What is CIP?
Clean-In-Place (CIP) is a common method used in cleaning your sanitary heat exchangers. As the name suggests, this process allows you to sanitize your unit without having to disassemble, and clean its components individually. However, this method of cleaning is not only used in heat exchangers. Entire CIP systems can be dedicated to executing your cleaning process for other equipment such as vessels, sanitary process lines and other equipment used in processing plants. Depending on a few variables such as product type, volume of product processed and specific equipment used, the level of intricacy of the system can change.
CIP vs. COP
Cleaning in place (CIP) is a moderately straightforward and effective process that is achieved by having a system dedicated to sanitization, pre-piped into your equipment to execute your cleaning process. It can be as simple as pushing a few buttons and actuating a few valves to run the necessary cleaning cycle for your specific needs.
Cleaning out of place (COP) requires the user to remove any piping equipment, disassemble the heat exchanger and clean the components individually, costing valuable time and labor. However, some equipment and machinery are unable to be cleaned in their dedicated location, so cleaning out of place is necessary.
What process requires CIP?
Although a multitude of industries can benefit from a CIP system, we typically see them in the food and beverage industry, as it is crucial to follow strict health guidelines set by the FDA and other agencies. When in the sanitary process industry, the possibility of cross-contamination is always of utmost concern and proper measures must be taken in order to attain a clean, consistent product.
Benefits of systems with CIP capabilities
The main benefit of having a clean-in-place system is that it cuts down your overall operating cost. This eliminates unnecessary opening of your equipment, reduces spare parts consumption and also minimizes the man hours spent completing those tasks.
CIP systems offer more of a consistent overall product due to the fact that an automated system is put in place, reducing human error. As mentioned earlier, not all industries could benefit from a CIP system, but just ask anyone who has maintenances a heat exchangers, an automated open and close feature makes all the difference. Thermaline offers a line of automated heat exchangers that make opening and closing the unit as simple as pressing a button if an entire CIP system does not make sense for your operation.
Steps involved in the CIP Cleaning Cycle
Please keep in mind that not all processes are the same, and methods will vary. Each CIP system has its own set of unique parameters that dictate its respective steps including specific equipment, durations and temperatures.
Pre-Rinse
The pre-rinse wets the inner surfaces of the equipment used, initiates the entire cleaning process, removing any remaining residue that may have been left over.
Caustic Wash
The caustic solution used in CIP has a very high pH level that is meant to break down the fats and proteins that may be present- left over from the product. The caustic will do a much better job at removing residue as it acts on a chemical level.
Intermediate Rinse
Fresh water is pumped and sprayed in to remove the material that the caustic wash helped break down.
Final Rinse
Rinse using either city water or DI water to flush out the residual cleaning agents used on the previous step. The water is then drained completely from the system, then typically flushed with air to dry off any remaining moisture.
Sanitizing Rinse
This rinse may be needed to kill off any microorganisms that are present before starting the next run. The active ingredient used in this step is typically peracetic acid. This step is very important as it addresses any health concerns and to offer consistency with each batch.
Optional Acid Wash Step
An additional step after the caustic wash may be used in some processes, typically in the dairy industry to remove the scale that builds up during each batch. Within stainless units, calcified mineral stains may be common and acid does an amazing job at cleansing and brightening the stainless steel. Again, all processes are not the same and may not be used in your industry.
Things to Note
A very common procedure that can be implemented throughout the process is air-blowing. This is simply adding compressed air throughout the equipment to dry the residual moisture that may be left after the previous step. Another method that is used before the cleaning of the equipment begins is pigging. Most commonly used in double tube units to flush out any valuable excess product that may still be trapped in the tubes. It is essentially a built-in system within the heat exchanger that sends a foam plug through the pipeline with compressed air. We tend to see this practice put into effect in plants where products such as sauces and dips are being processed.
The Thermaline Difference
Thermaline offers a variety of heat exchangers that are customized and sized to your specific process. Our plate heat exchangers are utilized in systems that only require liquid heating with a lower flow rate where recirculation and full load heating needs to occur. Thermaline’s HYGA model is our most corrosion resistant 3A compliant shell and tube unit that is ideal for any sanitary processing that requires rigorous code to be upheld. These models come standard with 32 RA rated seamless inner tubes along with connections and the distribution area all upholding the same polish rating. These particular units are the gold standard in the dairy industry as sanitation is everything, we’ve seen outstanding performance in the field with this model, but it doesn't stop there.
Our HYGS models provide a sanitary design with corrosion resistant inner tubes along with polished nozzles. This model best suits the needs of a sanitary process that does not need to meet the stringent demands of 3A compliancy. Both models have fully drainable leak paths and seal welds. Each one of our heat exchangers offer different levels of sanitary design to meet the necessary requirements while still making economic sense.
