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5/27/20081Design for CIPDesign for CIPBy By Nicholas Jeffery and Elliott SuttonNicholas Jeffery and Elliott SuttonSuncombeSuncombe LtdLtd1.1. WhatWhat isis CIP?CIP?22 B fitB fit f CIP?f CIP?Topics to be CoveredTopics to be Covered2.2. BenefitsBenefits of CIP?of CIP?3.3. WhyWhy use CIP?use CIP?4.4. How CIP WorksHow CIP Works5.5. CleaningCleaning in Place in Place DetailDetail6.6. Types of CIP SystemsTypes of CIP Systems6.6. Types of CIP SystemsTypes of CIP Systems7.7. SterilisationSterilisation in Placein Place8.8. MonitoringMonitoring9.9. Design Design ConsiderationConsideration10.10. SummarySummary5/27/20082CIP or in its full form, Cleaning In Place, is defined as What is CIP?What is CIP?”Equipment and techniques to allow cleaning of process equipment without dismantling or manual cleaning with minimal operator involvement”.Reproducible, Repeatable, Validateable and Controllable Results Reduction of Cleaning Time Benefits of CIP?Benefits of CIP?Increased productivity through reduction of down time Chemical Handling Reduction Simple Operation Cost and Utility Savings including chemicals, water and effluent labour time etc water and effluent, labour time etc. Health and Safety Batch Traceability and Records Stronger Chemicals and higher temperatures can be usedEnvironmental Issues and Legislation5/27/200831) CIP is superior to any cleaning methodAutomated, with parameter monitoring & controlRepeatability ? reliabilityHuman errors eliminatedWhy Use CIPWhy Use CIPEliminate contaminated products2) Lower operating costsReduced labour costsCleaning turnaround time reducedWater / solvents / detergents usage significantly reduced3) Safety Improvement3) Safety ImprovementReduced exposure of product to personnelNo equipment dismantling / vessel entryEliminates hazardous activities, eg HP water blastingCIP relies on the principal of applying a suitable detergent or solvent at a suitable flow, pressure, How CIP WorksHow CIP Workstemperature and concentration for the correct length of time. The science is based on applying the required amount of energy to the equipment to ensure that it is cleaned. The energy is primarily provided by the solution temperature (thermal energy), the use of detergent or solvent (chemical energy) and the application of suitable pipeline velocities or pressures (kinetic energy).5/27/20084TimeTime MechanicalMechanicalCIP Energy SourcesCIP Energy SourcesChemicalChemicalTemperatureTemperatureEffect on cleaning operation: TemperatureTemperatureSoil EffectProteins mediumFats goodSugars goodSalts goodNote : Generally a 10°C temperature increase will improvecleaning efficiency by 50% (above 30°C)5/27/20085Effect on cleaning operation: 1) Turbulence in PipingLaminar flow Re < 2 300MechanicalMechanicalLaminar flow Re < 2,300Transition flow 2,300 < Re < 3,000Turbulent flow Re > 3,000Reynolds number, Re = D v ? D is pipe internal diameterµ v is fluid velocity? is fluid densityµ is fluid viscosityLAMINAR FLOWNote : Normally take velocity to be >2 m/s? 1½” tube at 2 m/s ? Re = 78,000TURBULENT FLOWEffect on cleaning operation : 2) Action in EquipmentMechanical Mechanical (continued…)(continued…)a) Automatic Tank Wash devices• Fixed Spray Devices• Self-powered Rotating• Self-powered TurbinePROCESS VESSEL5/27/20086Effect on cleaning operation: Chemical Chemical (Detergent)(Detergent)Soil Water Alkali AcidProteins poor good mediumFats poor good mediumSugars good -- --Salts medium medium goodNote : required concentrations depend on soil level, processes used, working time, temperture, ….Quality of Water used for aqueous cleaning is Quality of Water used for aqueous cleaning is critical for performance:critical for performance:Water Used for Cleaning ProcessWater Used for Cleaning Process•• Chemical properties (pH, hardness, etc.)Chemical properties (pH, hardness, etc.)