIP system needed. Smaller facilities usually require compact CIP systems, while bigger facilities require more powerful cleaning solutions.<\/p>\n\n\n\n<p class=\"\"><strong>Type of Equipment &#8211; <\/strong>The material used for the process piping and equipment will influence the design of your CIP system. You want to ensure the system won\u2019t cause extensive chemical and mechanical damage during cleaning operations.<\/p>\n\n\n\n<p class=\"\"><strong>Type of Product &#8211;<\/strong> Different types of foods and chemical contaminants present unique cleaning requirements. Therefore, considering the type of product you\u2019ll be cleaning regularly will help you understand the features needed for your CIP system.<\/p>\n\n\n\n<p class=\"\"><strong>Budget &#8211; <\/strong>The full extent of CIP system features and capabilities mainly depends on the processor used and your budget. A smaller budget will get you the most basic CIP system available, while more money can buy a fully automated system.<\/p>\n\n\n\n<p class=\"\"><strong>Safety and Compliance &#8211; <\/strong>Ensure the CIP system you get for your specific plant complies with industry regulations.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Ensuring Food Safety With Hygienic Manufacturing<\/h2>\n\n\n\n<p class=\"\">We pick up germs daily from all kinds of places without even realizing it. With time, some of these germs can easily cause serious foodborne diseases such as salmonella, listeria, and Hepatitis A.<\/p>\n\n\n\n<p class=\"\">As a result, those involved in food production need to observe the following practices of hygienic manufacturing to ensure food safety:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li class=\"\">Always rinse fresh raw materials with running water<\/li>\n\n\n\n<li class=\"\">Train your employees on the importance of maintaining a clean work environment<\/li>\n\n\n\n<li class=\"\">Wash, sanitize, and disinfect contact surfaces and equipment using hot and soapy water before and after use<\/li>\n\n\n\n<li class=\"\">Avoid reusing water and chemicals when handling allergens to avoid cross-contamination<\/li>\n\n\n\n<li class=\"\">Ensure all areas in the food processing plant are free of pests and insects to prevent contamination<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Work With a Workplace Safety Expert Today<\/h2>\n\n\n\n<p class=\"\">Do you need help staying in compliance with OSHA regulations? At Process Equipment &amp; Controls (PEC), we have what it takes to help you achieve the health and <a href=\"https:\/\/processequipmentandcontrols.com\/about\/safety\/\">safety<\/a> standards required in your line of business.<\/p>\n\n\n\n<p class=\"\">Contact us today to learn more about our services.<\/p>\n\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button is-style-fill\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/processequipmentandcontrols.com\/contact-us\/\">Let&#8217;s Talk<\/a><\/div>\n\n\n\n<div class=\"wp-block-button is-style-outline is-style-outline--0240a6f197559ea9aa229646bbde9370\"><a class=\"wp-block-button__link wp-element-button\" href=\"\/service\">What We Do<\/a><\/div>\n<\/div>\n\n<\/div><\/div><\/section>","protected":false},"excerpt":{"rendered":"","protected":false},"author":6,"featured_media":1243,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_seopress_robots_primary_cat":"none","_seopress_titles_title":"Clean-In-Place (CIP) Systems for Hygienic Manufacturing | PEC","_seopress_titles_desc":"Do you need help staying in compliance with OSHA regulations? Reach out to Process Equipment & Controls to help you achieve the regulatory standards required!","_seopress_robots_index":"","nf_dc_page":"","footnotes":""},"categories":[1],"tags":[],"class_list":["post-1612","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"acf":[],"_links":{"self":[{"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/posts\/1612"}],"collection":[{"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/users\/6"}],"replies":[{"embeddable":true,"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/comments?post=1612"}],"version-history":[{"count":3,"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/posts\/1612\/revisions"}],"predecessor-version":[{"id":2808,"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/posts\/1612\/revisions\/2808"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/media\/1243"}],"wp:attachment":[{"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/media?parent=1612"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/categories?post=1612"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/processequipmentandcontrols.com\/wp-json\/wp\/v2\/tags?post=1612"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}