1) System Design and Integration
Before beginning the system design and integration process it’s important to assess the current process layout and current equipment in the facility in addition to the equipment and components that will be part of the clean-in-place system. Once that assessment is completed, a design is drafted to account for the various integrations and future needs of the facility. This is when factors such as flow rates, temperature, pressure, and chemical concentrations are considered.
2) Equipment Selection
Once the design has been approved selecting the ideal equipment is the next step. This is where automation and other advanced options are decided on. Not all CIP systems are automated, most commonly this is due to budget, but could also be due to other factors.
3) Centralized Control System
With the design and equipment selection completed it is time for a centralized control system to be implemented. This is what allows operators to monitor and control the clean-in-place system to ensure it’s working optimally. This is also where we consider what Human-Machine Interface (HMI) panels or Supervisory Control and Data Acquisition (SCADA) systems to use so the system is user-friendly.
4) Recipe Management
Another important piece of the puzzle is the recipe management and how the different recipes require different procedures for proper cleaning. Some facilities use a single CIP system for more than one product, and each of those production lines needs to have specific steps, chemicals, concentrations, temperatures, and durations for effective sanitization.
5) Sensors and Automation
Technology has come a long way and continues to be improved upon meaning that there are new ways to automate and measure each step of the process. This is what allows the Centralized Control Systems to function as it requires sensors to be functioning properly and automated systems to be in working order. With sensors you can monitor key parameters like flow rates, pressure, temperature, conductivity, and chemical concentrations, and configure the automated systems to make adjustments based on real time data so you’re always operating at maximum efficiency.
Sensors and automation can also reduce the risk of injuries or errors via safety interlocks.
6) Chemical Management
Chemical management can be a challenge if you don’t have exact measurements and data to ensure dosing processes are being done correctly. That’s why implementing an automated system that accurately measures dosing is so important, it allows for a chemical management system to track chemical usage, inventory, and disposal.
7) Data Logging and Reporting
Proper data logging and reporting allows facilities to have reports available for compliance, traceability, and quality control purposes. There are also automated reports that provided critical information such as key parameters and deviations.
8) Maintenance and Validation
Once all of these components are in place it’s important to establish a routine maintenance schedule for clean-in-place equipment, this ensures consistent performance. It’s crucial to validate the CIP system regularly to verify it is still being effective in achieving cleanliness and sanitation standards.
9) Training and Documentation
With all of the components chosen, implemented, and ready to use, the next logical step is training and documentation. While modern systems are much easier to use and understand, there is still required training and documentation so operators have a comprehensive knowledge of the system, maintenance needed, troubleshooting, and safety procedures.
10) Continuous Improvement
Although the system may be working as expected just like all of the equipment in the facility it’s important to monitor and look for improvements as conditions change. We recommend regularly reviewing the CIP processes and performance to identify areas of potential efficiency gains, and to stay up to date with the latest best practices in the industry.
If you want more information on implementing a CIP system you can read the full article by clicking this link or you can call us at (916) 782-5212.
