Clean-in-place (CIP) systems are automated systems used to clean the interior surfaces of industrial equipment such as pipes, vessels, tanks, and filters, without the need for disassembly. This process has replaced several manual methods, which typically involved dissembling the product to clean each separate component.
Since their introduction in the mid-1950s, CIP systems have revolutionized numerous industrial processes, making cleaning operations faster, less labor-intensive, and more consistent. The unique CIP system design has also increased overall process safety by reducing the exposure of plant personnel to hazardous cleaning chemicals.
Components of CIP Systems
Although CIP systems vary widely in configuration, operation, and degree of automation, they all consist of the following basic elements:
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Programmable logic controllers — Programmable logic controllers (PLC) are specialized digital computers used to control industrial processes and machines. These devices automate and optimize CIP cleaning processes by controlling actions such as rinse cycles, flow rates, pressures, and water/chemical consumption.
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Balance tanks — Balance tanks are used to maintain a constant fluid level above the pump inlet. Some cleaning systems may utilize multiple balance tanks to prevent cross-contamination, increase cleaning capacity, or improve system efficiency.
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Sensors — Sensors are typically used in balance tanks to help maintain consistent tank volumes, detecting maximum and minimum tank levels and transmitting data to logic controllers for appropriate action.
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Valves — Automated CIP systems use valves to regulate the flow of water and chemicals during the cleaning process. These valves are often controlled by actuators, which take action based on the output of programmable logic controllers.
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Data acquisition — Data acquisition systems are responsible for sampling specific parameters and converting them into digital signals to be acted upon by the logic controller. These systems are used to report key metrics such as temperature, pressure, flow, and water levels.
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Spray nozzle systems — Spray nozzles are precision devices used to deliver the cleaning or rinsing agent during cleaning. Nozzles can be adjusted to change the distribution area of the liquid or create a greater impact on the surface being cleaned.
CIP Industries and Applications
Mix vessels, bioreactors, fermenters, and other storage equipment are regularly cleaned by CIP systems. CIP is especially useful in industries in which the quality of process fluids is highly sensitive to contamination. The process is typically used to destroy bacteria and cell cultures, remove residue and debris, and control bioburden and endotoxin levels in processing equipment. In fact, industries have become so reliant on CIP that in 1978, the U.S. Food and Drug Administration (FDA) published a set of clean-in-place guidelines for pharmaceutical manufacturing.
Below are a few of the most common industries making use CIP methods for process equipment.
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Food and beverage
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Dairy
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Brewing
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Processed foods
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Pharmaceutical
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Biomedical
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Cosmetics
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Specialty chemicals
The Value of CIP Systems
CIP systems continue to evolve, gaining popularity among a range of industries worldwide. Their fast, automated, and efficient method of cleaning helps improve the quality of process products while reducing the costs and stress associated with maintenance downtime.
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