C.I.P.

CLEANING
DEFINITION
C.I.P. stands for "cleaning-in-place". A pipeline that can be circulated or a vessel that
can be sprayed with a minimum of hand detailing and physical changes to the equipment
configuration is considered "C.I.P."
Typically, a "C.I.P." system would include a solution reservoir, a supply pump, and a
return circuit In the case of a tank or other similar vessel, a spray device and some type
of return pump may also be included. Cleaning solution that is put through a spray device
to wash a vessel and then directly to drain or to a pipeline that is flushed through directly
to drain could not be considered "C.I.P.", as there is no recirculation established.
APPLICATIONS
Any closed vessel (tanker, tank, vat, chamber, hopper, or bin) can be "C.I.P." cleaned
using one of the following spray devices: Disc, stick, ball, ring, or tanker spray. Also, any
closed circuit, including piping, pumps, valves, and plate heat exchangers can be cleaned
in place.
With appropriate adaption, a "C.I.P." system can clean both tanks and line circuits.
"C.I.P." of closed vessels requires careful consideration of hydraulic balance so that
all components of the system are compatible. The solution supply must be adequate so
that the "C.I.P." supply pump is not starved. The supply pump should be self-relieving so
that it will not become air-bound. The supply pumps should be of generous size --
typically 7.5 HP. The sum of the flow rates of the spray devices involved must be less
than the capacity of the supply pump, or the spray pattern will not be satisfactory. The
vessel must be sloped to drain, and the drop from the outlet of the vessel to the suction
side of the return pump, if one is incorporated, should be greater than 30 cm (12 inches).
The return pump, if one is used, must also be relieved so that it does not become air-
bound.
"C.I.P." of pipeline circuits is somewhat less complicated than is the case with
vessels. What goes in the pipeline must come out at the other end. However, this is an
oversimplification. Care must be taken to engineer the pipeline circuit so that the flow
rate and pressure are adequate. This becomes difficult in a pipeline circuit that involves
many different loops and valves If the valves are air operated, they can be sequenced so
that the individual loops comprising the circuit recirculate separately. The multiple loop
circuit becomes increasingly complicated as the number of valves increases, and while
there is no limit to the number of loops a circuit may contain, practicality may dictate
splitting the circuit into smaller circuits.
PARAMETERS AFFECTING "C.I.P."
The success in cleaning any vessel or pipeline circuit in place depends on five
considerations: time, temperature, pressure, concentration, and hydraulics. To a certain
degree, a trade-off exists between one and another: increasing temperature may
decrease the time required to "C.I.P.", and so forth.
The time consideration refers to the length of time at temperature that recirculation is
established. For example, a milk tank in a dairy normally would be washed at
temperature for 15 to 20 minutes. The time for a pipeline would be 10 to 15 minutes at
temperature.
Using the same dairy plant example, temperatures to "C.I.P." a pipeline would be in
the range of 65 to 70C (150 - 160F). Temperatures for a tank or silo would be 60 to
65C (140 - 145F). The reason for the lower temperature when washing a silo or tank is
that excessive temperatures cause expansion which can eventually cause cracks in the
welds and seams of such a vessel.
Typically pressures when washing a line circuit would range from 60 to 100 pounds
per square inch. The pressures involved in washing a vessel may be lower -- 60 psi.
Concentration is, to a great extend, dictated by the type of soil being cleaned. For
example: a processing vat with burnt-on soils may require 1 to 1.5 % causticity. Pipeline
circuits generally do not require more than 2,500 ppm concentration.
Proper hydraulics are of utmost importance in any "C.I.P." cleaning, whether it be a
vessel or a pipeline In the case of a pipeline, effective cleaning cannot be accomplished if
the pipeline is patched together with pipes of various sizes, such as 1.5 inch, 2 inch, 2.5
inch, and 3 inch. Pipeline size uniformity is most desirable. The proper balance of the
solution reservoir, supply pump and return pump, if incorporated, is critical. In the case of
a vessel, the spray device must be properly sized and placed so that the proper
cascading effect is achieved.
PRODUCT SELECTION
The type of product used for "C.I.P." depends on the soils being cleaned In the case
of heavy soils of a fatty nature that are burned on or caramelized, a caustic product is
indicated. Where the soils are lighter, and can be removed with a pre-rinse, a milder
alkaline product is adequate. When proteins are involved, chlorine must be incorporated
in the wash cycle to peptize these proteins. Desirable characteristics in the product are:
Low-foaming, phosphated for good rinsing, and chelated to treat water hardness. In
every case, the alkaline wash cycle should be followed with an acid post rinse. The post
rinse solution should be at a pH level so that the residual left on the surface of the vessel
or in the pipeline is approximately 4.5 to 5. In the case of a vessel, this solution should be
allowed to drain In the case of a pipeline, the acid solution should remain in the pipeline
until preparing for production.
