Cleaning of production halls and equipment in beer production
Clean-in-place (CIP) is a method of cleaning the interior surfaces of pipes, vessels, process equipment, filters and associated fittings, without disassembly.
The benefit of using CIP is that the cleaning is faster, less labour-intensive and more repeatable, and poses less of a chemical exposure risk to people. CIP started as a manual practice involving a balance tank, centrifugal pump, and connection to the system being cleaned. Since the 1950s, CIP has evolved to include fully automated systems with programmable logic controllers, multiple balance tanks, sensors, valves, heat exchangers, data acquisition and specially designed spray nozzle systems. Simple, manually operated CIP systems can still be found in use today.
Depending on soil load and process geometry, the CIP design principle is one of the following:
- deliver highly turbulent, high flow-rate solution to effect good cleaning (applies to pipe circuits and some filled equipment).
- deliver solution as a low-energy spray to fully wet the surface (applies to lightly soiled vessels where a static sprayball may be used).
- deliver a high energy impinging spray (applies to highly soiled or large diameter vessels where a dynamic spray device may be used).
Elevated temperature and chemical detergents are often employed to enhance cleaning effectiveness.
A typical CIP cycle consists of many steps which often include (in order):
- Pre-rinse with WFI (water for injection) or PW (purified water) which is performed to wet the interior surface of the tank and remove residue. It also provides a non-chemical pressure test of the CIP flow path.
- Caustic solution single pass flush through the vessel to drain. Caustic is the main cleaning solution.
- Caustic solution re-circulation through the vessel.
- Intermediate WFI or PW rinse
- Acid solution wash – used to remove mineral precipitates and protein residues.
- Final rinse with WFI or PW – rinses to flush out residual cleaning agents.
- Final air blow – used to remove moisture remaining after CIP cycle.
Critical parameters must be met and remain within the specification for the duration of the cycle. If the specification is not reached or maintained, cleaning will not be ensured and will have to be repeated. Critical parameters include temperature, flow rate/supply pressure, chemical concentration, chemical contact time, and final rinse conductivity (which show that all cleaning chemicals have been removed).
Each brewhouse will have different CIP-programs for different equipment:
- Brewhouse vessel CIP
- Wort line CIP
- Filter CIP
- Filler CIP
- CIP of CIP-Vessels
Plus each CIP – program may use different cleaning media including
- Water (fresh water, recycled water for pre cleaning)
- Disinfection agents
Basis CIP System
Typically controlled by a stand alone PLC/HMI Panel that requires the brewer to operate the production equipment manually to ensure proper sanitation. Often, these systems will require that the brewery be shut down during sanitation as it is too difficult to ensure that the CIP and the Process will not mix. Usually without feedback to the rest of the brewery. You can connect them to the plant system in the future
Fully Integrated CIP System
One Automation System for both production and CIP needs. The Brewer can schedule CIP “Batches” as well as production batches on the same system. They are custom developed to meet a specific breweries needs. Can trace what has and what has not been cleaned and can schedule CIP recipes for pieces of equipment (such as a Mash Tun) or whole production lines (such as the entire brewery). The brewery automation system can actually hold up batches until the sanitation is guaranteed and documented.
- Brewhouse CPI
- Brewery Systems
Source: GEA Brewery Systems