Modern Trends in CIP Automation

Early CIP systems typically had a one size fits all group of cycle types. Modern automation systems allow for the individualization of CIP “recipes” very similar in concept to batch system recipes. For each product that is produced on a given set of processing equipment, there is a unique corresponding CIP recipe associated with that product.

Different sets of processing equipment, making the same product, may also have different cleaning requirements. For example, you may have a group of 10 tanks, all the same size, all capable of making the same product. The tank nearest to the CIP system may be 300 feet closer than the farthest tank. The closer tank requires less cleaning solution to fill the pipe to and from the CIP system, will lose less energy, and will generally use less cleaning chemicals compared to the farthest tank. The same product, made with different sets of processing equipment, can have different optimized CIP cycles.

A modern automation system will also optimize cleaning times based on such factors. In the batching world a master recipe is generally executed on a number of different batch tanks. CIP recipes operate in a similar manner. When they are run on a particular piece of equipment, the system individually adjusts the master CIP recipe to optimize for differences based on physical location factors as described above.

CIP recipe optimizations that match what you make to where you make it can yield significant savings in cleaning time and costs. While the costs savings are interesting to everyone, the time savings can be of particular interest if your plant is capacity constrained. Such cleaning time reductions produce in effect more production capacity from your existing processing equipment.

Safety First

Managing allergenic and gluten cross-contamination is a top priority for food processors. An automation system can assist with product scheduling to mitigate these risks, while optimizing your overall production capacity. It does so by coordinating the operations of the automated CIP system with the automated production equipment.

Complicating any scheduling process is the requirement to sequence the manufacturing of certain product types in specific orders. For instance, with no intervening cleaning it may be permissible to follow a vanilla pudding product run with chocolate pudding. Reverse the production order, and residual traces of chocolate color could ruin your vanilla product. Of even greater concern is the potential for allergenic/gluten cross-contamination from one product into another.

A CIP matrix editor brings the production and cleaning operational areas together. All product types are listed in both rows and columns. One group defines the previous product run, and the other the next run. The matrix point where each product type meets defines the cleaning requirements between these runs. These requirements can range from none at all where one product can freely follow the other; to a short rinse required between product runs; to full scale long wash requirements; or anything in between.

The trend in many food manufacturing facilities is processing an ever increasing number of SKUs. It is often difficult and time consuming to put together the optimum production schedule with these changing requirements. When combined with an automated production scheduler, a CIP matrix editor can be instrumental in developing the most efficient method to stage product runs based on your orders in hand.

During actual production, the automation system will use the CIP matrix data to confirm the validity of the operation. When a production run is initiated every piece of applicable process equipment is first checked to insure the matrix requirements are met, or the run is disallowed. This production run configuration data is typically maintained and controlled by quality assurance, and cannot be overridden by operations staff.