Cleaning in Place

How to clean?

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 Why focus on cleaning?

► The purpose of cleaning is to:

− Prepare lines for the next
production run
− Eliminate dirt (food) for bacteria that
could eventually lead to
contamination of the line
− Clean away potential contaminants
created by a line stop from
maintenance, changeover, etc.

CIP – an integral part of the whole production cycle

Cleaning methods

CIP COP Manual wet Manual dry

WET DRY

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 CIP
PRODUCT
T T T TT T
I U E II E
T R M M
M C
R B P EE H
A U E N
T L R O
I E A L
O N T O
N C U G
E R Y
E

1.5% >1.5m/s ~75°C ~30min Design

TRAINING
TRAINING
Cleaning / CIP

• Cleaning effects

• Cleaning procedure

• Cleaning validation

• Cleaning out of place

• External cleaning

• Cleaning objects

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 Security Level
Initials/YYYY-MM-DD /6
Principle of cleaning

Thermal force
Mechanical force Chemical force

Soil

Adhesive forces holding soil on surface

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Zinner's circle

► The key to successful cleaning

− Flow (Turbulence)
− Concentration (Titration)
− temperature
− time

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 Mechanical cleaning effect
► Minimum 1.5 m/s flow velocity for adequate mechanical
cleaning effect
► Flow rate needed to achieve 1.5 m/s in straight smooth pipes

Pipe Diameter Flow Volume

(litres/hour) (litres/100 m pipe)

25.0 mm (1") ~ 2 070 ~ 40

38.0 mm (1.5") ~ 5 100 ~ 99

51.0 mm (2") ~ 9 600 ~ 184

63.5 mm (2.5") ~ 15 400 ~ 287

76.0 mm (3") ~ 22 500 ~ 408

101.6 mm (4") ~ 40 200 ~ 748

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 Security Level
Initials/YYYY-MM-DD / 11
CIP system

Circuit A1

CIP Station Group A

Circuit A2

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Example of a CIP station

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Flow versus design

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Flow versus design

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/ 16
 Degree of Solubility of Soil Deposits

Principle constituents of soil deposits from milk products have varying

degrees of solubility in water and cleaning solutions:

Water Alkali Solution Acid Solution

Lactose Good Poor Poor
Fat Poor Good Medium
Proteins Poor Good Medium
Mineral Salts Medium Medium Good

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Adherence of the Soils on surfaces

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 Detergent alternatives

Pure chemicals
• Sodium hydroxide
• Nitric acid
• Phosphoric acid

Pure chemicals + additive

Formulated detergents

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Additives can help to penetrate soils

Surface Active Agent - Surfactant

Hydrophobic Hydrophilic

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 Surfactants

Helps to make water more

WET…Improves Wetting Penetration
Water Only: Beads Form

Soil Crack Soil

Water Plus Surfactant: Wetted Surface

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 Alkaline Function
► Protein dissolving and fat
saponifying e-
e- e-

► Source of negative ions e-

e-
e-
e-
e- e-
► Inflate soils e-
e-

e- e- e-
e- e-
e- e-
► Disperse e- e-
e-

e- e-

e- e-
e-
e-
e-
e- e-
e-
e- e-

e-
e-
e- e-
e-
Typical concentration:
1.5 to 2% at 70 to 80°C (170 F)
Saponifying: convert into soap
 Acid function
► Minerals removal like:
− Calcium phosphate (milk stone)
− Water minerals

► Also promotes passivation of SS

− They precipitate basically in hot surfaces.

Typical concentration
0.5 to 1% at 60 to 70°C (170F)

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 Concentration
An increase in
chemical
concentration does
not necessarily
increase the
cleaning efficiency.

There is an
optimum
concentration,
above which the
cleaning efficiency
decreases and
cleaning time
increases.

Fouling and Cleaning in Food

Processing (H. Kessler, D.Lund)
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Concentration
With too high a chemical concentration, particularly on high
protein liquids, the fouling layer may seal. Chemical reactions
occur by which the protein gels (rubber-like top layer) preventing
further penetration of the alkaline solution.

Consequently the fouling removal takes much more time.

The gel effect depends on the alkaline concentration,

temperature and contact time on the fouling layer.

Gel
effect

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 Time

It is dependent on the product composition, the heat treatment,

equipment design etc…

A cleaning cycle can be split up into 3 phases:

Time Phase Description

Phase 1 Diffusion of water into the fouled substance, thus

inflating the solid particles by water absorption
Phase 2 Corresponds to the combined mechanical and
chemical attack.
Phase 3 The removal (carry out) of the deposit.

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Flow (Turbulence)

A minimum velocity is required in the cleaning agent to:

• Create a mechanical shear stress to remove the soils from the wall
(boundary layer where residues will deposit)

•To be able to transport the soil out of the line: Video

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 Flow(Turbulence)
For piping, the velocity of 1.5 m/s
(5 ft/s) means:

Always ensure that your flow is not split:

In dead ends product velocity cannot be achieved and are only cleaned by
turbulence in the dead zone. They should be avoided.
When not possible follow design rules:

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Temperature

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Thermal cleaning force

► Increased effectiveness of a detergent with

increased temperature
► As a rule of thumb, cleaning with alkaline
detergent should be done at the same
temperature as the product has been exposed
to, but at least 80 °C.
► A formulated detergent always has an
optimum temperature which should be used.
► Acid detergents are recommended to be used
at temperatures of > 60°C

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 Common CIP temperatures

Type of Temperature
Cleaning objects
detergent range (C)
Milk collection tankers, tanks and
60-80 C
pipes

NaOH 70-90 C Milk pasteurisers

90-140 C UHT plants

60-65 C Tanks, pipes, milk pasteurisers

HNO3
H3PO4 80-85 C UHT plants

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 Cleaning sequence
Pre-rinse
• Water at 40-60°C
• To remove sugar and melt any fats.