TYPES OF SYSTEMS
The simplest form of "C.I.P." system is referred to sometimes as a pot and a pump,
where the solution reservoir may be portable. The pump may also be portable to allow it
to be moved about and connected to whatever equipment is being cleaned in place.
In another type of "C.I.P." system, solution is circulated and flushed to drain at the end
of the wash cycle.
A third type of "C.I.P." system is the solution recovery system, where the alkaline
solution is recovered and reused In some solution recovery systems, the alkaline solution
is used as a pre-rinse in the subsequent "C.I.P." cycle. In an other type of solution
recovery system, the alkaline solution is recovered in a large alkaline tank. This is known
as a soil bank system. A soil bank system requires a chemical boost for each pipeline or
vessel that is cleaned in place, as some of the solution is lost through leakage and/or
pumped to drain during post rinse cycles.
A good "C.I.P." system includes: Pre- and post rinse cycles. The pre-rinse cycle
would be with clear, temperate water. This may be in three or more bursts. The pre-
rinse flushes excess soils to drain. The alkaline or caustic step in "C.I.P." is the only step
at temperature. The post rinse may also be in bursts, in which case acid would be
injected in the last burst of the post rinse. The purpose of the post rinse is to tie up any
carryover alkalinity, treat minerals in the water, and allow free-rinsing.
FEED SYSTEMS
"C.I.P." systems lend themselves nicely to automatic feed. However, there are
systems which are hand-fed, particularly if there is a preference for a powdered rather
than a liquid product. Various types of pumps may be used to pump liquid detergent into
a "C.I.P." system. These pumps may be governed by manual electric controls or tied into
a control panel that feeds chemical automatically. A soilbank type of "C.I.P." system
would present a unique problem in that the detergent solution reservoir would have to
provide with an initial charge and thereafter fed with a boost each time a vessel or a
pipeline circuit is cleaned in place. Soil bank "C.I.P." systems often incorporate a
conductivity probe to govern the feed pump. However, timed feed is surprisingly accurate
and eliminates the problems involved with a conductivity probe.
INDUSTRY APPLICATIONS
The majority of "C.I.P." cleaning is done in dairy plants, fluid milk plants, ice cream
plants, and condensing operations. Much of the technology developed for this industry
has been applied very successfully to other industries such as the Soft Drink, Food, and
Pharmaceutical Industries. With increasing labour costs on the one hand and the
reliability and dependability of clean-in-place functions on the other, the trend in the Food
Industry is toward "C.I.P.", wherever applicable. Whatever the industry, the same rules
pertain --- the soil must be identified and the proper detergent prescribed. The proper
combination of pre-rinse, wash and post rinse steps is important. In general, it should not
be necessary to become involved in the electrical and mechanical details of a "C.I.P."
system. What is important, however, is to closely monitor the time, temperature,
pressure, concentration, and hydraulics of the system. Of utmost importance is to assure
the effectiveness of clean-in-place by observation.
C.I.P. PROCEDURES (LINE CIRCUITS)
1. Pre-rinse to drain with tap water until discharge is clear.
2. Recirculate with OXYCLEAN at 1 to 125 (200 ppm chlorine) for 10 minutes at
70C. If multiple loop circuit with a programmed sequenced valve cluster is involved, each
loop should recirculate for 10 minutes at temperature.
3. Flush to drain with tap temperature water until the discharge is clear, and same pH
as the water supply.
4. Recirculate with ACID-O-CLEAN at 1 to 250 of water, tap temperature, for 3
minutes per loop. Leave acid solution in lines until ready to start production.
ALTERNATE TO STEP 4
Recirculate with ACID-O-CLEAN at 1 to 250 of water, tap temperature, for 3 minutes
per loop. Prior to start of production, sanitise lines with CL-18 at 110 grams per 100
litres of water (200 ppm chlorine), tap temperature, for 3 minutes per loop.
C.I.P. PROCEDURES (TANK CIRCUITS)
1. Pre-rinse to drain with tap water until discharge is clear.
2. Recirculate with OXYCLEAN at 1 to 125 (200 ppm chlorine) for 10 minutes at
60C.
3. Flush to drain with tap temperature water until the discharge is clear, and same pH
as the water supply.
4. Recirculate with ACID-O-CLEAN at 1 to 250 of water, tap temperature, for 3
minutes If burst post-rinses are used, inject the ACID-O-CLEAN into the final burst.
5. Allow tank or vessels to drain.
ALTERNATE TO STEP 4
Recirculate with ACID-O-CLEAN at 1 to 250 of water, tap temperature, for 3 minutes.
Prior to using the tank or vessel, sanitise with CL-18 at 110 grams per 100 litres of water
(200 ppm chlorine), tap temperature, for 3 minutes.