Efficient CIP in Industry: the key to a high-quality process

The CIP (Cleaning-in-place) process is responsible for cleaning the manufacturing industry’s equipment, without taking it apart. In the food industry, these processes work through inline process measures, which are used to control the cleaning temperature, flow, and concentration of detergent in real time. This aspect contributes to optimization, being responsible for reducing waste of natural resources such as water and energy.

The CIP is mandatory in industry sectors such as oil and food, but especially in those that are highly regulated in terms of quality and safety. CIP works through cycles, and its duration differs, according to the product produced on the specific line. The order of the steps may vary, but in general, the CIP process encompasses:

A pre-rinse using RO-treated water, performed three times, each lasting 1 minute, to remove the raw dirt;
Caustic washing with an average duration of 30 minutes to dissolve organic and inorganic waste. The solution has on its composition products such as caustic soda, phosphoric and nitric acids, and sodium hypochlorite (hypo);
1-minute intermediate rinse, also using treated water;
Sanitizer washing, lasting up to 10 minutes. This solution contains products such as sodium hypochlorite, 70% alcohol, and peracetic acid (PAA), and kills resistant bacteria and microorganisms, such as Escherichia coli;

Different types of CIP

Besides the general type of process described, the CIP has several variations, according to its configuration and level of automation. Some examples are:

Total loss CIP: In this type of cleaning, the chemical solution is used only once and goes directly to the drainage;
Re-use CIP: Cleaning products are stored after use, treated and reused in following cycles;
Multi-channel: This process has multiple channels for cleaning different equipment parts simultaneously;
Fixed or mobile systems: fixed systems are integrated to the production line, while mobile systems can be moved around if needed;
Centralized Vs Distributed Processes: A centralized CIP system is a single system that delivers cleaning solutions to an entire process facility. It can supply many different circuits and coordinate many operations from a single location. A distributed system means individual sections of the plant can be cleaned with a local dedicated unit;

In the pharmaceutical industry, the most widely used cleaning method is the Single-Pass CIP. Its use is justified because this type is perfect for cleaning raw dirt. Specifically, this industry uses the Total Loss process to clean Active Pharmaceutical Ingredients (APIs), excipients, and tablet coatings from equipment. The cleaning solution circulates only once through the system and then is discarded. This is particularly useful when cleaning residues must not come into contact with any other type of material.

In the chemical industry, CIP process must be designed to withstand the harsh chemicals and high temperatures that come along with chemical production. Cleaning solutions should be carefully selected to ensure that they do not react with any other chemical ingredients.

How to optimize the CIP process

In the process of CIP, some aspects can damage the process efficiency, which may differ depending on the type of industry. In the beverage industry, for example, it can be longer and require the use of more chemicals. This happens because soft drinks like soda have sugar in their recipe, which makes the cleaning process harder due to their high adhesion to surfaces.

The CIP cycle is extensively utilized because of its automated aspect, but during its running some tasks still require human intervention. Regular equipment maintenance, sensors calibration, and replenishment of chemicals may require manual actions. Data science is a big ally in these cases, specially by providing information that allows these tasks to be performed in a planned and optimized way.

On a production line that produces liquid supplies, the equipment utilized often includes complex matrix valve and pipes. Mapping and analyzing matrix data allows the optimization of the CIP cycle. Data science applied to this equipment also contributes to other factors, such as:

Time: Monitoring CIP time leads to a positive impact by identifying which processes are within or outside the standard parameters, and in which ones need improvement;
Water and energy: These natural resources are essential in industry, and their monitoring allows for the reduction of their consumption;
Cleaning solutions: Monitoring the amount of chemicals used in the solution results in cost savings for manufacturing industries, as these can be expensive;

It is important to emphasize that all elements used in CIP have equal importance and participation in the process. The temperature of the product and its the contact time with the surface help to clean residues more quickly. Just as the right combination of the chemical/acid solution leads to a more effective action.

Inspection of the CIP process

The parameters for inspecting the CIP process in the manufacturing industry are very strict and involve several steps. This special attention is because a poorly executed CIP leads to a negative impact on several areas, including the quality of the final product. In the beverage industry, if the process is not within the cleanliness standards, there’s a risk of microbiological and chemical contamination of products. The efficient run of CIP compromises security, affects customer satisfaction, and can even lead to recalls.

The Brazilian Government inspects the CIP process through the Ministry of Agriculture, Livestock and Supply (MAPA). The evaluation of sanitary conditions is done through videoscope analysis of the system and the measurement of equipment according to national and international standards. In the shop floor, Brazilian industries inspect cleaning process within the TACT parameters, based on the type of the processes.

The United States also monitor these safety and quality parameters. Manufacturing industries must comply with strict rules of the FDA (Food and Drug Administration), organization responsible for promoting public health through food supervision. As an example there is the definitive registration of which cleaning products and disinfectants should be used in the food industry.

Worldwide, other guidelines include the EHEDG (European Hygienic Engineering & Design Group), the 3-A Sanitary Standards and the ISBT (International Society of Beverage Technologists). They provide detailed guidance on the management, validation and design of CIP installations to ensure that verified elements meet sanitary requirements.

Data analysis as the future of CIP

According to a survey published by Transparency Market Research (2019), the CIP process is expected to have an annual growth of 15.7%. This implies that with this industry investment, factories that do run CIP regularly may be in a competitive disadvantage.

The reason for this growth is the industry’s often interest in sustainable strategies, which prioritize efficiency and are better for the environment. Industries that search for eco-friendly practices, as a result, are also investing in the implementation of CIP processes that reduce water and energy use. Also, the increased concern about health issues, such as food poisoning and cross-contamination, has encouraged the food industry to invest more in CIP.

Integrate the CIP process with technologies such as data science is revolutionizing the industry. This way, it is possible to cross-reference variables such as time and speed, to identify conductivity problems or equipment maintenance. Data collection and analysis help ensure the streamline of operations, reduced manual work, and add more consistency during the CIP cycle.

Another trend is the use of innovative transition sensors, which determine when one phase of the cycle ends and when the next one should begin. In addition, the industry is increasingly seeking to meet new market demands, and for this happens it is seeking to develop new products and recipes. To keep up with this pace, processes are also updating, including CIP, which is increasingly modern and efficient. Learn more about us.

Check how the CIP Process works in a digitalized industry: