1. A three-step program instead of the conventional five-step, where the cleaning process is reduced by a sanitation step and a rinse cycle. The three-step program combines cleaning and sanitation into one step, reducing cleaning time to the shortest possible and utilizing the lowest possible amounts of utilities and chemicals and resulting in reduced usage of water, energy and time.
2. Rapid CIP is normally done at ambient or moderate temperatures which therefore reduces the requirement of heating the detergent solutions to up to 80-85°C. It reduces expensive energy consumption as well as time that is required for heating and cooling of the entire CIP and production equipment that are under cleaning. As the manufacturing equipment does not undergo thermal stress, the life of the equipment and its consumable parts such as gaskets is prolonged.
3. Many times, Rapid CIP it is based on the use of acidic detergents and disinfec
tants. These acidic chemicals make cleaning and disinfection possible in a single step at ambient temperatures. Being acidic, they also facilitate the rapid rinsing of the equipment and pipelines under cleaning, thereby saving time and water. The acidic CIP program can be deployed under a carbon dioxide environment which further adds to the benefit of saving time and the cost of carbon dioxide that is normally wasted under alkaline cleaning conditions.
4. Reduced water and chemical usage for cleaning also reduces the load on effluent treatment plants, further adding to cost savings on waste water treatment. This helps the manufacturer to meet the local regulations due to less generation of waste water.
Can you elaborate on how Rapid CIP technologies can be integrated in line with optimized sustainable solutions and maximum utilization of their production capacity at the lowest in-use costs?
Yes, typical savings potential that can be achieved by implementing Rapid CIP programs are shown in the example given in the table below.
Note: These numbers are indicative and will vary depending on actual site conditions and type of soil.
* In the case of ambient temperature CIP, energy cost reduction is 100%. However, with some specific, hard-to-clean soils, alkaline cleaning may be required to be done at elevated temperatures.
In selecting the right application and chemistry, there are many variables to choose from when designing the right cleaning program. The two most important parameters for choosing the right chemistry are the type of soiling present and the CIP hardware & hydraulics.
However, the implementation of effective CIP programs comes with some basic principles and these are:
• Hardware has to be as per engineering requirements
• CIP-able process equipment – no dead ends
• Adequate flow rates through pipes and spray devices
• Selection of appropriate spray devices
• Capacities of return pumps
• Interface management tools
• Use of best practices
The success of CIP program requires application knowledge and expertise that can help to achieve sustainability KPIs. Key considerations can be CIP phase interface management, CIP rinsing management and reduction of energy in hot CIP programs, among others.
CIP phase interface management is about managing the separation of CIP phases, such as rinse water and detergent. It relies on managing interfaces into pipes and avoiding interfaces in vessels, where the large area for interface interaction and the dynamic nature of the process can lead to significant CIP solution losses. Poor interface management contributes significantly to excess water, chemical, emissions and CIP operational time. In the case of hot CIP operations, it also contributes to excess energy usage. Effective CIP interface management is a combination of correct CIP distribution system design, and correct sequencing of CIP events when changing CIP phases.
CIP rinsing management has a bearing on effective water management. It is about determining the right measuring values (turbidity or pH) to terminate the rinse sequence and the location on the CIP system at which the rinsing values will be measured. For a pre-rinsing sequence where the objective is to remove water removable soil, turbidity would be a more appropriate measure. For post-detergent rinsing, pH would be a more appropriate measure than the typical “conductivity plus a little time”. Thus, managing the rinsing sequence has an impact on the amount of water used or wasted, and the time taken for effective cleaning.
In hot CIP operations, the CIP tank is often kept at the operating temperature and this requires energy. However, steam consumption can be reduced by heating only the required detergent volume for the CIP circuit rather than maintaining the entire tank at the operating temperature. This can reduce the energy requirement by around 50%. However, implementation of this strategy requires some modification to CIP systems. The advanced design of “static leg” CIP systems allows for all the flexibility required to provide these conditions, however they can also be successfully met by the adjustment of existing CIP units.
There are a myriad of programs and activities to improve efficiency and sustainability in CIP while maintaining its effectiveness and this article has highlighted just a few technical opportunities. The point is that choosing a sustainable program need not be at the expense of productivity, and ultimately, profitability. The reality is that the scale at which resources such as water is used by this industry is huge, by virtue of the product and the production process.
Brewers, bottlers, alcoholic and non-alcoholic beverage makers are adding to the problem of water stress but they can also choose to be part of the solution by ensuring sustainable use. In short, a key CIP parameter is to clean more with less.