Alkali circulation
• Remove proteins and fats

Rinse
• Purge dissolved soil and remove any residues
of the detergent.

Acid circulation
• Dissolve mineral salts and deposits left by
hard water.

Final rinse
• Purge dissolved soil and residues of the acidic
detergent.
 Cleaning Procedure (Alkali)

• The plant is flushed with water to remove any loose soil (if high fat
product lukewarm water)

• The plant is then pre-rinsed with water at 50-60°C, to remove sugar

and melt any fats. The temperature should not exceed 60°C in order to
avoid denaturing of any native proteins, which then become much more
difficult to clean.

• Alkaline detergent is then circulated in the system to remove organic

soil such as proteins and fats. Alkali is added to the concentration set-
point and the temperature is raised to the temperature set-point. The flow
is kept at a level giving satisfactorily flow velocity. The alkali step lasts for
a pre-set time period.

• Water is then used to purge out the alkaline detergent plus the dissolved
soil.

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 Cleaning Procedure (Acid)

•Acidic detergent is then most commonly circulated through the plant, to

dissolve mineral deposits and deposits caused by hard water, scaling.
The frequency of when an acidic step is applied varies depending on:
- whether the surfaces are hot or cold,
- the type of food and
- the water quality.
For example it is common to only apply an acid step once a week on cold
dairy surfaces. During the acid step concentration, flow and temperature
is kept at its set-point for the pre-set time.

•Water is then used to purge the acidic detergent and rinse out dissolved
soil. The final water rinse must also ensure that any detergent residues
are removed and only water is left in the plant. Now the plant should be
visible clean.

•Disinfection or sterilization is then applied before production starts to

kill bacteria or other living organisms to a certain level.
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Cleaning in Place
CIP monitoring and validation
 Safety means Control

of concentration, flow, temperature and time

Water Acid Lye

Concentration
& temperature

Steam
Lye Acid
conc. conc.

Time
Flow

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Verifying cleaning result

► Visual check (no product

residues)
► Bacteriological test
► Swab test
► ATP luminescence test
(adenosine triphosphate
bioluminescence)

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 3 Methods and acceptance criteria
Performance

*Note: pH measurement is an indication. The measurement is not enough reliable because of the low ionic strength in the soft water (used for CIP).
The results have to be always compared with the ingoing and outgoing water (Final rinse water and rinsing water balance vessel/ fresh water).

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 3.Acceptance Criteria –
Recommended Analysis
All Wet Cleaned Equipment Surfaces

• Visual Inspection - No visual residues. Bright, smooth,

and odorless.
• Microbiological by swab test:
TPC = <100 cfu/50 or 100 cm2
Coliforms/EB = <10 cfu/50 or 100 cm2

• ATP or Protein swabs – according to guidance from the

manufacture recommendations.
.

• Rinsing Water – same pH as factory potable water used

for cleaning
 CIP parameters to Control and
Monitor

► Flow
− Flow transmitter
► Temperature
− Temperature transmitter
► Time
► Detergent concentration
− Electrical conductivity
− Chemical titration
 Water Quality- Cleaning

Recommendation:
IDF (International Dairy Federation):
Hardness 3-4odH
pH > 8,3
Chloride < 50 ppm
Sulphate < 100 ppm
Iron < 0,1 ppm
Manganese < 0,1 ppm

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Water Quality- Hardness

Examples of kits
for water analyses

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COP (Cleaning out of Place)

► Lower filling pipe

► Disinfectant solution
(do not rinse off before
reassembling)
► Check the weight of float

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External cleaning of filling machines

► Upper filling pipe

► LS-element
► LS counter pressure roller
► Air-nozzles
► Rollers are clean and
undamaged
► Inductors are clean
► Jaw system and final folder
properly cleaned

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Cleaning units

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CIP liquids

• Tank cleaning
• Pipe cleaning
Recovery • Cold surfaces
• Pasteurizers

• UHT CIP
Single • Evaporators
use • Or other heavily fouled
objects

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 The benefits of Single use vs. Recovery
should be evaluated for Central CIP…

Advantages Disadvantages
• Always new CIP liquids • High running cost
Single use • Small investment • High environmental
load

• Reduced consumption • Disadvantages

Recovery
of detergent, energy, • Larger investment
water, etc…
• Less load on waste
water system

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 …as well as Centralised vs. Decentralised

Advantages Disadvantages
• One control • Long piping
Centralised • Handling of CIP liquids
at one location

• Could be shorter piping • One PLC at each CIP

Decentralised • Less risk for cross station
contamination • Detergent tanks in
production

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Cleaning objects

Pipe cleaning Tank cleaning

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Tank cleaning

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Sprayballs

LKRK LKSB LKTA LKRJ

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 CIP of packaging machines

Serial cleaning

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Integrated Cleaning Unit ( ICU)

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