•• Biological properties (bioburden, endotoxins)Biological properties (bioburden, endotoxins)Washing. Most critical is water hardness Washing. Most critical is water hardness –– effects effects PrePre--Rinsing. Solely for flushing out of residue prior to Rinsing. Solely for flushing out of residue prior to washing step. Usually based on practicality of what water washing step. Usually based on practicality of what water is available.is available.Rinsing. In general, the final rinse used for equipment Rinsing. In general, the final rinse used for equipment should use the same quality water as used in the final stage should use the same quality water as used in the final stage of manufacture.of manufacture.efficiency of cleaning of aqueous surfactant solutions.efficiency of cleaning of aqueous surfactant solutions.5/27/20087The duration of each CIP cycle step is to be optimised according to the main following parameters :Time Time (Duration)(Duration)according to the main following parameters :Type of Process Equipment Type of Process Carried OutDuration of Process Run Cleaning solution temperatureChemical concentrationStep Operation Cleaning AgentTemp. (ºC)Time (Min.)Usage1 Pre-Rinse Water 20 – 30 2 – 5 To drainTypical CIP ProgrammeTypical CIP ProgrammePre Rinse Water2 Alkali Clean 2% Caustic70 – 90 5 – 30 Re-circulated3 Inter-rinse Water 20 – 30 1 – 5 To drain4 Acid clean 1% Phosphoric50 – 70 3 – 15 Re-circulated5 Inter rinse Water 20 – 30 4 – 10 To drain5 Inter-rinse Water 20 30 4 10 To drain6 Final Rinse Quality Water 20 – 30 4 – 10 To drain7 Air Purge Sterile Air 20 – 30 2 - 4 To drain5/27/20088Boil Out (Fill / Flood) SystemTypes of CIP SystemsTypes of CIP SystemsTotal LossSingle Use Recirculation Re - Use (Recovery)Multi ChannelFixed & Mobile SystemsSIP, WIP and COPDetergentWater(Solvent)AdvantagesNo / Small Capital InvestmentVery Small VesselsBoil Out System Boil Out System (Fill/Flood)(Fill/Flood)PROCESS VESSELHeatyCleans Complicated Mixer SystemsNo additional Equipment NeedSolvent based DisadvantagesHigh Detergent & Water UsageDrainExtended Cleaning TimesHealth & Safety ConsiderationsDifficult to Monitor /Validate5/27/20089WaterSTotal Loss SystemTotal Loss SystemCIPPUMPPROCESS VESSELSpray ballWATER BREAK TANKALTERNATIVEDOSING POSITIONDETERGENTDOSING PUMPDRAINAdvantagesImproved Health & SafetySi l I t ll tiWaterTotal Loss SystemTotal Loss SystemSimple InstallationCIPPUMPWATER BREAK TANKTo ProcessVesselDisadvantagesHigh Detergent & Water UsageExtended Cleaning TimeDifficult to Monitor / ValidateDETERGENTDOSING PUMPifficult to Monitor / Validate5/27/200810AdvantagesFlexible SystemLower Cost Installation (than R U )WaterDETERGENT DOSING PUMPWATER Single Use Recirculation SystemSingle Use Recirculation SystemRe-Use)Good Economy for Local SystemSmall Floor SpaceLOW CROSS CONTAMINATION RISKCIP PUMPDRAINBREAK TANKCIP RETURNPUMPDRAINDisadvantagesNot Suitable for Large Centralised SystemsDAdvantagesGood Water / Detergent UsageC t li d S t & C t lReRe--Use SystemUse SystemFreshWaterDetergent Dosing PumpDETERGENT TANK DrainCentralised Systems & ControlsDisadvantagesInflexibilityHigher Equipment & Installation CostsCIP PUMPCIP RETURNPUMPCROSS CONTAMINATION RISK FOR DIS-SIMILAR PRODUCTS OR RAW/COOKED CONDITION5/27/200811Detergent RECOVEREDReRe--Use System with Recovered Water TankUse System with Recovered Water TankFreshWaterDetergent Dosing PumpPROCESS VESSELSpray ballRECOVERED WATER TANKDETERGENT TANK DrainCIP PUMPCIPRETURNPUMP1234MultiMulti--Channel ReChannel Re--Use Use