Automated Cleaning in the Process Industry: Insights into CIP and Disinfection

In industrial environments such as the food processing and pharmaceutical sectors, so-called cleaning-in-place (CIP) systems are widely used. These automated systems make it possible to clean equipment without disassembly, which contributes to process continuity and efficiency. This saves both time and money.

What is CIP?

A CIP system consists of mixing tanks, pumps, piping with valves, and a central control unit [1]. The system is used for the internal cleaning and disinfection of process equipment. Pipes, storage tanks, reactors, and filters, among other components, are cleaned in this manner. During the cleaning process, rinsing, cleaning, and disinfecting agents are circulated through the system in sequence. This removes visual (visible), chemical (residues), and microbiological (microorganisms) contaminants [2].

How does CIP work?

Cleaning-in-place is performed in several steps. The specific steps depend on the extent and type of contamination. Not only is the cleaning agent used important, but temperature, flow rate, pressure, and contact time also play a significant role [2]. A CIP routine might look like this, for example:

1. Preparation: Any remaining product flows are removed from the system to prevent them from interfering with the cleaning process.
2. Cleaning: Cleaning fluids, such as hot water, alkaline solutions, or acids, are pumped through the system to loosen and remove fats, proteins, and scale deposits.
3. Rinsing: A final rinse with clean water removes any remaining cleaning agents.
4. Disinfection: A disinfection step is necessary to kill microorganisms.
5. Inspection: Finally, an inspection of the cleaning and disinfection is performed, after which the equipment can be put back into service.

Rinse and cleaning fluids are returned to the CIP system, where they are reused or discharged. For example, lightly contaminated rinse water can be useful as the first rinse fluid in the next cycle.

CIP and Watter

Disinfection is a critical step in the CIP process for ensuring microbiological hygiene. Several factors play a role in selecting a disinfectant, such as effectiveness, material compatibility, operational safety and ease of use, cost, and environmental impact [2]. Watter’s innovative in-situ system offers all these advantages. The system produces a disinfectant on-site using only water, salt, and electricity. No special storage is required for the disinfectant, which minimizes the effort involved in transport and storage. This disinfectant is based on HOCl, which is highly effective against microbiological contamination and biofilm [3].

Technical implementation of the Watter system in CIP processes

The Watter system can be effectively integrated into Cleaning-in-Place (CIP) systems for disinfection. The technical implementation requires attention to a few key points:

• On-site production
  • The system generates hypochlorous acid (HOCl) suitable for direct application after the final rinse step of the CIP process. Because you always use a fresh, low-concentration solution, the risk of DBPs is very low.
  • The system can utilize an external buffer to accommodate peaks.
• Connection to the CIP circuit
  • Via the external ½” WDS connection.
  • Injection of the disinfectant is performed using a dosing pump.
  • Positioning: after cleaning, before the process is completed.

• Dosing and process monitoring
  • Dosing tailored to installation size and microbiological requirements.
  • The Watter system automatically checks whether the produced solution meets the set criteria.
  • If the solution does not meet the criteria, it is automatically discharged into the sewer. The system then performs a reset on its own.
  • In case of persistent deviations, the system issues an error message requiring intervention.

• Monitoring and maintenance
  • The Watter system’s information panel displays the system status.
  • Periodic tasks:
    • Replacing the water filter.
    • Cleaning the air filters.
    • Checking the salt supply.

With this configuration, the Watter system can be easily integrated into existing CIP processes without major modifications to the infrastructure.

References

1. Pant, K. J., Cotter, P. D., Wilkinson, M. G., & Sheehan, J. J. (2023). Towards sustainable Cleaning‐in‐Place (CIP) in dairy processing: Exploring enzyme‐based approaches to cleaning in the Cheese industry. Comprehensive Reviews in Food Science And Food Safety, 22(5), 3602–3619. https://doi.org/10.1111/1541-4337.13206
2. Thomas, A., & Sathian, C. T. (2014). Cleaning-In-Place (CIP) System in Dairy Plant- review. IOSR Journal Of Environmental Science Toxicology And Food Technology, 8(6), 41–44. https://doi.org/10.9790/2402-08634144
3. Kiamco, M. M., Zmuda, H. M., Mohamed, A., Call, D. R., Raval, Y. S., Patel, R., & Beyenal, H. (2019). Hypochlorous-Acid-Generating Electrochemical Scaffold for Treatment of Wound Biofilms. Scientific Reports, 9(1). https://doi.org/10.1038/s41598-019-38968-y