CIP Technologies. August 1st, 2017

Transcription

1 CIP Technologies August 1st, 2017

2 CIP vs. COP Clean-In-Place (CIP) An automated system for cleaning processing equipment in place without disassembly. o Spray clean vessels and pressure/flow clean piping o Remove residue with chemical o Little manual intervention Clean-Out-of-Place (COP) COP is required to clean process items that are unable to be cleaned in place and must be disassembled to achieve a complete clean.

3 Critical Cleaning Parameters (TACT) Effective cleaning is a combination of both Physical and Chemical processes. When one parameter is decreased the other parameters must compensate. Time Action Chemical/Concentration Temperature Temperature Chemistry Time Action

4 Clean-In-Place (CIP) An automated procedure in which the process equipment is cleaned without disassembly by circulation of cleaning solutions along the process flow path. Advantages Highly reproducible, especially if automated May provide utility savings over manual processes Disadvantages Requires high initial investment Requires extensive engineering of the process and CIP system to ensure cleanability Cannot be applied to all processes

5 Food Plant Cleaning Sequence Example Typical CIP Cleaning Sequence STEP STEP DESCRIPTION TIME (min) TEMP ( F⁰ ) % CHEM. CONCEN. FLOW (gpm) 1 Pre-Rinse none 43 2 Alkaline Wash Rinse none 43 4 Acid Washoptional Rinse none 43 6 Sanitizer Rinse ppm 43 7 Airblow to drain 4 none none NA

6 Pharma Plant Cleaning Sequence Example Typical CIP Cleaning Sequence STEP STEP DESCRIPTION TIME (min) TEMP ( F⁰ ) % CHEM. CONCEN. FLOW (gpm) 1 Pre-Rinse none 43 2 Alkaline Wash Rinse none 43 4 Acid Washoptional Rinse none 43 6 Sanitizer Rinse ppm 43 7 Airblow to drain 4 none none NA

7 CIP Applications Process equipment Product Tanks & Lines Mixers & Blenders Bioreactors & Fermenters Coating Equipment Spiral Freezers Centrifuges

8 CIP of Process Tanks Cascade water down interior surfaces Spray devices installed in tank All tank interior surfaces must be wetted Tank must be evacuated at rate greater than supplied to avoid pooling in tank

9 Spray Ball Coverage Verification How do you verify that your spray devices are covering 100% of the surface area to be cleaned? Riboflavin Testing Procedures Set-up Dye Specification and Application Procedure Rinsing Procedure Inspection and Acceptance Rejection Documentation Post Test Procedure Spray device Test Form

10 CIP of Process Lines Pump solution through lines with sufficient velocity to create turbulent flow. Target velocity > than 5 ft/second If you do not wet the surface it will not be cleaned

11 5 Feet Per Second Cleaning Chart Tube Diameter Flow rate needed to achieve 5 FPS gpm gpm gpm gpm gpm gpm gpm gpm gpm

12 Apply Cleaning Solutions: Once-Through or Recirculate Once-Through CIP Cleaning solution is introduced into process from CIP system and not recirculated. Typical for rinses. Recirculated Cleaning solution is introduced into process from CIP system and returned to the CIP and back to the process multiple times. Typical for chemical washes.

13 Apply Cleaning Solutions: Once-Through or Recirculate Recirculated Cleaning solution is introduced into process from CIP system and returned to the CIP and back to the process multiple times Return pump or other means used to return solutions

14 Single Use of CIP Solutions New cleaning solutions are made with new for each recipe Applied to all cleaning steps Pre-Rinses Alkali Washes Acid Washes Final Rinses

15 Re-Use of CIP Solutions Cleaning Solutions are used multiple times for different CIP circuits When is Re-use common? Alkali Wash Solutions Acid Wash Solutions Final Rinses saved for use as next pre-rinse Sanitizer Rinses - Europe

16 1 Cold RO Water Pre-Rinse to WFI RO Steam Target Tank Chem VERIFY SUPPLY FLOW RATE VERIFY RETURN FLOW

17 2 Hot RO Water Solution Wash Recirculated Wash WFI RO HOLD FOR RETURN TEMP Steam HOLD FOR CHEMICAL CONCENTRATION Target Tank Chem VERIFY SUPPLY FLOW RATE VERIFY RETURN FLOW

18 4 Rinse CIP Tank Rinse tank/wfi through spray ball WFI RO Steam Target Tank Chem

19 5 Hot RO Post-Rinse Post-Rinse To WFI RO Steam Target Tank Chem VERIFY SUPPLY FLOW RATE VERIFY RETURN FLOW

20 8 Rinse CIP Tank Rinse tank/wfi through spray ball WFI RO Steam Target Tank Chem

21 12 Hot WFI Post-Rinse to Post-Rinse To WFI RO Steam Target Tank Chem VERIFY SUPPLY FLOW RATE VERIFY RETURN FLOW

22 13 Air Blow Supply Line WFI RO Steam Target Tank Chem

23 Food & Beverage 3-Tank CIP System

24 Food & Beverage 3-Tank CIP System 1. Pre-rinse to

25 Food & Beverage 3-Tank CIP System 4. Detergent Wash Recirculation Hold for Temperature and Chemistry Hold for Temperature Hold for Conductivity Verify Supply Flow

26 Food & Beverage 3-Tank CIP System 6b. Post-rinse Solution Return to Rinse Recovery Tank Until Full Verify Supply Flow

27 Food & Beverage 3-Tank CIP System 8. Sanitize Rinse to Verify Supply Flow

28 Food & Beverage 3-Tank CIP System 9. Air Blow and Pump Back to

29 Configurations 1-Tank All solutions made up in a common tank Tank is cleaned through sprayball before changing solution types Time should be allowed for repeated filling and cleaning of tank 2-Tank 1st Tank- chem wash solutions 2 nd tank used for final rinse. Optional -Both tanks cleaned through sprayballs Faster than a 1-tank. Final rinse tank filling begins at start of cycle 3-Tank 1st Tank- Saved chem wash solutions 2nd tank- Saved final rinse used for pre-rinse, 3rd tank -cold or hot final rinse. Optional- tanks cleaned through sprayballs Faster than a 2-tank system

30 Portable CIP Systems CIP system brought to the cleaning application Eliminates the need for permanent piping Utility connections required at each point of use Low water usage no long supply and return line Requires more time for setup Suitable for large and small scale applications Identical cleaning performance to Fixed Place systems

31 Stationary CIP Systems Typically installed in a utility space Utilities are only required in one location Supply and return piping are permanently installed Reduced setup time over portable systems

32 Questions??????