SystemSystemFRESHWATERCAUSTICSOLUTIONACIDSOLUTIONREUSEDWATERASEPTICSOLUTION1 2 3 4 512345/27/200812MultiMulti--Channel SystemChannel SystemSOLUTION VesselAVesselBcross-contaminationRe-Use Single UseSolution Tanks 2 to 5 1 or noneSoln. Temperatures Fixed AdjustableSystem ComparisonsSystem Comparisonsp jSoln. Concentrations Fixed AdjustableSimultaneous operations1 to 4(Multi-channel)1 onlyFlexibility Poor HighCross contamination High Risk Small RiskInvestment cost Higher LowerInvestment cost Higher LowerRunning Cost Lower HigherMAIN CRITERIA CLEANING COST CLEANING QUALITY5/27/200813Example: 3000 L Storage Vessel, with 100 Lpm Sprayball1.5% Detergent. 5 min Rinses. 20 min DetergentSystem ComparisonsSystem Comparisons (continued…)(continued…)SYSTEM WATER DETERGENTBoil Out System 6500 L 45 LTotal Loss 3000 L 30 LSingle Use 1200 L 3 LPartial Re-Use 1100 L 2 LPartial Re Use 1100 Full Re-Use 600 L 2 LStatic CIP UnitStatic CIP UnitTypical Static CIP SystemTypical Static CIP System5/27/200814Mobile CIP UnitMobile CIP UnitReduces Pipework InstallationLimits to size of unit & CapacityService RequirementsHeating problemsIdeal for small cleaning dutiesgTypical Mobile CIP SystemTypical Mobile CIP SystemThere is no legislative distinction between Clean In Place (CIP) and Wash In Place (WIP), however the general industry WIP or CIP?WIP or CIP?however the general industry view on the terminology is that CIP means a totally automatic cleaning sequence with no manual involvement, whereas as WIP includes some manual intervention. In practical terms CIP requires high levels of q gvalidation, against WIP which requires less stringent validation. Typical WIP SystemTypical WIP System5/27/200815The introduction of the ATEX directive to include all components that are ATEX certified, mechanical ATEX CIP ConsiderationsATEX CIP Considerations,as well as electrical The problems with component selection associated with systems that reside continually in an ATEX areaCan use aqueous or solvent cleaning mediaATEX rated spraydevicesInert atmospheres for spray cleaningTypical ATEX CIP SystemTypical ATEX CIP SystemCIP results in the equipment being chemically clean. This is defined as "th l f ll id f il d ll CIP What is the Result of CIP?What is the Result of CIP?"the removal of all residues of soil and all CIP agents so that contact with the cleaned surface does not result in physical contamination". If the equipment being cleaned needs to be micro-biologically clean then an additional process micro biologically clean then an additional process can be carried out. This process is called SIP.5/27/200816SIP or in its full form, Sterilising In Place is the generic term for sanitizing, disinfecting or t ili i i t ll ft CIP lWhat is SIP?What is SIP?sterilizing equipment normally after a CIP clean.SIP results in the removal of any remaining microbiological contamination. Sanitation or Disinfection is normally applied after the full CIP has been carried out. It is achieved by th i t d ti f iti di i f t t Chemical SIPChemical SIPthe introduction of a sanitiser or disinfectant chemical into the final rinse waters of the CIP.Typical Chemical Sanitisers are: Chlorine, hypochlorite, hydrogen peroxide, ozone, peracetic acidacid.5/27/200817Thermal sterilisation is achieved by the application of steam or hot water at a suitable temperature for it bl ti Thermal SIPThermal SIPa suitable time. Thermal Sterilisation has the advantage of affecting areas such as sample points, which may not be treated by chemical means.Typical Thermal SIP methods are: dry heat, steam, superheated waterWhen is a CIP Application When is a CIP Application not a CIP Application?not a CIP Application?Answer: When it is a COP Application.COP or Cleaning