Clean-in-place (CIP) systems have been used in the food, beverage, and dairy industry for more than 60 years. However, running these systems often wastes large quantities of water, energy, and chemicals. To combat these losses, engineers have been generating new solutions to optimise the clean-in-place process and improve the overall performance of these systems.
Importance & Benefits of Optimising CIP Processes
Efficiency Gains
Optimising CIP processes can decrease the time it takes to clean the equipment, increasing production levels and making them more efficient. This also comes with substantial cost savings in terms of cleaning agents and water usage.
Conserving Materials
An optimised CIP system uses fewer chemicals and less water, which can conserve important materials, especially if your company handles your wastewater treatment on-site.
Quality Assurance
A fully optimised clean-in-place system ensures a sanitary clean and gives you complete confidence that your process is yielding a high-quality product.
Common Issues in CIP Processes
Residue Build-up
There might be a presence of stagnant residual water, residual cleaning materials, or residual product left behind at the end of the cleaning cycle, particularly in low-drain regions. This can cause microbe formation and increases the risk of product contamination.
Inadequate Cleaning
Equipment failure in clean-in-place systems is common and can happen at any stage of the process. Such failure results in improper cleaning which in turn, can have a big impact on food safety and violate strict industry safety regulations.
Water and Resource Waste
The CIP process uses a significant amount of energy and materials; chemicals, detergents and sterilising fluids are all used in the cleaning procedure. Once used in the process, these materials all become waste and must be disposed of.
Best Practices for CIP Optimisation
Robust Cleaning Protocols
Following robust protocols, including maintaining the optimum flow rate and pressure within a clean-in-place system, can help optimise the system’s cleaning performance.
Utilising Advanced CIP Technologies
Smart CIP technologies can calculate the optimal mix of water, chemicals, temperature, and flow, so plant managers can reduce system energy costs while still following important safety standards.
Automation and Control Systems
Installing automation and control systems, such as sanitary sensors, can optimise the duration of each individual cleaning step and ensure reproducible quality of the cleaning result.
Monitoring and Quality Control
Real-time Process Monitoring
Monitoring the clean-in-place process in real time is also an essential part of system optimisation. Failing to effectively monitor the process can lead to overcaution and results in wastage not only in cleaning resources but in production time, too.
With a wealth of experience in the supply, installation, and ongoing maintenance of clean-in-place solutions, our equipment can help businesses in the food, dairy, and beverage industries meet strict CIP system requirements. To find out more, contact S4 Engineering today.