Out of Place is when the equipment is moved to the cleaning equipment prior to a CIP clean5/27/200818Conductivity To Monitor Strength To Separate PhasesTemperature In Feed Line to ControlCIP Monitoring SystemsCIP Monitoring SystemsTemperature In Feed Line to ControlIn Return Line to MonitorFlow In Feed & Return to Confirm RatePressure In Feed Line for Spray DeviceIn Return for Integrity TestingTime From the Control SystemyTurbidity In Return Line to Monitor‘Cleanability’ of components & fittings used for process installationsSafety breaks & circuit separationCIP/Process DesignCIP/Process DesignSafety breaks & circuit separationCircuit balancing of CIP circuitPrevention of ‘dead legs’ in process circuitsSurface finish of tanks and piping Surface finish of tanks and piping Welding techniques5/27/200819Made of corrosion-resistant and cleanable materialsMust confine the cleaning solutionEquipment/System to be Equipment/System to be cleaned…cleaned…Must confine the cleaning solutionMust be drainable, with no pockets or ledgesAny corners should be roundedGaskets & seals – crevice-free, non-absorbent, non-reactive, non-porous (FDA-approved elastomers)elastomers)Minimum interconnecting fittings in pipingAll valves & instruments should be cleanableUse of hoses should be minimised CIP INPUTCircuitCircuitSeparationSeparationCIP OUTPUTCIP INPUTCIP INPUTCIP OUTPUTRouting PlateCIP INPUTCIP OUTPUTCIP OUTPUTRouting Plate5/27/20082015 m3/hCIP INPUTAlways have a higher output flow than input flow for CIPCircuit BalanceCircuit Balance10 m3/h 15 m3/hCIP INPUTCIP OUTPUTp20 m3/hCIP OUTPUTCIP INPUTSafety BreakSafety BreakSystemSystemCIP INPUTCIP INPUTAlways have safe separation between process and l iDouble blockand bleedCIP INPUTcleaningRouting Plate5/27/200821CIP INPUTPreventation ofPreventation ofDeadlegsDeadlegsCIP INPUTPROCESSBeware of Dead-legs in the process and cleaning circuitsPROCESSuncleanableL = 3 DL = 5 D DeadDead--legslegslimit of cleanabilityOKL = 1 DL = 3 DL = 0 D OKBestL = 0 DZero dead-legvalve5/27/200822- Mechanical ActionEnsure sufficient Pipework VelocityPipework VelocityLaminar Flow(Low Velocity)Re 2300fluid flow velocities in the process and cleaning circuitsRe 3000Turbulent Flow(High Velocity)AdvantagesNo maintenanceSpray Devices Spray Devices –– FixedFixedLow Pressure Low Pressure –– High FlowHigh FlowDisadvantagesHigher Water UsageLess Mechanical ActionSpecial Spray PatternsEasier to MonitorLess Pump PowerLess Mechanical ActionLess Bounce BackLonger cleaning times5/27/200823AdvantagesLower Water UsageG t M h i l A tiSpray Device Spray Device –– RotatingRotatingHigh Pressure High Pressure –– Low FlowLow FlowDisadvantagesHigher Pump PowerMore Difficult to MonitorGenerally Higher CostGreater Mechanical ActionGreater Bounce BackGreater Throw Distances‘Turbodisk’Generally Higher CostMore Difficult to “Aim” SprayHigher MaintenanceSlottedJets100%30minutesSurface FinishSurface Finish0 30roughness(µm) 0 30 (µm)roughness0 3 0 3TIME TO DESTROY 99,9%OF MICRO-ORGANISMS(relative values)REDUCTION % OF MICRO-ORGANISMSAFTER A STANDARD CIP CYCLE(relative values)5/27/200824Welding TechniquesWelding TechniquesPoor Hand WeldPoor Hand Weld• Difficult to clean• Drainage problems • CorrosionOrbital WeldEvaluation of Cleaning RiskSummary of CIP/SIPSummary of CIP/SIPCIP Unit Selection (Skid Packages)Flexibility allowing CustomisationCIP / SIP / Process Interface from start Incorporate Hygienic DesignIncorporate Hygienic DesignMonitoring to Ensure Repeatability5/27/200825Thank You For Thank You For Your AttentionYour AttentionFor More Information Contact SuncombeFor More Information Contact SuncombeTel: +44 (0)20 8443 3454Tel: +44 (0)20 8443 3454www.suncombe.comwww.suncombe.com